Fabric comprising barrier coating and hygiene article comprising same

Abstract

A fabric suitable as an alcohol repellent fabric is provided. The fabric includes a fibrous substrate including a first outermost surface and a second outermost surface wherein a non-fluorinated barrier coating (NFBC) or a fluorinated barrier coating (FBC) is located on at least a portion of the first outermost surface of the fabric, on at least a portion of the second outermost surface of the fabric, or on both.

Description

[0001] Related applications

[0002] This application claims priority under 35 U.S.C. §119(e) to U.S. patent application No. 63 / 427,609, filed on November 23, 2022, the entire disclosure of which is hereby expressly incorporated herein by reference. Technical Field

[0003] Embodiments of the disclosed invention generally relate to fabrics comprising a non-fluorinated barrier coating (NFBC) or a fluorinated barrier coating (FBC) disposed on at least a portion of a first outermost surface of the fabric, wherein the NFBC or FBC imparts improved barrier properties associated with low surface tension fluids (e.g., alcohol and blood). Despite the absence of fluorine atoms, fabrics comprising the NFBC can provide the same or improved barrier properties as fabrics treated with the FBC. Hygiene articles comprising the fabrics are also provided. Background Art

[0004] Conventional absorbent articles, such as disposable diapers, utilize absorbent material typically positioned between a liquid-permeable topsheet and a liquid-impermeable backsheet to absorb body exudates. Conventional absorbent articles, such as diapers, often include elasticized waistbands and leg cuffs to help reduce leakage of body exudates. Some conventional absorbent articles also include elasticized containment or barrier flaps at the legs or waist of the article to further reduce leakage.

[0005] The liquid-impermeable backsheet on conventional absorbent articles is configured to provide a barrier between the absorbent body within the absorbent article and the wearer's clothing. Typical backsheets are both liquid- and vapor-impermeable. For example, many conventional absorbent articles include backsheets made of a polymeric film that is both liquid- and vapor-impermeable.

[0006] However, there remains a need in the art for a nonwoven-based barrier fabric that achieves similar or improved barrier rejection performance with respect to the permeation of low surface tension fluids (eg, alcohol and blood) compared to conventional polymeric films. Summary of the Invention

[0007] One or more embodiments of the present invention can solve one or more of the above problems. According to certain embodiments of the present invention, a fabric is provided, which includes a fiber substrate, the fiber substrate including a first outermost surface and a second outermost surface. The fabric may also include a non-fluorinated barrier coating (NFBC) located on at least a portion of the first outermost surface of the fabric, at least a portion of the second outermost surface of the fabric, or both. In this regard, the NFBC does not contain fluorine atoms. According to certain embodiments of the present invention, the entire fabric may not contain fluorine atoms. According to certain embodiments of the present invention, the fluorinated barrier coating (FBC) may be located additionally or alternatively on at least a portion of the first outermost surface of the fabric, on at least a portion of the second outermost surface of the fabric, or on both.

[0008] In another aspect, the present invention provides an absorbent article comprising a fabric having a NFBC and / or FBC, such as those described herein, a liquid-permeable topsheet, and an absorbent body positioned between the fabric and the liquid-permeable topsheet.

[0009] In another aspect, the present invention provides an absorbent diaper comprising a front region, a back region, and an intermediate crotch region between the front region and the back region. The absorbent diaper may also comprise at least one barrier leg cuff, wherein the at least one barrier leg cuff comprises a fabric having a NFBC and / or a FBC, such as those described herein.

[0010] In yet another aspect, the present invention provides a method of forming a fabric. The method may include the steps of: (i) providing or forming a fibrous substrate comprising a first outermost surface and a second outermost surface; (ii) topically applying a fluorinated barrier coating (FBC) composition or a non-fluorinated barrier coating (NFBC) composition to at least a portion of at least the first outermost surface, wherein the NFBC comprises (a) a plurality of radiation-curable silicones or (b) a dispersion comprising a solvent, a wax or a component thereof, and a retention aid; and (iii) (a) if the NFBC composition comprises a plurality of radiation-curable silicones, curing the plurality of radiation-curable silicones by exposure to radiation, such as ultraviolet (UV) radiation, or (b) actively or passively evaporating the solvent from the dispersion or FBC composition to provide a fabric having NFBC and / or FBC, such as those described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Throughout the text, like reference numerals refer to like elements, wherein:

[0012] Figure 1Ashows a perspective view of an absorbent article according to one embodiment of the present invention;

[0013] Figure 1B Shown along Figure 1A a cross-sectional view taken along line X–X of ; and

[0014] Figure 1C Show Figure 1A A perspective view of a portion of an absorbent article. DETAILED DESCRIPTION

[0015] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0016] The present invention generally relates to the use of lower surface tension chemicals, such as fluorinated chemicals and / or chemicals without fluorine atoms, to coat nonwoven surfaces (e.g., silicone rubber has a surface tension of 19-22 mJ / m 2 According to certain embodiments of the present invention, nonwoven surfaces may be coated with chemistries that do not contain fluorine atoms, which may replace reliance on fluorine compounds while achieving similar or improved barrier rejection properties (e.g., preventing low surface tension fluids from penetrating the fabric). According to certain embodiments of the present invention, fabrics including NFBCs exhibit comparable or better performance than C6 fluorochemically treated materials, for example, in terms of preventing penetration of lower surface tension fluids and passing a blood drop test for synthetic blood according to ASTM F1670M (e.g., 15 minutes of drop exposure without blood penetration). By way of example only, polypropylene may have a 30.5 mJ / m 2 The surface tension of polyethylene can be 31.6mJ / m 2 Coating or covering a fabric formed of, for example, polypropylene or polyethylene with NFBC can reduce the surface tension of the treated surface caused by the NFBC, which can make the treated surface resistant to penetration by low surface tension fluids.

[0017] According to certain embodiments of the present invention, fabric (for example, nonwoven fabric) can be manufactured by any known method, such as those described and disclosed herein.In addition, fabric can be made of a wide range of selected polymeric materials, such as polyolefins (for example polypropylene, polyethylene, their copolymers, etc.), polyesters, polyamides, natural fibers (for example cotton, etc.) and cellulose fibers (for example rayon, wood fibers, etc.). According to certain embodiments of the present invention, for example, fabric includes a nonwoven fabric comprising a polyolefin thermoplastic polymer. For example, nonwoven fabric can include polypropylene (for example, polypropylene is broadly defined, and includes copolymers and blends containing polypropylene). According to certain embodiments of the present invention, nonwoven fabric can include polyethylene (for example, polyethylene single-component fibers, bicomponent fibers including polyethylene components, flash-spun polyethylene fibers, etc.).

[0018] According to certain embodiments of the present invention, nonwoven fabrics may include continuous fibers (e.g., spunbond fibers), staple fibers, fine fibers (e.g., broadly defined to include meltblowing, melt film fibrillation, electrospinning, etc.). As described above, certain embodiments of the present invention may include nonwoven fabrics comprising a layer of cellulose fibers (e.g., wood pulp) and a layer of synthetic fibers (e.g., thermoplastic polymers) that are mechanically entangled together (e.g., hydraulically entangled together). According to certain embodiments of the present invention, nonwoven fabrics may include continuous fibers (e.g., spunbond fibers) and fine fibers (e.g., meltblown fibers), such as fabrics having a spunbond-meltblown-spunbond (SMS) structure, such as an SMS or SSMMS structure, in which one or more layers of meltblown fibers are sandwiched between layers of continuous fibers.

[0019] The term "substantially" or "essentially" may encompass the total amount specified according to certain embodiments of the invention, or largely but not the total amount specified (e.g., 95%, 96%, 97%, 98% or 99% of the total amount specified) according to other embodiments of the invention.

[0020] The terms "polymer" or "polymeric", as used interchangeably herein, may include homopolymers, copolymers, such as block, graft, random and alternating copolymers, terpolymers, and the like, and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the terms "polymer" or "polymeric" shall include all possible structural isomers; stereoisomers, including but not limited to geometric isomers, optical isomers, or enantiomers; and / or any chiral molecular configuration of such polymer or polymeric material. These configurations include but are not limited to isotactic, syndiotactic, and atactic configurations of such polymer or polymeric material. The terms "polymer" or "polymeric" shall also include polymers made from various catalyst systems, including but not limited to Ziegler-Natta catalyst systems and metallocene / single-site catalyst systems. According to certain embodiments of the present invention, the terms "polymer" or "polymeric" shall also include polymers produced by fermentation methods or of biological origin.

[0021] As used herein, the terms "nonwoven" and "nonwoven web" may include a web having a structure of individual fibers, filaments and / or threads that are interwoven but not in a repetitive manner as identifiable in a knitted or woven fabric. According to certain embodiments of the present invention, nonwoven fabrics or webs may be formed by any conventional method known in the art, such as meltblowing, spunbonding, needlepunching, hydroentanglement, air-laid and bonded carding. As used herein, a "nonwoven web" may include multiple individual fibers that have not undergone a consolidation process. In some cases, a "nonwoven web" may include multiple layers, such as one or more spunbond layers and / or one or more meltblown layers. For example, a "nonwoven web" may include a spunbond-meltblown-spunbond structure.

[0022] As used herein, the terms "fabric" and "nonwoven fabric" may include fiber webs in which a plurality of fibers are mechanically entangled or interconnected, fused together, and / or chemically bonded together. For example, a nonwoven fiber web of individually laid fibers may be subjected to a bonding or consolidation process to bond at least a portion of the individual fibers together to form a bonded (e.g., united) fiber web of interconnected fibers.

[0023] As used herein, the terms "consolidated" and "consolidation" may include bringing at least a portion of the fibers of a nonwoven web together so that they are brought closer together or attached thereto (e.g., heat-fused together, chemically bonded together, and / or mechanically entangled) to form one or more bond sites that act to increase resistance to external forces (e.g., wear and tension) compared to an unconsolidated web. For example, one or more bond sites may include discrete or localized areas of web material that have been softened or melted and, optionally, subsequently or simultaneously, compressed to form discrete or localized deformations in the web material. Additionally, the term "consolidated" may include an entire nonwoven web that has been processed so that at least a portion of the fibers are brought closer together or attached thereto (e.g., heat-fused together, chemically bonded together, and / or mechanically entangled), such as by thermal bonding or mechanical entanglement (e.g., hydroentanglement), to name a few examples. Additionally, the terms "consolidated" and "consolidation" may include bonding by through-air bonding operations. As used herein, the terms "through-air bonded" and "through-air bonding" may include nonwoven webs that are consolidated by a bonding process in which hot air is used to fuse fibers at the surface of the web and, optionally, within the web. By way of example only, the hot air may be blown through the web in a conveyor-type oven, or drawn through the web as a vacuum is created as it passes through a porous drum. The temperature and velocity of the hot air are parameters that may determine the level or degree of bonding in the nonwoven web. According to certain embodiments of the present invention, the temperature of the hot air may be high enough to melt, induce flow, and / or fuse a plurality of fibers having a lower melting point temperature or a lower melting point temperature starting point (e.g., amorphous fibers) to a plurality of fibers having a higher melting point temperature or a lower melting point temperature starting point (e.g., semi-crystalline or crystalline fibers). According to certain embodiments of the present invention, such webs may be considered "consolidated nonwovens," "nonwoven fabrics," or simply "fabrics."

[0024] As used herein, the term "layer" may include generally identifiable groups of similar material types and / or functions that exist in the XY plane.

[0025] As used herein, the term "spunbond" may include fibers formed by extruding a molten thermoplastic material as filaments from a plurality of thin, generally circular capillaries of a spinneret, followed by rapid reduction of the diameter of the extruded filaments. According to embodiments of the present invention, spunbond fibers are generally not tacky when deposited onto a collecting surface and may be generally continuous as disclosed and described herein. Note that the spunbond materials used in certain composite materials of the present invention may include nonwovens described in the literature.

[0026] As used herein, the term "continuous fibers" refers to fibers that are not cut from their original length prior to forming a nonwoven web or nonwoven fabric. The average length of the continuous fibers may be from greater than about 15 centimeters to greater than one meter, and may be up to the length of the formed web or fabric. For example, the continuous fibers used herein may include fibers wherein the fiber length is at least 1,000 times the average fiber diameter, such as at least about 5,000, 10,000, 50,000, or 100,000 times the average fiber diameter.

[0027] According to certain embodiments of the present invention, the term "meltblown" as used herein may include fibers formed by extruding a molten thermoplastic material as a molten thread or filament through a plurality of fine die capillaries into a converging high-speed (usually hot) gas (e.g., air) stream, the gas stream thinning the filaments of the molten thermoplastic material to reduce their diameter, which may be a microfiber diameter. According to an embodiment of the present invention, the die capillaries may be circular. The meltblown fibers are then carried by the high-speed air stream and deposited on a collecting surface to form a web of randomly distributed meltblown fibers. The meltblown fibers may include microfibers, which may be continuous or discontinuous and are typically tacky when deposited on a collecting surface. However, the length of the meltblown fibers is shorter than that of the spunbond fibers.

[0028] As used herein, the term "melt fibrillation" may include a general class of manufactured fibers defined as one or more polymers being melted and extruded into a number of possible configurations (e.g., coextruded, homogeneous, or bicomponent films or filaments) and then fibrillated or fiberized into a plurality of individual filaments to form melt-fibrillated fibers. Non-limiting examples of melt-fibrillation processes may include meltblowing, melt fiber bursting, and melt film fibrillation. As used herein, the term "melt film fibrillation" may include a process in which a melt film is produced from a melt and then a fluid is used to form fibers (e.g., melt film fibrillated fibers) from the melt film. Examples include U.S. Patents 6,315,806, 5,183,670, 4,536,361, 6,382,526, 6,520,425, and 6,695,992, the contents of each of which are incorporated herein by reference to the extent such disclosures are consistent with the present disclosure. Other examples include U.S. Patents 7,628,941, 7,722,347, 7,666,343, 7,931,457, 8,512,626, and 8,962,501, which describe Arium ® for making melt-film fibrillated fibers (e.g., having submicron fibers). TM Melt-film fibrillation method.

[0029] As used herein, the term "aspect ratio" includes the ratio of the length of the major axis to the length of the minor axis of the cross section of the fiber in question.

[0030] As used herein, the term "multicomponent fiber" may include fibers formed from at least two different polymeric materials or compositions (e.g., two or more) that are extruded from separate extruders but spun together to form one fiber. As used herein, the term "bicomponent fiber" may include fibers formed from two different polymeric materials or compositions that are extruded from separate extruders but spun together to form one fiber. The polymeric materials or polymers are arranged in substantially constant positions in different regions across the cross-section of the multicomponent fiber and extend continuously along the length of the multicomponent fiber. The configuration of such multicomponent fibers can be, for example, a sheath / core arrangement in which one polymer is surrounded by another polymer, an eccentric sheath / core arrangement, a side-by-side arrangement, a pie-like arrangement, or an "island-in-the-sea" arrangement, each of which is a multicomponent fiber, including those known in the art of bicomponent fibers.

[0031] As used herein, the term "fluorochemical" may include any of various compounds containing fluorine, particularly organic compounds in which fluorine replaces a majority of hydrogens attached to carbon (e.g., fluorocarbons such as perfluoroalkanes). Fluorochemicals can exhibit low surface tension and low viscosity and are extremely stable due to the strength of the carbon-fluorine bond. Fluorides are immiscible with most organic solvents.

[0032] As used herein, the term "dry basis" may include calculations or measurements of weight percentages where the presence of water and / or other solvents (e.g., alcohols) is ignored or excluded for the purposes of the calculation or measurement. Weight percentages are typically measured on a dry basis to eliminate the effects of evaporation and / or condensation that may naturally occur throughout the useful life of the composition or article.

[0033] The term "cellulose fibers" as used herein may include fibers derived from hardwood trees, softwood trees, or a combination of hardwood trees and softwood trees, prepared by any known suitable cooking, refining, and bleaching operations for use, for example, in papermaking furnishes and / or fluff pulp furnishes. Cellulose fibers may include regenerated fibers and / or virgin fibers. Regenerated fibers differ from virgin fibers in that the fibers have been through a drying process at least once. In certain embodiments, at least a portion of the cellulose fibers may be provided by non-woody herbaceous plants, including but not limited to kenaf, cotton, hemp, jute, flax, sisal, or abaca. In certain embodiments of the present invention, the cellulose fibers may include bleached or unbleached pulp fibers, such as high-yield pulp and / or mechanical pulp, such as thermomechanical pulping (TMP), chemimechanical pulp (CMP), and bleached chemithermomechanical pulp (BCTMP). In this regard, as used herein, the term "pulp" may include cellulose that has been subjected to processing treatments such as heat treatment, chemical treatment, and / or mechanical treatment. According to certain embodiments of the present invention, the cellulose fibers may include one or more pulp materials.

[0034] All integer endpoints disclosed herein that can produce smaller ranges within a given range disclosed herein are within the scope of certain embodiments of the present invention. For example, the disclosure of about 10 to about 15 includes disclosed intermediate ranges, such as: about 10 to about 11; about 10 to about 12; about 13 to about 15; about 14 to about 15; and so on. In addition, all single decimal (e.g., reported to the nearest tenth) endpoints that can produce smaller ranges within a given range disclosed herein are within the scope of certain embodiments of the present invention. For example, the disclosure of about 1.5 to about 2.0 includes disclosed intermediate ranges, such as: about 1.5 to about 1.6; about 1.5 to about 1.7; about 1.7 to about 1.8; and so on.

[0035] According to certain embodiments of the present invention, a fabric is provided that includes a fiber substrate comprising a first outermost surface and a second outermost surface. The fabric may further include a non-fluorinated barrier coating (NFBC) located on at least a portion of the first outermost surface, at least a portion of the second outermost surface, or both. In this regard, the NFBC does not contain fluorine atoms. According to certain embodiments of the present invention, the entire fabric may be fluorine-free. According to certain embodiments of the present invention, a fluorinated barrier coating (FBC) may additionally or alternatively be located on at least a portion of the first outermost surface, at least a portion of the second outermost surface, or both. For example, the NFBC and / or the FBC may be located on at least a portion of the first outermost surface and also on at least the second outermost surface. The first outermost surface may have the NFBC in one or more separate and discrete locations or be completely coated with the NFBC. According to certain embodiments of the present invention, the second outermost surface may have the NFBC in one or more separate and discrete locations or be completely coated with the NFBC. According to certain embodiments of the present invention, the first outermost surface may include the FBC, while the second outermost surface may include the NFBC. According to certain embodiments of the present invention, a fabric (eg, a nonwoven fabric) may be free of FBC.

[0036] According to certain embodiments of the present invention, the FBC (if present) includes at least one fluorochemical, including at least one C4 fluorochemical, C6 fluorochemical, C8 fluorochemical, C10 fluorochemical, or any combination thereof. While the FBC can be applied by various topical application procedures, such as spraying, kiss-rolling, and immersion in a bath, the FBC can also include a digitally printed or sprayed composition, including a plasma-cured composition, the composition including at least one fluorochemical, including at least one C4 fluorochemical, C6 fluorochemical, C8 fluorochemical, C10 fluorochemical, or any combination thereof. For example, the digitally printed or sprayed FBC can include a plasma-cured composition; wherein the plasma-cured composition includes a polymerized composition of a free radical-curable monomer composition, the free radical-curable monomer composition including at least a first set of monomers, the first set of monomers including at least one free radical-polymerizable functional group and at least one side chain including from about 4 to about 10 fluorinated carbon atoms, such as 4, 5, 6, 7, 8, 9, or 10 fluorinated carbon atoms. The digitally printed or sprayed FBC, for example, may comprise a plasma-cured composition, wherein the plasma-cured composition comprises a polymerized composition comprising a perfluoroalkylethyl methacrylate comprising at least one side chain containing from about 4 to about 10 fluorinated carbon atoms, e.g., 4, 5, 6, 7, 8, 9, or 10 fluorinated carbon atoms.

[0037] According to certain embodiments of the present invention, FBC can be formed by the FBC composition including one or more fluorochemicals. When in the pre-cured state, the FBC composition can include one or more monomers, which include one or more fluorochemical chains and one or more polymerizable functional groups (for example, free radical polymerizable functional groups polymerized by the action of free radicals). For example, the one or more fluorinated chemical chains can impart the required alcohol repellency in the cured composition, and the one or more polymerizable functional groups enable, for example, the pre-cured alcohol repellent composition to be cured by free radical mediation, for example, when exposed to one or more atmospheric pressure plasma curing operations. Although the polymerizable functional group is not particularly limited, according to certain embodiments of the present invention, acrylate and / or methacrylate groups and other groups with double and / or triple bonds can be used. For example, the polymerizable functional group can include acrylate or methacrylate groups, allyl groups, alkynyl groups, styrene groups, vinyl ether groups, vinyl ester groups, vinylamide groups, maleate groups, fumarate groups, crotonate groups, cinnamate groups or norbornene groups. After being applied on the fiber structure, the FBC composition of pre-curing can move to near the plasma treatment area so that the excited material from it hits on it.Polymerizable monomer solidifies when being exposed to plasma treatment, forms the alcohol repellent composition that adheres to the solidification of fiber structure.As an example, the hydrocarbon part of polymerized 2-(perfluorohexyl) ethyl acrylate (commonly referred to as C6) is bonded to each other and is bonded to fiber structure, and fluorinated chain backs to fiber structure and repels alcohol, water and / or oil.According to some embodiments of the present invention, the FBC of pre-curing and / or solidification comprises the water that is less than about 5 % by weight, is less than the water of about 3 % by weight, is less than the water of about 2 % by weight or is less than the water of about 1 % by weight or is less than the water of about 0.5 % by weight.According to some embodiments of the present invention, the FBC of pre-curing and / or solidification is not water-free.

[0038] According to certain embodiments of the present invention, the first outermost surface, the second outermost surface, or both may include at least a portion coated with a combination of FBC and NFBC. For example, the ratio of FBC to NFBC may be from about 0.1:1 to about 10:1, such as at least about any of the following: 0.1:1, 0.3:1, 0.5:1, 0.8:1, 1:1, 1.5:1, 2:1, 2.5:1, 3:1, 3.5:1, 4:1, 4.5:1, and 5:1, and / or at most about any of the following: 10:1, 9:1, 8:1, 7:1, 6:1, and 5:1.

[0039] According to certain embodiments of the present invention, NFBC can be located on at least the first outermost surface and in one or more treated discrete regions. For example, the one or more discrete treated regions can cover from about 1% to about 100% of the first outermost surface, such as at least about any of 1%, 3%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, and 50%, and / or at most about any of 100%, 99%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, and 50%. Additionally or alternatively, the second outermost surface can include NFBC located in one or more treated discrete regions of the second outermost surface. For example, the one or more discrete treated areas of the second outermost surface may cover from about 1% to about 100% of the second outermost surface, such as at least about any of the following: 1%, 3%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, and 50% and / or at most about any of the following: 100%, 99%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, and 50%. According to certain embodiments of the present invention, for example, the NFBC may include a first NFBC comprising a first NFBC composition located on the first outermost surface of the fabric and a second NFBC comprising a second NFBC composition located on the second outermost surface of the fabric. The first NFBC composition and the second NFBC composition may be the same or different from each other.

[0040] According to certain embodiments of the present invention, the fabric may include an antistatic composition located on a first outermost surface and the NFBC may be located on a second outermost surface. According to certain embodiments of the present invention, the antistatic composition may be located on at least a portion of the first outermost surface and also located on at least the second outermost surface. The first outermost surface may have the antistatic composition at one or more separate and discrete locations, or be completely coated with the antistatic composition. According to certain embodiments of the present invention, the second outermost surface may have the antistatic composition at one or more separate and discrete locations, or be completely coated with the antistatic composition. According to certain embodiments of the present invention, the NFBC and the antistatic composition may be applied separately to the fiber substrate and / or to different areas of the fiber substrate, either on the same side of the fiber substrate or on different sides of the fiber substrate. Additionally or alternatively, the NFBC may be incorporated into the antistatic composition (e.g., formulated into a single composition comprising ingredients of both the NFBC and the antistatic composition). In this regard, a single composition can provide a method for simultaneously applying the NFBC and the antistatic agent.

[0041] According to certain embodiments of the present invention, the antistatic composition comprises at least one antistatic agent, wherein the antistatic composition comprises at least one of a nonionic antistatic agent, an anionic antistatic agent, a cationic antistatic agent, an amphoteric antistatic agent, or any combination thereof. According to certain embodiments of the present invention, at least one antistatic agent comprises an alkyl phosphate or a phosphate ester.

[0042] According to certain embodiments of the present invention, the antistatic composition may comprise from about 0.01 to about 10% by weight of the fabric (e.g., on a dry weight basis), for example, at least about 0.01, 0.05, 0.1, 0.25, 0.5, 0.75, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, and 5% by weight of the fabric (e.g., on a dry weight basis), and / or at most about any of: 10, 9, 8, 7, 6, and 5% by weight of the fabric (e.g., on a dry weight basis).

[0043] According to certain embodiments of the present invention, the NFBC includes a cured siliconized coating. For example, the cured siliconized coating may include a radiation-cured silicone network. The radiation-cured silicone network may be cured and / or bonded to the fiber structure via one or more free radical curing functional groups. For example, the radiation-cured silicone network may include the reaction product of one or more silicone acrylate oligomers or polymers or one or more epoxy silicone oligomers or polymers.

[0044] According to certain embodiments of the present invention, the one or more silicone acrylate oligomers or polymers are selected from formula (I):

[0045]

[0046] in,

[0047] R1-R9 are independently selected from -H, C1-C10 groups, -OH, alkoxy and acrylate functional groups,

[0048] R10 is selected from C1-C10 hydrocarbons;

[0049] n is selected from 1 to about 100, such as at least about any one of 1, 3, 5, 10, 20, 30, 40, and 50, and / or at most about any one of 100, 90, 80, 70, 60, and 50, and

[0050] m is selected from 1 to about 100, such as at least about any one of 1, 3, 5, 10, 20, 30, 40, and 50, and / or at most about any one of 100, 90, 80, 70, 60, and 50.

[0051] According to certain embodiments of the present invention, for example, the acrylate group from formula (I) may be a methacrylate group. Additionally or alternatively, one or more of R1-R10 may include an acrylate or methacrylate group.

[0052] According to certain embodiments of the present invention, the one or more epoxysiloxane oligomers or polymers are selected from formula (II):

[0053]

[0054] in

[0055] R1-R9 are independently selected from -H, C1-C10 groups, -OH, alkoxy and acrylate functional groups,

[0056] R10 is selected from C1-C10 hydrocarbons;

[0057] n is selected from 1 to about 100, such as at least about any one of 1, 3, 5, 10, 20, 30, 40, and 50, and / or at most about any one of 100, 90, 80, 70, 60, and 50, and

[0058] m is selected from 1 to about 100, such as at least about any one of 1, 3, 5, 10, 20, 30, 40, and 50, and / or at most about any one of 100, 90, 80, 70, 60, and 50.

[0059] According to certain embodiments of the present invention, the NFBC may include a coating composition comprising (a) a wax or a component thereof having an acid value of 10 mg to 220 mg KOH / g, as measured according to USP 401, such as at least about any of 10, 15, 20, 30, 40, 50, 60, 80, and 100 mg KOH / g, as measured according to USP 401 and / or at most about any of 220, 200, 180, 160, 150, 140, 120, and 100 mg KOH / g, as measured according to USP 401, and (b) a retention aid comprising a nitrogen-containing polymer independently selected from:

[0060] (i) a nitrogen-containing polymer of formula (III),

[0061]

[0062] wherein 'a', 'b', 'c', 'd' and 'e' represent the molar percentage of each repeating unit contained in the nitrogen-containing polymer of formula (III),

[0063] wherein R0 is independently selected from:

[0064] H,

[0065]

[0066] and their combinations, and

[0067] in:

[0068] Rz is independently selected from H, -CH3 and combinations thereof,

[0069] Rx is independently selected from H, -OH, -COOH, -COOR1, -OCOR1, -R1, -R3OH, -OR1, -NR1R1, -R3NH2, -NH2, -COO(CH2)2N(R1)2, -COO(CH2)2N+(R1)3X - 、-COO(CH2)3N+(R1)3X - and their combinations, provided that when R x When it is -NH2, R z It is -CH3,

[0070] Y is independently selected from H, -OH, -R1, -OR1, -NR1R1, -NH2 and combinations thereof,

[0071] Z is independently selected from H, -OH, -C=O, -R1, -OR1, -NR1R1, -NH2 and combinations thereof,

[0072] R1 is independently selected from H, a linear or branched alkyl or alkenyl group containing up to 22 carbons, and combinations thereof,

[0073] R2 is independently selected from H, monosaccharides, oligosaccharides, polysaccharide moieties, linear or branched alkyl or alkenyl groups of up to 22 carbons optionally containing hydroxyl or aldehyde groups, and combinations thereof,

[0074] R3 is independently selected from a linear or branched alkyl or alkenyl group containing up to 22 carbon atoms or a combination thereof,

[0075] R4 is independently selected from linear or branched alkyl groups containing up to 18 carbons, optionally substituted with hydroxyl groups, and combinations thereof,

[0076] R5 is independently selected from H, -OH, -COOH, -COOR1, -OCOR1, -R1, -R1OH, -OR1, -CONH2, -CONHCHOHCHO, -NR1, -NR1R1, -R1NH2, -NH2, and combinations thereof,

[0077] A is independently selected from C=O, -CH2, and combinations thereof, and

[0078] X- is independently an anion;

[0079] ii. Polyethyleneimine;

[0080] iii. polyaminoamide;

[0081] iv. a copolymer formed from the reaction product of epichlorohydrin and dimethylamine; and

[0082] v. Their combination.

[0083] According to certain embodiments of the present invention, 'a', 'b', 'c', 'd' and 'e' of formula (III) may each independently have a value of 0 to 100 mol %, for example, at least about any of the following: 0, 1, 3, 5, 8, 10, 15, 20, 25, 30, 35, 40, 45 and 50 mol %, and / or up to about any of the following: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55 and 50 mol %.

[0084] Those skilled in the art will appreciate that many waxes, particularly naturally occurring waxes, comprise a combination of individual components. For example, naturally occurring beeswax comprises palmitate, palmitoleate, and oleate esters of long-chain (e.g., 30-32 carbon) aliphatic alcohols, each of which is a "component thereof" with respect to beeswax. For ease of reference, the term "wax or its components" may be collectively referred to as "wax" throughout the remainder of this specification.

[0085] Although according to certain embodiments of the present invention, the wax may not be limited to any particular wax, provided that the wax has an acid value of 10 mg to 220 mg KOH / g, generally the wax may be selected from stearates, beeswax (synthetic and natural), candelilla wax, palmitates, behenates, and combinations thereof. For example, the wax of the sizing agent may be beeswax or stearates, or both. Alternatively, the wax may be behenate or palmitate, or both.

[0086] According to certain embodiments of the present invention, the coating composition may include any composition disclosed in U.S. Serial No. 17 / 498,221 (i.e., U.S. Publication No. 2022 / 01788078), for example as a component of NFBC, assigned to AGC Chemicals Americas, Inc. (PA, USA), the contents of which are incorporated herein by reference to the extent that their disclosure is consistent with the purposes of the embodiments of the present invention.

[0087] According to certain embodiments of the present invention, the NFBC may comprise from about 0.05 to about 20 weight percent of the fabric on a dry basis, for example, at least about any of 0.05, 0.08, 0.1, 0.3, 0.5, 0.8, 1, 1.2, 1.5, 1.6, 1.8, 2, 3, 4, and 5 weight percent on a dry weight basis, and / or at most about any of 20, 18, 15, 12, 10, 8, 6, and 5 weight percent on a dry weight basis.

[0088] According to certain embodiments of the present invention, the fibrous substrate has a basis weight of about 5 to about 200 grams per square meter (gsm), such as at least about any of the following: 5, 8, 10, 12, 15, 18, 20, 30, 40, 50, 60, 70, 80, 90, and 100 gsm and / or at most about any of the following: 200, 175, 150, 125, and 100 GSM. Additionally or alternatively, the fabric (e.g., the fibrous substrate plus the NFBC and any other additives) can have a basis weight of about 5 to about 200 gsm, such as at least about any of the following: 5, 8, 10, 12, 15, 18, 20, 30, 40, 50, 60, 70, 80, 90, and 100 gsm and / or at most about any of the following: 200, 175, 150, 125, and 100 GSM.

[0089] According to certain embodiments of the present invention, the fabric has a first ratio of NFBC (fabric dry basis weight %) to antistatic composition (fabric dry basis weight %) or at least one antistatic agent of about 0.2: 1 to about 3: 1, for example, at least about any one of the following: 0.2: 1, 0.4: 1, 0.6: 1, 0.8: 1, 1: 1, and / or at most about any one of the following: 3: 1, 2.5: 1, 2: 1, 1.5: 1, and 1: 1. According to certain embodiments of the present invention, the at least one antistatic agent may comprise from about 0.01 to about 0.5 weight percent of the fabric dry basis, for example, at least about any one of the following: 0.01, 0.02, 0.05, 0.08, 0.1, 0.2, and 0.25 weight percent, based on the dry weight of the fabric, and / or at most about any one of the following: 0.5%, 0.4%, 0.3%, and 0.25% by weight, based on the dry weight of the fabric. According to certain embodiments of the present invention, the fabric may not contain any antistatic agents.

[0090] According to certain embodiments of the present invention, the fibrous substrate may include one or more woven materials, one or more nonwoven materials, one or more film layers, one or more natural and / or synthetic cellulose layers (e.g., pulp, paper, tissue, etc.), or any combination thereof. According to certain embodiments of the present invention, the one or more nonwoven materials may include one or more spunbond layers, one or more meltblown layers, one or more melt filament layers, one or more electrospun layers, one or more carded nonwoven layers, one or more spunlace layers, or any combination thereof. For example, the fibrous substrate may include SMS, S, SS, SSS, meltblown alone or spunlace fibers or pulp, or in combination with any nonwoven layer or layers described and disclosed herein.

[0091] According to certain embodiments of the present invention, the fibrous substrate may include cellulosic fibers and synthetic fibers. For example, the fibrous substrate may include one or more physically entangled (e.g., hydroentangled) nonwoven layers comprising only synthetic (e.g., thermoplastic) fibers or a combination of synthetic fibers and cellulosic fibers (e.g., pulp, rayon, viscose, etc.). By way of example only, one or more spunbond layers and one or more cellulosic layers (e.g., airlaid pulp layers, tissue layers, etc.) may be stacked and subjected to hydroentanglement to physically consolidate the spunbond and cellulosic fibers into a single nonwoven layer.

[0092] According to some embodiments of the present invention, the fiber structure may include one of the following structures:

[0093] (Structure 1) S1 a -M b -S2 c ;

[0094] (Structure 2) S1 a -N d -S2 c ;

[0095] (Structure 3) S1 a -M b -N d -S2 c ;

[0096] (Structure 4) S1 a -N d -S3 e -N d -S2 c ;

[0097] (Structure 5) S1 a -N d -M b -N d -S2 c ;

[0098] (Structure 6) S1 a -M b -S3 e -M b -S2 c ;

[0099] (Structure 7) S1 a -M b -N b -M b -S2 c ; or any combination thereof;

[0100] in

[0101] "M" includes a meltblown layer or a melt film filament layer;

[0102] “N” includes submicron fiber-containing layers;

[0103] 'S1' comprises a first spunbond layer;

[0104] 'S2' comprises a second spunbond layer;

[0105] 'S3' comprises a third spunbond layer;

[0106] "a" represents the number of layers and is independently selected from 1, 2, 3, 4 and 5;

[0107] "b" means the number of layers is independently selected from 1, 2, 3, 4, 5, 6, 7 and 8;

[0108] "c" means the number of layers is independently selected from 1, 2, 3, 4 and 5; and

[0109] "d" indicates the number of layers independently selected from 1, 2, 3, 4, and 5;

[0110] “e” indicates that the number of layers is independently selected from 1, 2, 3, 4, and 5.

[0111] According to certain embodiments of the present invention, the fibrous structure may include one or more layers comprising a plurality of cellulose fibers, wherein the plurality of cellulose fibers include a plurality of natural synthetic fibers, a plurality of synthetic cellulose fibers, or a combination thereof. According to certain embodiments of the present invention, the plurality of cellulose fibers may be physically entangled with a plurality of spunbond fibers, a plurality of meltblown fibers, a plurality of staple fibers, or any combination thereof. As described above, the fibrous structure may be physically entangled (e.g., hydroentangled) with a plurality of layers, including any fibrous structure according to Structures 1-7.

[0112] According to certain embodiments of the present invention, the fibrous structure may comprise from about 0 to about 60 weight percent meltblown fibers, for example, at least about any of: 0, 5, 10, 15, 20, 25, 30, and 35% by weight and / or at most about any of: 60, 55, 50, 45, 40, and 35% by weight.

[0113] According to certain embodiments of the present invention, the fabric may include at least one adhesive. The at least one adhesive (if present) may, for example, include anionic adhesives, cationic adhesives, nonionic adhesives, amphoteric adhesives, or any combination thereof. According to certain embodiments of the present invention, the adhesive may include an adhesive that is a self-crosslinking chemical (e.g., a self-crosslinking nonionic adhesive) that improves barrier properties, particularly when formulated with NFBC. In this regard, for example, the NFBC may include one or more binders that bind to the fabric through the same application time and / or operation. According to certain embodiments of the present invention, the adhesive may include an ethylene-vinyl acetate copolymer emulsion, an acrylic emulsion, a vinyl acrylic emulsion, or a combination thereof. For example, the at least one adhesive may include at least one of an acrylic adhesive, a styrene-butadiene rubber adhesive, a vinyl copolymer adhesive, a vinyl acetate adhesive, an ethylene vinyl acetate adhesive, a polyvinyl chloride adhesive, a polyurethane adhesive, or any combination thereof. According to certain embodiments of the present invention, the at least one adhesive includes an acrylic adhesive, such as an anionic acrylic adhesive, a cationic acrylic adhesive, or a nonionic acrylic adhesive. According to certain embodiments of the present invention, the binder can comprise from about 0.01 to about 50 weight percent of the fabric dry basis, for example, at least about 0.01, 0.05, 0.1, 0.2, 0.25, 0.5, 0.75, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 8, and 10 weight percent, and / or at most about any of the following: 50, 40, 30, 20, 18, 15, 12, and 10 weight percent, based on the dry weight of the fabric. According to certain embodiments of the present invention, the inclusion of a binder can improve the water repellency and / or alcohol repellency of the fabric. Additionally or alternatively, the binder can comprise from about 10 to about 60% by weight of the NFBC on a dry basis, e.g., at least about any of 10, 15, 20, 25, and 30% by weight of the NFBC on a dry weight basis, and / or at most about any of 60, 58, 55, 52, 40, 48, 45, 42, 40, 38, 35, 32, and 30% by weight of the NFBC on a dry weight basis. Additionally or alternatively, the NFBC can have a dry basis ratio of the total solids content of the NFBC excluding the binder to the solids content of the binder of about 0.5: 1 to about 8: 1, for example, at least about any of 0.5: 1, 0.8: 1, 1: 1, 1.2: 1, 1.5: 1, 1.8: 1, 2: 1, 2.2: 1, 2.5: 1, 2.8: 1, and 3: 1, and / or at most about any of 8: 1, 7.5: 1, 7: 1, 6.5: 1, 6: 1, 5.8: 1, 5.5: 1, 5.2: 1, 5: 1, 4.8: 1, 4.5: 1, 4.2: 1, 4: 1, 3.8: 1, 3.5: 1, 3.2: 1, and 3: 1. However, according to certain embodiments of the present invention, the fabric can be binder-free.

[0114] According to certain embodiments of the present invention, the fibrous substrate includes one or more spunbond layers, one or more meltblown layers, one or more melt filament layers, one or more electrospun layers, one or more carded nonwoven layers, and / or one or more hydroentangled layers, which may independently comprise synthetic polymers such as polyolefins, polyesters, polyamides, or any combination thereof. The polyolefin may, for example, include polypropylene, polypropylene copolymers, polyethylene copolymers, or any combination thereof.

[0115] According to certain embodiments of the present invention, the fabric has an alcohol repellency rating of at least 5 as measured according to IST 80.8, or an alcohol repellency rating of at least about 6 as measured according to IST 80.8, or an alcohol repellency rating of at least about 7 as measured according to IST 80.8, or an alcohol repellency rating of at least about 8 as measured according to IST 80.8.

[0116] According to certain embodiments of the present invention, the fabric has an electrostatic decay of about 0.01 to about 0.5 seconds, as tested according to IST40.2 at 50% RH and using 10% residual charge as the cutoff level, for example, at least about any of the following: 0.01, 0.02, 0.05, 0.08 and 0.1 seconds and / or at most about any of the following: 5, 4, 3, 2, 1.5, 1.2 and 1 second.

[0117] According to certain embodiments of the present invention, the fabric has an electrostatic decay of about 1 to about 3 seconds, as tested according to IST 40.2 at 30% RH and using 10% residual charge as a cutoff level, for example, at least about any one of the following: 1, 1.2, 1.4, 1.6, 1.8 and 2 seconds and / or at most about any one of the following: 3, 2.8, 2.6, 2.4, 2.2 and 2 seconds.

[0118] According to certain embodiments of the present invention, the fabric has a hydrohead of about 10 mbar to about 100 mbar, for example, at least about any of 10, 20, 30, 40, 50, 60, 65, 70, 75, and 80 mbar and / or at most about any of 100, 95, 90, 85, and 80 mbar.

[0119] According to certain embodiments of the present invention, the fabric has a bond area defined by a plurality of discrete bond sites, for example, the bond area comprises no more than 40%, no more than 30%, no more than 25%, no more than 20%, no more than 15%, no more than 10%, no more than 5%, or no more than 3%.

[0120] According to certain embodiments of the present invention, the fabric can be provided in the form of a sanitary article, such as an absorbent underpad, a feminine hygiene product, a pull-on diaper, or a diaper. As described above, the fabric can include one or more discrete treatment areas. These one or more discrete treatment areas can include areas at high risk of exposure to body fluids, such as blood, urine, or feces.

[0121] In another aspect, the present invention provides an absorbent article comprising a fabric having a NFBC and / or FBC, such as those described herein, a liquid-permeable topsheet, and an absorbent body positioned between the fabric and the liquid-permeable topsheet. As described above, the absorbent article can be an absorbent underpad, a feminine hygiene product, a pull-on diaper, or a diaper (e.g., children's and adult diapers). In this regard, for example, a fabric having a NFBC and / or FBC, such as those described herein, can include a backsheet for at least a portion of the article. For example, a fabric having a NFBC and / or FBC, such as those described herein, can replace a conventionally used film-based backsheet. According to certain embodiments of the present invention, for example, the absorbent article may not include a backsheet comprising a film.

[0122] In another aspect, the present invention provides an absorbent diaper comprising a front region, a back region, and an intermediate crotch region positioned between the front region and the back region. The absorbent diaper may also include at least one barrier leg cuff, wherein the at least one barrier leg cuff comprises a fabric comprising a NFBC and / or FBC, such as those described herein. For example, the at least one barrier leg cuff may comprise a free distal edge and a shrinkable cuff positioned adjacent a longitudinal edge of the diaper. According to certain embodiments of the present invention, the at least one barrier leg cuff is attached to at least the crotch region of the diaper.

[0123] Figures 1A to 1C Example absorbent articles (e.g., diapers) according to certain embodiments of the present invention are shown. In this regard, Figures 1A to 1C The embodiments shown in the drawings are merely illustrative and non-limiting. Figures 1A to 1C Any particular structure shown in . Figure 1A and 1BAn exemplary diaper 1 according to certain embodiments of the present invention is shown, wherein the diaper 1 comprises a liquid-permeable top sheet 2, a liquid-impermeable bottom sheet 3, such as a barrier fabric described and disclosed herein, and a liquid-absorbent core 4 sandwiched between the liquid-permeable top sheet 2 and the liquid-impermeable bottom sheet 3. The top sheet 2 and the bottom sheet 3 may extend outwardly from the periphery of the liquid-absorbent core 4 and may be joined together in these outwardly extending regions to form leg-wrap flaps 11A and waist-wrap flaps 11B. The diaper 1 may be longitudinally composed of a front region 6, a back region 7, and an intermediate crotch region 8 between the front region 6 and the back region 7, an elastic member (first elastic member) 12 may be bonded to, for example, the inner surface of the back sheet 3 along the periphery of the waist-wrap flap 11B of the back region 7 in its stretched state, and a pair of fastening belts 13 may extend outwardly from the transversely opposite side edges of the back region 7, respectively. A pair of barrier leg cuffs 10 may extend longitudinally on the inner surface of the diaper 1 along laterally opposite (peripheral) sides of the diaper 1, passing through the front and back regions 6, 7 and the crotch region 8, wherein the barrier leg cuffs 10 may be positioned against the crotch of the wearer when the diaper 1 is worn. Each leg surrounding flap 11A may be cut away to form an arc-shaped recess on the outer side of the associated barrier leg cuff 10, and an elastic member (second elastic member) 16 may be bonded to the inner surface of the backsheet 3 in its stretched state parallel to and located inside the arc or parallel to the edge of the absorbent core.

[0124] See also Figure 1B The barrier leg cuffs 10 are of sufficient size along their bonded edges 17 to the inner surface of the diaper 1 to cover the leg surround flaps 11A and the wings 22 of the front and back regions 6 and 7 and to define substantially the same contour as the diaper 1.

[0125] Although Figures 1A to 1C A particular construction of an absorbent article according to one exemplary embodiment of the present invention is shown, but various other particular constructions incorporating the barrier nonwoven fabrics as disclosed herein may be utilized. For example, certain embodiments of the present invention may include an absorbent article as disclosed in U.S. Patent 7,435,243 (disclosing an absorbent article including a barrier leg cuff and an elasticized outer leg cuff), wherein the barrier leg cuffs may include the barrier nonwoven fabrics as disclosed herein. The contents of U.S. Patent 7,435,243 are incorporated herein by reference to the extent that such disclosure is consistent with the present disclosure. According to certain embodiments of the present invention, an absorbent article may include a variety of structures, including but not limited to the structures described in any of U.S. Patents 4,738,677, 4,795,454, and 5,582,606, wherein the barrier leg cuffs may include the barrier nonwoven fabrics as disclosed herein. The contents of U.S. Patents 4,738,677, 4,795,454, and 5,582,606 are incorporated herein by reference to the extent such disclosures are consistent with the present disclosure.

[0126] In yet another aspect, the present invention provides a method of forming a fabric. The method may include the steps of: (i) providing or forming a fibrous substrate comprising a first outermost surface and a second outermost surface; (ii) topically applying a fluorinated barrier coating (FBC) composition or a non-fluorinated barrier coating (NFBC) composition to at least a portion of at least the first outermost surface, wherein the NFBC comprises (a) a plurality of radiation-curable silicones or (b) a dispersion comprising a solvent, a wax or a component thereof, and a retention aid; and (iii) (a) if the NFBC composition comprises a plurality of radiation-curable silicones, curing the plurality of radiation-curable silicones by exposure to radiation, such as ultraviolet (UV) radiation, or (b) actively or passively evaporating the solvent from the dispersion or FBC composition to provide a fabric having NFBC and / or FBC, such as those described herein.

[0127] According to certain embodiments of the present invention, the plurality of radiation-curable silicones comprises silicone acrylate oligomers or polymers. The NFBC composition may further comprise a photoinitiator, such as an α-hydroxyketone, wherein curing of the plurality of radiation-curable silicones is carried out in an inert environment, such as nitrogen. In this regard, in the presence of the photoinitiator, the silicone acrylate oligomers or polymers may begin to react and cure upon exposure to radiation, such as UV radiation, to form a network of cured silicone acrylate oligomers or polymers. Advantageously, such curing operations of the silicone acrylate oligomers or polymers may be carried out at room temperature (e.g., 20-25°C). According to certain embodiments of the present invention, the method may further comprise the step of subjecting at least the first outermost surface to a corona treatment prior to the step of topically applying the NFBC composition.

[0128] According to certain embodiments of the present invention, the various radiation-curable silicones may include one or more epoxy silicone oligomers or polymers. The NFBC composition may further include a photocatalyst that forms a strong acid that initiates curing via epoxy groups upon exposure to radiation, such as UV radiation. When epoxy-functionalized silicone oligomers or polymers are used, the curing operation can advantageously be performed in an open environment (e.g., in the presence of oxygen).

[0129] According to certain embodiments of the present invention, the dispersion comprising a solvent, a wax or a component thereof, and a retention aid may comprise any composition disclosed in U.S. Serial No. 17 / 498,221 (i.e., U.S. Publication No. 2022 / 01788078), for example, as a component of NFBC assigned to AGC Chemicals, Inc. (PA, USA), the contents of which are incorporated herein by reference to the extent that their disclosure is consistent with the purposes of the embodiments of the present invention. In this regard, for example, the solvent may include various solvated liquids or may include a single liquid. The solvent typically includes at least water. Other liquids that may optionally be included in the solvent are water-miscible liquids. Specific examples of water-miscible solvents include at least one solvent selected from propylene glycol, dipropylene glycol, tripropylene glycol, propylene glycol monomethyl ether, propylene glycol monoethyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monoethyl ether, tripropylene glycol monomethyl ether, diacetone alcohol, and combinations thereof. Most typically, the solvent comprises water or a combination of water and at least one water-miscible solvent selected from propylene glycol, dipropylene glycol, and tripropylene glycol.

[0130] Based on the dispersion of 100 weight portions, dispersion can comprise the solvent of the amount of at least 40 weight portions conventionally.Or, dispersion can comprise the solvent of the amount of 40 to 90,50 to 90,60 to 90,70 to 90,80 to 90,50 to 80,60 to 80 or about 70 weight portions, based on the dispersion of 100 weight portions.For example, solvent can comprise water (for example tap water) and dipropylene glycol, and wherein often based on the dispersion of 100 weight portions, the amount of water is 50 to 75 weight portions, and the amount of dipropylene glycol is 15 to 40 weight portions.In addition or alternatively, wax can be present in dispersion with the amount of 10 to 50 weight portions conventionally, based on the dispersion of 100 weight portions.Or, wax can exist with the amount of 10 to 45,10 to 40,10 to 35,15 to 50,20 to 50 or 25 to 50 weight portions based on the dispersion of 100 weight portions. According to certain embodiments of the present invention, the dispersion may include 0.1-12 parts by weight of a retention aid, based on 100 parts by weight of the dispersion. Alternatively, the retention aid may be present in the dispersion in an amount of 0.1 to 12, 0.3 to 12, 0.5 to 12, 0.7 to 12, 0.9 to 12, 2.0 to 12, 3.0 to 12, 4.0 to 12, 5.0 to 12, 0.1 to 10, 0.1 to 8, 0.1 to 6, or 0.1 to 4 parts by weight, based on 100 parts by weight of the dispersion.

[0131] According to certain embodiments of the present invention, the step of providing a fibrous substrate may include providing a pretreated fibrous substrate, wherein the pretreated fibrous substrate optionally comprises an antistatic composition located on at least a portion of the first outermost surface, at least a portion of the second outermost surface, or both.

[0132] According to certain embodiments of the present invention, the step of topically applying the NFBC composition can include a spraying operation, a roller coating operation, such as a kiss-coating operation, or an offset gravure coating operation. Additionally or alternatively, the method can include bonding the fiber structure, such as by a thermal bonding method or an ultrasonic bonding method. For example, the bonding operation can include thermal calendering or hot-through bonding of the fabric.

[0133] Example

[0134] The present disclosure is further illustrated by the following examples, which should in no way be construed as limiting. That is, the specific features described in the following examples are merely illustrative and not limiting.

[0135] Example Group 1

[0136] A.Test Method

[0137] The basis weights of the following examples were measured according to ASTM test method D3776. The results are expressed in units of mass per unit area (g / m2). 2 (gsm)) provided.

[0138] The alcohol repellency of the following examples was measured according to test method IST 80.8.

[0139] The pressure heads of the following examples were measured according to standard test method IST 80.8 and with a pressure increase rate of 60 mbar / min. A larger water pressure head value is more desirable for improving barrier performance.

[0140] Air permeability is a measure of the airflow through a sheet at a specified pressure difference between the surfaces of the sheet and is based on ASTM D737 with a test area of ​​38 cm 2 , the test pressure @125Pa, and in ml / dm 2 A higher air permeability value indicates improved comfort for surgical gown and drape applications.

[0141] The low surface tension penetration time (LSTST) is a test that determines the time it takes for a specified amount of liquid discharged at a specified rate to completely penetrate a nonwoven fabric sample. The method used here is a modification of WSP 70.3(05). The changes are as follows: The test liquid is a 32 mN / m surface tension liquid prepared with Triton-X-100 and distilled water.

[0142] B. General Manufacturing Methods

[0143] All base nonwoven material samples are made of polypropylene SMS nonwoven material, and the polypropylene SMS nonwoven material includes at least one layer of polypropylene meltblown fiber, and the polypropylene meltblown fiber is located between at least two layers of polypropylene continuous spunbond fiber and is point-bonded using a hot calender. More specifically, the sample base material of the present invention is a SMMMS or SMMMMS structure made on a 5 or 6 beam production line called Reicofil 4 with similar speed and process conditions. The method includes forming a plurality of continuous spunbond filaments from a first weaving beam (e.g., weaving beam 1), depositing them on a porous moving surface, then using weaving beams 2, 3, 4 (e.g., for a three-layer meltblown structure) or weaving beams 2, 3, 4, 5 (e.g., for a four-layer meltblown structure) to form polypropylene meltblown fibers, depositing them on top of the continuous spunbond filament layer from weaving beam 1, subsequently using another weaving beam (e.g., weaving beam 5 or weaving beam 6) to spin continuous spunbond filaments, depositing them on top of the meltblown layer to form an intermediate nonwoven composite web. The intermediate composite web was then fed to the nip of a calender where it was point bonded at a pressure of 950 N / cm and a temperature of 160°C. The bond pattern occupied approximately 18% of the nonwoven surface. The bond points had an elliptical shape. For example, the inventive example identified as Example 3 was made using this method. However, Inventive Example 8 was a hydrofractionated composite of wood pulp and synthetic fibers. Inventive Examples 10 and 12 were 100% PET spunlace fabrics.

[0144] Table 1 below provides a summary of the test result data for the examples of the present invention (Examples 3, 8, 10, 12, 14, which were coated with NFBC) and comparative examples (Examples 1, 2, 4, 5, 6, 7, 9, 11, 13, which were untreated or C6FC treated) or the breathable membranes identified in Table 1.

[0145] Regarding the examples of the present invention, Example 3 is a 44 gsm SMMMS structure that was hand-treated with ~1.5% NFBC active additive (e.g., dry basis). This example achieved an average liquid strikethrough time (LSTST) of 529 seconds (722 seconds maximum), which compares well to the C6FC-coated nonwoven of Example 1 having the same basis weight. Example 3 used 1 wt% of a wetting agent on a dry basis and 7 wt% of a cationic non-fluorochemical agent on a dry basis, such as those described and disclosed herein.

[0146] Example 8 is a 75 gsm EFP (e.g., a hydroentangled composite of wood pulp and polypropylene continuous fibers) treated with ~1.7% NFBC active additive (e.g., dry basis). This example achieved an average LSTST of 2372 seconds (up to 3252 seconds), a water head of 27 mbar, IPA 40% repellency, and a spray impact of <0.1 g / AATCC 42, performance properties similar to C8 or C6 FC chemically treated EFP materials used for surgical gowns or drapes. Example 8 used 8 wt% of a cationic non-fluorochemical agent, such as those described and disclosed herein, on a dry weight basis.

[0147] Examples 10 (30 gsm) and 12 (40 gsm) were formed from a 100% PET Spunlance base material manufactured in Berry Europe-Ostomy nonwovens and treated with -1.7% NFBC active additive (dry basis). Each of these examples achieved an average hydrohead of approximately 11 mbar and an LSTST of 8.4 seconds. These properties meet the requirements for Berry Europe-Ostomy C6FC treated nonwovens. Examples 10 and 12 used 8% by weight, on a dry basis, of a cationic non-fluorochemical agent, such as those described and disclosed herein.

[0148] Additionally, embodiments of the present invention also passed the blood drop test using synthetic blood according to ASTM F1670M (eg, 15 minutes of drop exposure with no blood penetration).

[0149] In Example 14, a 13 gsm SMS nonwoven fabric was constructed having 16 wt% meltblown fibers (AMB 1.5) wherein the SMS was treated with ~1.5% active additive (dry basis) NFBC. This example achieved an average LSTST of 35 seconds, which is comparable to fluorine-treated diaper backsheets currently on the market.

[0150]

[0151]

[0152] Table 1

[0153] Example Group 2

[0154] Another set of examples was conducted and tested for various physical properties. For example, a 45 gsm PP SMMMSKamisoft material and 44 gsm and 69 gsm PP SMMMMS nonwovens were produced and coated with Non-FC Example A with a higher percentage of adhesive compared to Examples 8, 11, and 13 from Example Set 1. The test results are listed in Table 2 below. These coated samples with a higher percentage of adhesive (e.g., on a dry weight basis) contained 1.76 wt% solid Non-FC Example A chemicals, with 1.6 wt% adhesive (based on dry weight, the ratio of Non-FC Example A (excluding adhesive) to adhesive was 1.1:1). The results showed that up to 70% ethanol repellency was achieved using test method IST 80.8. Furthermore, the treated nonwovens retained MD tensile strength (tested using Berry MONC Laboratory Test Procedure 56: 30 cm / min tensile speed, 10 cm gap, 50 mm x 175 mm sample size, 50 mm clamp size, measured in N / 5 cm) after the finishing process. The static decay was tested using the standard test method IST 40.2 at 50% RH using 50% residual charge as the cutoff level. The properties of the resulting fabrics (Examples 8, 11, and 13) are summarized in Table 2 below. The static decay at 50% RH and 50% cutoff was required to be less than 1 second, with a target of 0.5 seconds.

[0155] The adhesive used was a self-crosslinking nonionic acrylic adhesive emulsion. By adding higher amounts of adhesive, the observed IPA (isopropyl alcohol repellency) rating increased from 4 to 5 (40% to 50% IPA repellency) and the ethanol repellency rating increased from 5 to 7 (50% to 70% IPA repellency). In addition, for 30 gsm, 40 gsm, 100% PET spunbond nonwoven materials and 40 gsm PE spunbond, PP SMMMMS nonwoven materials, 0.8 wt% to 1.6 wt% of the non-FC formulation on a dry basis was added.

[0156] Sample (2) 40 gsm PE spunbond (medical ostomy nonwoven fabric) treated with -1.32% dry weight add-on (= 1.32 wt%) of non-FC Example A plus 1.2% binder achieved IPA 50% repellency and 70% ethanol repellency. Example 2 used 1.2 wt% on a dry weight basis of a wetting agent, 6 wt% on a dry weight basis of a cationic non-fluorochemical agent, such as those described and disclosed herein, and 3 wt% on a dry weight basis of a binder, as described below.

[0157] Samples (4) and (6) 30 gsm and 40 gsm 100% PET Spunlance (medical ostomy nonwoven) treated with ~1.32% dry weight addition (= 1.32 wt%) of non-FC Example A plus 0.8% binder achieved IPA 50% repellency and 70% and 80% ethanol alcohol repellency. These examples used 1.2 wt% or dry basis of wetting agent, 6 wt% on dry basis of a cationic non-fluorochemical agent, such as those described and disclosed herein, and 2 wt% on dry basis of binder, as described below.

[0158] Samples (8), (11), and (23) were 45 gsm, 44 gsm, and 69 gsm polypropylene SMMMS nonwovens, respectively. Each sample used 1.6 wt% on a dry weight basis of a wetting agent, 8 wt% on a dry weight basis of a cationic non-fluorochemical agent, such as those described and disclosed herein, and 4 wt% on a dry weight basis of a binder, as described below.

[0159]

[0160]

[0161]

[0162] Table 2

[0163] In the above invention examples, non-FC Example A is a cationic acrylic polymer containing alkylsilane methacrylate groups. The above wetting agent is Alkanol TM 6112 (decan-1-ol; CAS No. 112-30-1).

[0164] These and other modifications and variations may be made to the present invention 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. In addition, it should be understood that aspects of the various embodiments may be interchangeable in whole or in part. Furthermore, it will be understood by those skilled in the art that the foregoing description is merely exemplary and is not intended to limit the present invention as further described in these appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein.

Claims

1. A fabric comprising: (i) a fibrous substrate comprising a first outermost surface and a second outermost surface; as well as (ii) a non-fluorinated barrier coating (NFBC) disposed on at least a portion of the first outermost surface of the fabric, at least a portion of the second outermost surface of the fabric, or both, and / or a fluorinated barrier coating (FBC) disposed on at least a portion of the first outermost surface of the fabric, at least a portion of the second outermost surface of the fabric, or both.

2. The fabric of claim 1 , wherein the fabric comprises the FBC, and wherein the FBC comprises at least one fluorochemical comprising at least one C4 fluorochemical, C6 fluorochemical, C8 fluorochemical, C10 fluorochemical, or any combination thereof.

3. The fabric of claim 2, wherein the FBC comprises a digitally printed or sprayed composition comprising a plasma cured composition.

4. The fabric of claim 1 , wherein the fabric comprises the NFBC, and wherein the NFBC comprises a first NFBC comprising a first NFBC composition located on a first outermost surface of the fabric, and a second NFBC comprising a second NFBC composition located on a second outermost surface, and wherein the first NFBC composition and the second NFBC composition are the same as or different from each other.

5. The fabric of claim 1, wherein the NFBC comprises a cured siliconized coating comprising a network of radiation-cured silicone.

6. The fabric of claim 5, wherein the radiation-cured silicone network comprises the reaction product of one or more silicone acrylate oligomers or polymers or one or more epoxysilicone oligomers or polymers.

7. The fabric of claim 1 , wherein the fibrous substrate comprises one or more spunbond layers, one or more meltblown layers, one or more melt fibrillated layers, one or more electrospun layers, one or more carded nonwoven layers, one or more hydroentangled layers, or any combination thereof.

8. The fabric of claim 1, wherein the fabric further comprises at least one binder.

9. An absorbent article comprising: (i) the fabric according to claim 1; (ii) a liquid permeable topsheet; as well as (ii) an absorbent body positioned between the tissue and the liquid-permeable topsheet.

10. The absorbent article of claim 9, wherein the absorbent article is a diaper or a feminine hygiene product.

11. An absorbent diaper comprising: A front region, a back region, a middle crotch region between the front region and the back region, and at least one barrier leg cuff, wherein the at least one barrier leg cuff comprises the fabric of claim 1.

12. The absorbent diaper of claim 11, wherein the at least one barrier leg cuff comprises a free distal edge and a contractible cuff positioned adjacent a longitudinal edge of the diaper.

13. The absorbent diaper according to claim 11, wherein the at least one barrier leg cuff is attached at least to the crotch region of the diaper.

14. A method of forming a fabric, comprising: (i) providing or forming a fibrous substrate comprising a first outermost surface and a second outermost surface; (ii) topically applying a fluorinated barrier coating (FBC) composition or a non-fluorinated barrier coating (NFBC) composition to at least a portion of at least said first outermost surface, wherein said NFBC comprises (a) a plurality of radiation-curable silicones, or (b) a dispersion comprising a solvent, a wax or a component thereof, and a retention aid; as well as (iii) (a) if the NFBC composition comprises radiation-curable silicones, curing the radiation-curable silicones by exposure to radiation, such as ultraviolet (UV) radiation, or (b) actively or passively evaporating the solvent from the dispersion or FBC composition.

15. The method of claim 14, further comprising the step of corona treating at least the first outermost surface prior to the step of topically applying the NFBC composition.

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