Membranes with malodor control

Abstract

A gas permeable membrane comprising a vapor permeable and liquid impermeable (VPLI) membrane is provided, the membrane comprising a microporous membrane comprising a plurality of micropores. The gas permeable membrane includes (a) a first outermost surface, (b) a second outermost surface, (c) a thickness extending between the first outermost surface and the second outermost surface, and (d) at least one odorant compound separant (OCSA) dispersed throughout the thickness of the gas permeable membrane. The present invention relates to a composition comprising at least one OCSA comprising (i) one or more ricinoleate salts, and / or (ii) one or more cucurbituril compounds, such as CB [5], CB [6], CB [7], CB [8], or any mixture thereof, and / or (iii) one or more zeolites, and / or (iv) one or more halogenated active aromatic sulfonamide compounds. Absorbent articles comprising such breathable films are also provided.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Patent Application No. 63 / 449,760, filed March 3, 2023, pursuant to 35 U.S. SC §119(e), the entire disclosure of which is expressly incorporated herein by reference. Technical Field

[0003] Embodiments of the present invention generally relate to membranes, such as breathable microporous membranes or non-breathable membranes, having at least one odorous compound sequestering agent (OCSA) applied locally and / or dispersed throughout the membrane thickness, wherein the at least one OCSA sequesters one or more odorous compounds through absorption, adsorption, coordination, covalent bonding, or any combination thereof. Absorbent articles comprising such membranes (e.g., as substrates) are also provided. Background Technology

[0004] Absorbent materials such as pads are widely used in absorbent products such as menstrual pads, diapers (for infants and people with incontinence), sanitary napkins, tampons, wound dressings, and bandages to absorb bodily fluids. These absorbent materials may incorporate highly absorbent polymers that absorb many times their own weight in fluids or other fibrous materials, such as cotton, wood pulp, and paper. Bodily fluids absorbed by such absorbent components may include vomit, blood, pus, sweat, semen, secretions, menstrual discharge, urine, and excretions. In this respect, bodily fluids may have an unpleasant odor (malodor) due to odor-producing molecules, which may be aliphatic, aromatic, or heterocyclic compounds containing oxygen, sulfur, or nitrogen. More pleasant odor molecules, such as fragrances, can be used to mask the odor-causing molecules.

[0005] However, there remains a need in the art for membranes that can be incorporated into various absorbent articles, membranes capable of isolating (e.g., neutralizing / or disrupting) one or more odor-causing molecules that are generated / released over a long period of time. Summary of the Invention

[0006] One or more embodiments of the present invention can solve one or more of the above-mentioned problems. According to certain embodiments of the present invention, a thin film, such as a breathable membrane, is provided, comprising a vapor-permeable and liquid-impermeable (VPLI) membrane. The VPLI may comprise a microporous membrane. The microporous membrane may comprise a plurality of micropores defining or otherwise providing a tortuous path for vapor flow through while providing desired liquid barrier properties. The microporous membrane may comprise (a) a first outermost surface, (b) a second outermost surface, (c) a thickness extending between the first and second outermost surfaces, and (d) at least one odorous compound barrier agent (OCSA) dispersed throughout the thickness of the membrane, wherein at least one OCSA comprises (i) at least one ricinoleate (e.g., zinc ricinoleate), and / or (ii) one or more cucurbituril compounds, such as CB[5], CB[6], CB[7], CB[8], or any mixture thereof, and / or (iii) one or more zeolites, and / or (iv) one or more halogenated active aromatic sulfonamide compounds.

[0007] In another aspect, the present invention provides a method for forming a breathable membrane, such as those described and disclosed herein. The method may include the following steps: (i) forming a polymer melt; (ii) adding a pore-forming filler material to the polymer melt; (iii) adding a dry masterbatch to the polymer melt, wherein the dry masterbatch contains at least one odorous compound separator (OCSA), the OCSA containing (a) at least one ricinoleate (e.g., zinc ricinoleate), and / or (b) one or more cucurbita compounds, such as CB[5], CB[6], CB[7], CB[8], or any mixture thereof, and / or (c) one or more zeolites, and / or (d) one or more halogenated active aromatic sulfonamide compounds; (iv) mixing the pore-forming filler material and the dry masterbatch into the polymer melt; (v) melt-extruding the polymer melt containing the pore-forming filler material and at least one OCSA to form an intermediate membrane; and (vi) incrementally stretching the intermediate membrane in the longitudinal and / or transverse directions to form the breathable membrane.

[0008] In another aspect, the present invention provides an absorbent article comprising: (i) a liquid-permeable top sheet (LPTS), such as a nonwoven fabric and / or a top-perforated membrane (TAF); (ii) a bottom sheet comprising a membrane, such as a breathable membrane as described and disclosed herein; and (iii) an absorbent core, wherein the absorbent core is located directly or indirectly between the LPTS and the bottom sheet.

[0009] In another aspect, the present invention provides a method for manufacturing an absorbent article, the method comprising the steps of: (i) providing or forming a liquid-permeable top sheet (LPTS), such as a nonwoven fabric and / or a top-perforated membrane (TAF); (ii) providing or forming a back sheet comprising a membrane, such as a breathable membrane as described and disclosed herein; (iii) providing or forming an absorbent core, wherein the absorbent core is located directly or indirectly between the LPTS and the back sheet; and (iv) bonding the back sheet directly or indirectly to the absorbent core. Attached Figure Description

[0010] The invention will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of the invention. In fact, 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 to enable this disclosure to meet applicable legal requirements. Throughout the text, the same reference numerals denote the same elements, wherein:

[0011] Figure 1 An absorbent article according to certain embodiments of the present invention is shown, wherein the substrate is directly bonded to the absorbent core;

[0012] Figure 2 An absorbent article according to certain embodiments of the present invention is shown, wherein a substrate is indirectly bonded to an absorbent core via an adhesive layer;

[0013] Figure 3 An absorbent article comprising a collection distribution layer located between a top sheet and an absorbent core, according to certain embodiments of the present invention, is shown;

[0014] Figure 4-10 Visual comparisons of the membranes were presented, and the effects of odor control masterbatch, calcium carbonate (CaCO3) filler, and activation on reducing urine odor were investigated; and

[0015] Figure 11-13 The visual comparison of the membrane was explained, and the necessity of combining the odor control masterbatch with calcium carbonate (CaCO3) filler and its activation for effective odor reduction were investigated. Detailed Implementation

[0016] The invention will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of the invention. In fact, 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 to enable this disclosure to meet applicable legal requirements. As used in the specification and appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly indicates otherwise.

[0017] This invention generally relates to membranes incorporating odor control functions, such as breathable or non-breathable membranes. According to certain embodiments of the invention, the breathable membrane may comprise a microporous membrane having a plurality of micropores that define or otherwise provide a tortuous path for vapor to pass through the membrane while providing a desired level of liquid barrier performance. For example, odor control functionality can be provided by incorporating one or more odorous compound separators (OCSAs) dispersed throughout the thickness of the breathable membrane. For example, one or more OCSAs may be incorporated into the breathable membrane as a melt additive into a film-forming melt (e.g., a polymer melt) used to prepare the membrane. For example, one or more OCSAs may be components of a dried (e.g., granular) masterbatch comprising a polymer carrier (e.g., a polymer matrix) and one or more OCSAs dispersed throughout the polymer carrier. For example, the dried masterbatch can be readily added to the polymer melt used to form the membrane. In this respect, one or more OCSAs may be directly incorporated into the polymer membrane formulation of the breathable membrane. As described above, the breathable membrane may include a microporous membrane that provides an increased surface area (e.g., through multiple micrometer-sized pores and / or micrometer-sized channels) to minimize odor in a soiled absorbent article. For example, odorous gaseous compounds are ensured a tortuous path with a high surface area through the microporous membrane layer, allowing the odorous gaseous compounds to interact with one or more OCSAs introduced into the microporous membrane. In other words, these embodiments can provide greater interaction between odorous gaseous compounds and one or more OCSAs present throughout the bulk or thickness (or membrane layer) of the microporous membrane. Therefore, a more efficient use of a given amount of OCSA can be achieved compared to incorporating one or more OCSAs into, for example, the absorbent core of an absorbent article. However, according to certain embodiments of the invention, one or more OCSAs may also be incorporated into the absorbent core and / or the acquisition distribution layer (ADL) if desired.

[0018] The term “substantially” or “substantially” may cover the total amount specified according to certain embodiments of the invention, or, according to other embodiments of the invention, largely but not the specified total amount (e.g., 95%, 96%, 97%, 98%, or 99% of the specified total amount).

[0019] The term "polymer" or "polymeric," as used interchangeably herein, may include homopolymers, copolymers such as block, graft, random and alternating copolymers, terpolymers, etc., and their blends and modifications. Furthermore, unless specifically limited otherwise, the term "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 term "polymer" or "polymeric" shall also include polymers made from various catalyst systems, including but not limited to Ziegler-Natta catalyst systems and metallocene / single-center catalyst systems. According to certain embodiments of the invention, the term "polymer" or "polymeric" shall also include polymers produced by fermentation methods or of biological origin.

[0020] As used herein, the term "layer" may include a generally identifiable combination of similar material types and / or functions present in the XY plane.

[0021] As used herein, the term "longitudinal" or "MD" includes the direction in which films and / or fabrics are produced or conveyed. The term "transverse" or "CD" as used herein includes the direction of films and / or fabrics that is substantially perpendicular to the MD.

[0022] As used herein, the term "membrane" can include one or more layers of polymer or elastomer produced using membrane extrusion processes such as cast film or blown film extrusion. The term can also include membranes that impart micropores by mixing polymers and / or elastomers with fillers, forming the mixture into a membrane, and optionally stretching the membrane.

[0023] As used herein, the term "microporous" membrane can include thin films or membranes having a narrow pore size distribution in the submicron range of 1.0 to 10 micrometers. Microporous membranes can be prepared by a number of methods, including (a) dissolving a polymer in a solution and then extracting the solvent with steam, (b) stretching a crystallizable polymer, which results in micro-sized tearing, and (c) stretching a mineral-filled polyolefin membrane. Polymers used for microporous membranes include PTFE, polyolefins, polyurethanes, polyamides, and polyesters.

[0024] As used herein, the term "filler" can include particles or particle aggregates and other forms of materials that can be added to polymer film blends. According to certain embodiments of the invention, fillers can be substantially without chemical interference or adverse effect on the extruded film. According to certain embodiments of the invention, fillers can be uniformly dispersed throughout the film or in layers contained in a multilayer film. Fillers can include, for example, particulate inorganic materials such as calcium carbonate (CaCO3), various clays, silica, alumina, barium sulfate, sodium carbonate, talc, magnesium sulfate, titanium dioxide, zeolite, aluminum sulfate, cellulose-type powders, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, glass particles, etc., and organic particulate materials such as high-melting-point polymers (e.g., from EIDuPont de Nemours and Company). and Pulp powder, wood flour, cellulose derivatives, chitin and chitin derivatives, etc. The filler particles may optionally be coated with fatty acids such as stearic acid or reduced stearic acid, or larger-chain fatty acids such as benzyl acid. Without wishing to be bound by theory, according to certain embodiments of the invention, the coated filler particles can promote the free flow of the particles (in bulk) and their easy dispersion into the polymer matrix.

[0025] As used herein, the term "monolithic" membrane can include any continuous membrane that is substantially pore-free or non-porous (e.g., without pores). In some alternative embodiments of the invention, a "monolithic" membrane may contain fewer pore structures than those found in microporous membranes. According to some non-limiting exemplary embodiments of the invention, a monolithic membrane can serve as a barrier to liquids and particulate matter, but allows water vapor to pass through, for example, by absorbing water vapor on one side of the membrane, transporting water vapor through the membrane, and releasing water vapor on the opposite side of the membrane.

[0026] As used herein, the term "highly permeable polymer" can include any polymer or elastomer that is selectively permeable to water vapor but substantially impermeable to liquid water and can form a breathable membrane. For example, the polymer is capable of absorbing and desorbing water vapor and providing a barrier to aqueous fluids (e.g., water, blood, etc.). For instance, a highly permeable polymer can absorb water vapor from one side of the membrane and release it to the other side, thereby allowing water vapor transport through the membrane. Because highly permeable polymers impart breathability to the membrane, membranes formed from such polymers do not need to include pores (e.g., monolithic membranes). According to certain embodiments of the invention, a "highly permeable polymer" can include a membrane having a density of at least 500 g / m³ when formed. 2Any thermoplastic polymer or elastomer with a moisture permeability (MVTR) of / day. According to certain embodiments of the invention, a “highly permeable polymer” may include any thermoplastic polymer or elastomer that, when formed into a film, for example, has a thickness of about 25 micrometers or less, has a moisture permeability (MVTR) of at least 750 g / m². 2 / day or at least 1000g / m 2 / day MVTR. According to certain embodiments of the invention, the highly permeable polymer may include, for example, a polyether block amide copolymer (e.g., from the Arkema Group). ), polyester block amide copolymers, copolyester thermoplastic elastomers (e.g., from DSM Engineering Plastics) From EIDuPont de Nemours and Company It can be any one or a combination of thermoplastic polyurethane elastomers (TPU). Highly breathable polymers can be used to form monolayer films.

[0027] Compounds should be described using standard nomenclature. For example, any position not substituted by any specified group should be understood as having its valence filled by a specified bond or hydrogen atom. A hyphen ("-") not between two letters or symbols is used to indicate the connection point of a substituent. For example, the aldehyde group -CHO is connected to the carbonyl group via a carbonyl group.

[0028] As used herein, the term "alkyl" refers to a fully saturated group consisting entirely of carbon and hydrogen atoms. Alkyl groups can be straight-chain, branched, or cyclic, and such groups can be referred to as straight-chain alkyl, branched alkyl, or cycloalkyl.

[0029] As used herein, the term "aromatic" refers to a group having a ring system containing a delocalized conjugated π system, wherein the delocalized conjugated π system has a number of π-electrons that conform to Hückel's rule. This ring system may include heteroatoms (e.g., N, S, Se, Si, O) or may consist only of carbon and hydrogen. Exemplary aromatic groups include phenyl, thiophene, naphthyl, and biphenyl.

[0030] As used herein, the term "aryl" refers to an aromatic group consisting only of carbon and hydrogen. Exemplary aryl groups include phenyl, naphthyl, and biphenyl.

[0031] As used herein, the term "heteroaryl" refers to an aromatic group containing at least one heteroatom. Exemplary heteroaryls include thiophene groups. Note that "heteroaryl" is a subset of "aromatic" and does not include "aryl".

[0032] As used in this article, the term "alkoxy" refers to an alkyl group bonded to an oxygen atom, such as —O—C. n H 2n+1It is linked to molecules containing this group.

[0033] As used in this article, the term "halogen" refers to fluorine, chlorine, bromine, and iodine.

[0034] As used herein, the term "substituted" means that at least one hydrogen atom on a specified group is replaced by another functional group such as halogen, -CN, or -NO2. In addition to the aforementioned functional groups, aromatic groups may also be substituted with alkyl or alkoxy groups. An exemplary substituted aryl group is methylphenyl.

[0035] As used in this article, the term "alkali metals" refers to lithium, sodium, and potassium.

[0036] As used in this article, the term "alkaline earth metals" refers to magnesium and calcium.

[0037] In one aspect, certain embodiments of the invention provide a breathable membrane comprising a vapor-permeable but liquid-impermeable (VPLI) membrane containing a microporous membrane. The microporous membrane may include a plurality of micropores defining or otherwise providing a tortuous path for vapor flow through while providing desired liquid barrier properties. Microporous membranes are typically prepared by dispersing finely divided particles of a non-hygroscopic filler material, such as an inorganic salt (e.g., calcium carbonate), into a suitable polymer, subsequently forming a polymer-filled membrane and stretching the membrane to provide good porosity and water vapor absorption or transport. According to certain embodiments of the invention, the microporous membrane may comprise a polyolefin, such as polyethylene or polypropylene, or a copolymer comprising a first polyolefin, such as first polyethylene, and a second polyolefin, such as second polypropylene. The microporous membrane may include (a) a first outermost surface, (b) a second outermost surface, (c) a thickness extending between the first and second outermost surfaces, and (d) at least one odorous compound separator (OCSA) dispersed throughout the thickness of the membrane, wherein at least one OCSA comprises (i) at least one ricinoleate (e.g., zinc ricinoleate), and / or (ii) one or more cucurbituril compounds, such as CB[5], CB[6], CB[7], CB[8] or any mixture thereof, and / or (iii) one or more zeolites, and / or (iv) one or more halogenated active aromatic sulfonamide compounds.

[0038] According to certain embodiments of the present invention, one or more halogenated active aromatic sulfonamide compounds (if present) may optionally have a structure according to molecular formula (I):

[0039]

[0040] R1, R2, R3, R4, and R5 are independently selected from hydrogen, COOR', CON(R”)2, alkoxy, CN, NO2, SO3R”, halogen, substituted or unsubstituted phenyl, sulfonamide, halosulfonamide, N(R”)2, substituted or unsubstituted C1-C 12 Alkyl groups, and substituted or unsubstituted aromatic groups;

[0041] R' is hydrogen, alkali metal, alkaline earth metal, or a substituted C1-C. 12 Alkyl or unsubstituted C1-C 12 Alkyl groups; and

[0042] R″ is hydrogen or a substituted or unsubstituted C1-C. 12 Alkyl groups, wherein the two R″ groups in CON(R″)2 and N(R″)2 can be chosen independently;

[0043] X is a halogen;

[0044] M is an alkali metal or an alkaline earth metal; and

[0045] n is the number of water molecules per molecule of sulfonamide compound.

[0046] Typically, M is sodium or potassium. X is typically chlorine, bromine, fluorine, or iodine, and in a specific embodiment, chlorine. The compound of formula (I) can be hydrated or undried, as indicated by the variable n. In a specific embodiment, the compound of formula (I) is a trihydrate (i.e., n = 3) or a hexahydrate (i.e., n = 6). In other embodiments, the compound is in solid form, such as a powder.

[0047] When phenyl and / or alkyl groups are substituted, one or more hydrogen atoms can be independently replaced by hydroxyl groups or halogens.

[0048] In a specific embodiment of molecular formula (I), R3 is methyl, COOH, or COOM1; R1, R2, R4, and R5 are independently selected from hydrogen, COOH, COOM1, COOR', CON(R”)2, alkoxy, CN, NO2, SO3R”, halogen, substituted or unsubstituted phenyl, sulfonamide, halosulfonamide, N(R”)2, substituted or unsubstituted C1-C 12 Alkyl groups, and substituted or unsubstituted aryl groups; X is a halogen; M1 is an alkali metal or alkaline earth metal; n is the number of water molecules per molecule of the sulfonamide compound.

[0049] In a further embodiment, R3 is methyl, COOH, or COOM1; R1, R2, R4, and R5 are independently selected from hydrogen, COOH, COOM1, COOR', CON(R”)2, alkoxy, CN, NO2, SO3R”, halogen, substituted or unsubstituted phenyl, sulfonamide, halosulfonamide, N(R”)2, substituted or unsubstituted C1-C 12 Alkyl groups, and substituted or unsubstituted aryl groups; X is a halogen; M is an alkali metal or alkaline earth metal; n is the number of water molecules per molecule of the sulfonamide compound; and at least one of R1, R2, R4, and R5 is not hydrogen.

[0050] In other embodiments of formula (I), R3 is selected from COOH, COOM1, COOR', CON(R”)2, CN, NO2, halogens, and substituted or unsubstituted C2-C. 12 Alkyl groups; R1, R2, R4, and R5 are independently selected from hydrogen, COOH, COOM1, COOR', CON(R”)2, alkoxy, CN, NO2, SO3R”, halogen, substituted or unsubstituted phenyl, sulfonamide, halosulfonamide, N(R”)2, substituted or unsubstituted C1-C 12 Alkyl groups, and substituted or unsubstituted aryl groups; X is a halogen; M is an alkali metal or alkaline earth metal; n is the number of water molecules per molecule of the sulfonamide compound.

[0051] In other embodiments of formula (I), R1, R2, R3, R4, and R5 are independently selected from hydrogen, COOH, COOM1, NO2, halogens, N(R”)2, substituted or unsubstituted C1-C 12 Alkyl groups and substituted or unsubstituted aromatic groups; X is a halogen; M is an alkali metal or alkaline earth metal; n is the number of water molecules per molecule of sulfonamide compound.

[0052] In other embodiments of formula (I), R2 and R4 are the same as each other; and R1, R3 and R5 are hydrogen.

[0053] In other embodiments of molecular formula (I), R2 and R4 are hydrogen; R1, R3 and R5 are the same as each other.

[0054] In a more specific embodiment of molecular formula (I), R3 is selected from COOH, COOM1, COOR' and CON(R”)2, and ideally, R3 is COOH or COOM1, while R1, R2, R4 and R5 are hydrogen.

[0055] In other embodiments of formula (I), R1, R2, R3, R4, and R5 are independently selected from hydrogen, COOH, COOM1, COOR', CON(R”)2, NO2, halogens, N(R”)2, substituted or unsubstituted C1-C 12Alkyl groups, and substituted or unsubstituted aromatic groups; wherein at least one of R1, R2, R3, R4 and R5 is not hydrogen; X is a halogen; M is an alkali metal or alkaline earth metal; n is the number of water molecules per molecule of the sulfonamide compound.

[0056] In other embodiments of formula (I), R3 is COOH or COOM1; R1, R2, R4 and R5 are independently selected from hydrogen, NO2, halogen, N(R”)2, substituted or unsubstituted C1-C 12 Alkyl groups and substituted or unsubstituted aromatic groups; X is a halogen; M is an alkali metal or alkaline earth metal; n is the number of water molecules per molecule of the sulfonamide compound. In further specific embodiments, at least one of R1, R2, R4, and R5 is not hydrogen.

[0057] In some embodiments of formula (I), at least one of R1, R2, R3, R4, or R5 is not hydrogen. In more specific embodiments of formula (I), at least two of R1, R2, R3, R4, or R5 are not hydrogen. In other words, the benzene ring contains a sulfonamide substituent and one or two other substituents.

[0058] In other embodiments of formula (I), the halogenated active aromatic sulfonamide compound has the structure of formula (II):

[0059]

[0060] Where R3 stands for COOR'; R' is hydrogen, alkali metal, alkaline earth metal, or substituted C1-C. 12 Alkyl, unsubstituted C1-C 12 Alkyl, substituted aromatic or unsubstituted aromatic;

[0061] X is a halogen; M is an alkali metal or alkaline earth metal; n is the number of water molecules per molecule of the sulfonamide compound. The N-chloro-4-carboxyalkylbenzene sulfonamide compound of formula (II) is also referred to herein as BENZ. When BENZ is combined with at least one fragrance, there is no detectable chlorine odor to most people.

[0062] The two specific sulfonamide compounds considered for use are N-chloro-p-toluenesulfonamide (i.e., chloramine-T) and N-chloro-4-carboxyalkylbenzenesulfonamide (i.e., BENZ). These two compounds are shown in the following molecular formulas (III) and (IV):

[0063]

[0064] Where M2 is hydrogen, an alkali metal, or an alkaline earth metal; X is a halogen, and M is independently an alkali metal or an alkaline earth metal; n is the number of water molecules in each molecule of each sulfonamide compound. Ideally, M2 is hydrogen, sodium, or potassium.

[0065] In other specific embodiments, one or more of R1, R2, R3, R4, and R5 are substituted with -COOR' (the others being hydrogen). In this regard, it is believed that halogenated active aromatic sulfonamide compounds have higher antimicrobial properties when they have two or more ionic charges. The antimicrobial properties of these compounds of formula (I) are undesirable because sulfonamide groups having halogen atoms bonded to nitrogen atoms are not present in molecules with known antimicrobial properties.

[0066] The halogenated active aromatic sulfonamide compounds of basic formula (I) are stable and do not decompose in aqueous solution, thus giving the disinfectant composition a long shelf life. Compounds of formula (I) are also highly soluble in water, have low toxicity, and exhibit minimal bleaching odor.

[0067] According to certain embodiments of the present invention, one or more halogenated active aromatic sulfonamide compounds may constitute from about 0.0001% to about 40% by weight of the microporous membrane, for example at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8 and 10% by weight of the microporous membrane, and / or at most about any one of the following: 40, 30, 20, 18, 15, 12 and 10% by weight of the microporous membrane.

[0068] One or more cucurbituril compounds, if present, refer to macrocyclic molecules consisting of methylene-bridged (-CH2-)-linked glycourea (=C4H2N4O2=) monomers. In this respect, cucurbituril is a member of the Cavitand family, and the general cucurbituril structure is based on a cyclic arrangement of glycourea subunits linked by methylene bridges, wherein oxygen atoms are positioned along the edges of the bands and tilted inward to form a partially closed cavity. The name derives from the resemblance of these molecules to squash, a member of the Cucurbitaceae family. Cucurbituril is usually written as cucurbituril[n]urea, where n is the number of glycourea units. Two common abbreviations are CB[n], or simply CBn. For example, cucurbituril[8]urea (CB[8]; CAS259886-51-6) is a barrel-shaped container molecule with eight repeating glycourea units and an internal cavity volume of 479A3 (see Structures below). CB[8] is readily synthesized using standard techniques and is commercially available (e.g., Sigma-Aldrich, MO USA). CB[8] is described below:

[0069]

[0070] According to certain embodiments of the invention, one or more cucurbituril compounds may be introduced into the bulk or thickness of a microporous membrane, wherein they may form complexes with malodor molecules. The one or more cucurbituril compounds may include compounds of CB[5], CB[6], CB[7], CB[8], CB[9], CB

[10] , CB

[11] , CB

[12] , CB

[13] , CB

[14] , or mixtures thereof. For example, one or more cucurbituril compounds may comprise a mixture of cucurbituril compounds of different sizes (e.g., cavities). By way of example only, one or more cucurbituril compounds may comprise a mixture of at least two different cucurbiturils selected from CB[5], CB[6], CB[7], and CB[8].

[0071] According to certain embodiments of the invention, one or more cucurbituril compounds, if present, may contain about 0.1 to about 99% by weight of CB[5] based on the total weight of cucurbituril, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, 40 and 50% by weight, and / or at most about any one of the following: 99, 95, 90, 80, 70, 60 and 50% by weight. Alternatively or additionally, one or more cucurbituril compounds, if present, may contain about 0.1 to about 99% by weight of CB[6] based on the total weight of cucurbituril, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, 40 and 50% by weight, and / or at most about any one of the following: 99, 95, 90, 80, 70, 60 and 50% by weight. Alternatively or alternatively, one or more cucurbituril compounds, if present, may contain about 0.1 to about 99% by weight of CB[7] based on the total weight of cucurbituril, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, 40 and 50% by weight, and / or at most about any one of the following: 99, 95, 90, 80, 70, 60 and 50% by weight. Alternatively or alternatively, one or more cucurbituril compounds, if present, may contain about 0.1 to about 99% by weight of CB[8] based on the total weight of cucurbituril, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, 40 and 50% by weight, and / or at most about any one of the following: 99, 95, 90, 80, 70, 60 and 50% by weight. Alternatively or, if present, one or more cucurbituril compounds may constitute a total concentration of the total weight of cucurbituril, and CB[5] and / or CB[6] and / or CB[7] and / or CB[8] may together constitute more than 75% by weight of the total weight of cucurbituril, more particularly more than about 90% by weight, and more particularly more than about 99% by weight. The remaining components of the cucurbituril mixture may contain CB[4], CB[9] and / or higher cucurbituril (i.e., CB

[10] -CB

[20] ), or cucurbituril of a single size or a mixture of these sizes.

[0072] If present, the average particle size of one or more cucurbituril compounds can be from about 0.01 micrometers to about 50 micrometers, for example, at least about any one of the following: 0.01, 0.5, 1, 3, 5, 8, and 10 micrometers, and / or at most about any one of the following: 50, 40, 30, 20, and 10 micrometers. Alternatively or additionally, one or more cucurbituril compounds are present in a non-complexed form.

[0073] According to certain embodiments of the invention, one or more ricinoleates, such as zinc ricinoleate, may be incorporated into the bulk or thickness of a microporous membrane, wherein they can freely isolate malodorous molecules. One or more ricinoleates may comprise transition metal salts of ricinoleic acid (e.g., copper) and / or post-transition metal salts of ricinoleic acid (e.g., zinc, aluminum, etc.). By way of example only, salts of ricinoleic acid may comprise a mixture of at least two different salts of ricinoleic acid. Alternatively, all salts of ricinoleic acid may be a single salt, such as zinc ricinoleate. Additionally or optionally, OCSA may comprise salts of other fatty acids, such as those found in vegetable oils (e.g., castor oil, which includes oleic acid, linoleic acid, stearic acid, and palmitic acid).

[0074] According to certain embodiments of the invention, one or more ricinoleates may comprise about 0.1 to about 100% by weight of zinc ricinoleate, based on the total weight associated with the ricinoleate, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, 40 and 50% by weight, and / or at most about any one of the following: 100, 99, 95, 90, 80, 70, 60 and 50% by weight. According to certain embodiments of the invention, one or more salts of ricinoleic acid (e.g., zinc ricinoleate) may comprise about 0.0001% to about 40% by weight of the microporous membrane, for example, at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8 and 10% by weight of the microporous membrane, and / or at most about any one of the following: 40, 30, 20, 18, 15, 12 and 10% by weight of the microporous membrane.

[0075] According to certain embodiments of the invention, one or more zeolites may be incorporated into the bulk or thickness of a membrane, such as a microporous membrane, wherein they can freely isolate malodorous molecules. One or more zeolites may comprise a microporous material (e.g., crystalline aluminosilicate) including, for example, silicon, aluminum, and oxygen atoms. One or more zeolites may comprise counterions, such as metal ions or H+. One or more zeolites may have a variety of framework structures, such as 3A, 4A, 5ALTA, MOR, HEU, and ANA types. By way of example only, one or more zeolites may comprise diatomaceous earth. Based on the maximum cross-sectional size, the average particle size of one or more zeolites may be from about 1 to about 200 micrometers, for example, at least about any one of the following: 1, 3, 5, 8, 10, 20, 40, and 50 micrometers, and / or at most about any one of the following: 200, 150, 100, 75, and 50 micrometers. Alternatively, one or more zeolites may comprise a plurality of pores defined through a single zeolite particle. In this regard, one or more individual zeolite particles may have an average pore size of 1 nm to 100 nm, for example, at least about any of the following: 1, 2, 3, 5, 8, 10, 15, 20, 25, 30, 40, and 50 nm, and / or at most about any of the following: 100, 90, 80, 70, 60, and 50 nm. Alternatively, according to certain embodiments of the invention, one or more zeolites may constitute from about 0.0001% by weight to about 40% by weight of the membrane, such as a microporous membrane, for example, at least about any of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8, and 10% by weight of the membrane, such as a microporous membrane, and / or at most about any of the following: 40, 30, 20, 18, 15, 12, and 10% by weight of the membrane, such as a microporous membrane.

[0076] According to certain embodiments of the invention, at least one OCSA comprises (I) one or more ricinoleates, such as zinc ricinoleate, (ii) one or more cucurbituril compounds, and / or (iii) one or more zeolites, and / or (iv) one or more halogenated active aromatic sulfonamide compounds, such as mixtures according to formula (I), wherein the ricinoleate comprises about 1 to 99% by weight of the total weight of the at least one OCSA, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, 40, and 50% by weight, and / or at most about any one of the following: 99, 95, 90, 80, 70, 60, and 50% by weight, and / or wherein said one or more cucurbituril compounds comprise about 1 to 99% by weight of the total weight of the at least one OCSA, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, and 50% by weight, 40 and 50% by weight, and / or at most about any one of the following: 99, 95, 90, 80, 70, 60 and 50% by weight, and / or wherein the one or more zeolites constitute about 1 to 99% by weight of the total weight of the at least one OCSA, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, 40 and 50% by weight, and / or at most about any one of the following: 99, 95, 90, 80, 70, 60 and 50% by weight, and / or wherein the one or more halogenated active aromatic sulfonamide compounds of formula (I) constitute about 1 to 99% by weight of the total weight of the at least one OCSA, for example at least about any one of the following: 0.1, 1, 3, 5, 8, 10, 20, 30, 40 and 50% by weight, and / or at most about any one of the following: 99, 95, 90, 80, 70, 60 and 50% by weight. The total weight of the at least one OCSA shall not exceed 100%.

[0077] According to certain embodiments of the invention, at least one OCSA may also comprise a plurality of nanoparticles thereon adsorbed with at least one metal ion, such as those described in U.S. Patent No. 7,794,737, the contents of which are incorporated herein by reference. For example, the plurality of nanoparticles may have an average diameter of about or less, for example, at most about any one of the following: 500, 400, 300, 200, and 100 nm, and / or at least about any one of the following: 1, 10, 20, 40, 60, 80, and 100 nm. According to certain embodiments of the invention, the at least one metal ion may be selected from copper ions, silver ions, gold ions, iron ions, and combinations thereof. Alternatively or additionally, the plurality of nanoparticles may comprise a substrate on which at least one metal ion is adsorbed, the substrate comprising silica, alumina, magnesium oxide, titanium dioxide, iron oxide, gold, zinc oxide, copper oxide, organic nanoparticles such as polystyrene, and combinations thereof. Alternatively or additionally, the plurality of nanoparticles may contain at least about 100 nm.2 The average surface area per g, for example, at least about any of the following: 100, 200, 300, and 500 M². 2 / g, and / or at most about any one of the following: 2000, 1500, 1000, 800, 600 and 500M 2 / g.

[0078] According to certain embodiments of the present invention, the microporous membrane comprises a pore-forming filler material comprising a plurality of particles, with a plurality of micropores formed around these particles. As described above, the pore-forming filler (e.g., the "filler" above) may comprise a variety of materials. According to certain embodiments of the present invention, the pore-forming material (e.g., the filler) may comprise about 3 to about 60% by weight of the microporous membrane, for example at least about any one of the following: 3, 5, 8, 10, 12, 15, 18, 20, 22, 25, 28, and 30% by weight of the microporous membrane, and / or at most about any one of the following: 60, 55, 50, 45, 40, 35, and 30% by weight of the microporous membrane. As described above, the pore-forming filler (e.g., the filler) may comprise, for example, calcium carbonate, having the chemical formula CaCO3.

[0079] As described above, at least one OCSA (regardless of type or combination of OCSAs) isolates one or more odorous compounds, such as one or more carboxylic acids, such as C1-C5 carboxylic acids (e.g., propionic acid, butyric acid, and valeric acid); sulfur-containing compounds, such as methanethiol and hydrogen sulfide; and nitrogen-containing compounds, such as indole, skatole, ammonia, trimethylamine, and urea. According to certain embodiments of the invention, at least one OCSA isolates one or more odorous compounds via absorption, adsorption, coordination, covalent bonding, or any combination thereof.

[0080] According to certain embodiments of the invention, the membrane may have a basis weight of about 5 to about 100 gsm, for example at least about any one of the following: 5, 8, 10, 12, 15, 18, 20, 22, 25, 28 and 30 gsm, and / or at most about any one of the following: 100, 90, 80, 70, 60, 50, 40 and 30 gsm.

[0081] According to certain embodiments of the present invention, the microporous membrane may have a density of about 200 to about 20000 g / m³. 2 / 24-hour moisture permeability (MVTR), as determined according to the EDAN / INDA World Strategy method: WSP 70.4(08), for example at least approximately any one of the following: 200, 220, 250, 280, 300, 320, 350, 380, 400, 420, 450, 500, 600, 700, 800, 900, 1000, 1200, 1400, 1500, 1600, 1800, 2000, 2500, 3000, 3500, 4000, 4500, 5000, 6000, 7000, 8000, 9000 and 10000 g / m 2 / 24, as determined according to WSP 70.4(08) and / or at most about any one of the following: 20000, 19000, 18000, 17000, 16000, 15000, 14000, 13000, 12000, 11000 and 10000 g / m² as determined according to WSP 70.4(08). 2 / twenty four.

[0082] According to certain embodiments of the invention, the microporous membrane comprises a melt-extruded membrane. Alternatively, the microporous membrane has undergone incremental stretching in the longitudinal and / or transverse directions. For example, incremental stretching can promote the formation of multiple micropores to enhance air permeability.

[0083] According to certain embodiments of the present invention, the microporous membrane may further comprise a coating adjacent to a first outermost surface of the microporous membrane, a second outermost surface of the microporous membrane, or both. This coating may comprise at least one OCSA containing a salt of one or more fatty acids (e.g., ricinoleic acid) dispersed throughout the coating, and / or one or more halogenated active aromatic sulfonamide compounds of formula (I) dispersed throughout the coating, and / or one or more cucurbituril compounds dispersed throughout the coating. For example, the coating may contain about 0.0001% by weight to about 50% by weight of a salt of one or more fatty acids (e.g., ricinoleic acid), such as at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8, 10, 15, 20, and 25% by weight of a salt of one or more fatty acids (e.g., ricinoleic acid), and / or at most about any one of the following: 50, 40, 30, and 25% by weight of a salt of one or more fatty acids (e.g., ricinoleic acid). Alternatively or concurrently, the coating may comprise about 0.0001% by weight to about 50% by weight of one or more halogenated active aromatic sulfonamide compounds of formula (I), such as at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8, 10, 15, 20 and 25% by weight of one or more halogenated active aromatic sulfonamide compounds of formula (I), and / or at most about any one of the following compounds: 50, 40, 30 and 25% by weight of the one or more halogenated active aromatic sulfonamide compounds of formula (I). Alternatively or concurrently, the coating may contain about 0.0001% by weight to about 50% by weight of one or more cucurbita compounds, for example at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8, 10, 15, 20 and 25% by weight of one or more cucurbita compounds, and / or at most about any one of the following: 50, 40, 30 and 25% by weight of the one or more cucurbita compounds. Alternatively or concurrently, the coating may have a coating thickness of from about 10 micrometers to about 2000 micrometers, for example at least about any one of the following: 10, 15, 20, 25, 30, 35, 40, 45, 50, 80, 100, 150, 200, 250, 300, 500, 800 and 1000 micrometers, and / or at most about any one of the following: 2000, 1800, 1500, 1200 and 1000 micrometers.

[0084] If a coating is present, it can be formed on the microporous membrane by a coating composition, which optionally contains one or more OCSAs or does not contain one or more OCSAs, an evaporable solvent (e.g., water, alcohol, or organic solvent), and a binder component (e.g., polymer resin, cellulose, or cellulose derivative). The coating can be formed by evaporating the coating composition over a period of time after it has been applied to the microporous membrane. That is, after the coating composition is applied to the microporous membrane, the solvent can be evaporated, thereby forming a coating on the microporous membrane (e.g., a dry coating). The coating composition can be applied to one or more surfaces of the microporous membrane by simple solution coating, spin coating, dip coating, profile coating, doctor blade coating, solution casting, extrusion / dispersion coating, spraying, gravure coating, printing techniques such as screen printing, inkjet printing, electrostatic application, atomization, wiping, spraying, or immersion, and other applications.

[0085] According to certain embodiments of the invention, the membrane may not include a breathable membrane (e.g., a microporous membrane and / or a monolithic membrane). Instead, the membrane may include an impermeable membrane. In this respect, in addition to moisture permeability (MVTR), the impermeable membrane may include the same properties and / or additives (e.g., OCSA) as those described above when discussing microporous membranes (e.g., breathable membranes). According to certain embodiments of the invention, for example, the MVTR of the impermeable membrane may have a value below about 200 g / m³, as determined according to the EDNA / INDA World Strategy method. 2 / 24-hour MVTR: WSP 70.4(08), for example at least approximately any one of the following: 0, 5, 10, 20, 30, 40 and 50 g / m² as determined by WSP 70.4(08). 2 / 24, and / or at most about any one of the following: 200, 150, 100, 75 and 50 g / m 2 / 24, determined according to WSP 70.4(08).

[0086] In another aspect, the present invention provides a method for forming a breathable membrane, such as those described and disclosed herein. The method may include the following steps: (i) forming a polymer melt; (ii) adding a pore-forming filler material to the polymer melt; (iii) adding a dry masterbatch to the polymer melt, wherein the dry masterbatch contains at least one odorous compound separator (OCSA), the OCSA containing (a) at least one ricinoleate (e.g., zinc ricinoleate), (b) one or more cucurbita compounds, such as CB[5], CB[6], CB[7], CB[8], or any mixture thereof, and / or (c) one or more zeolites, and / or (d) one or more halogenated active aromatic sulfonamide compounds; (iv) mixing the pore-forming filler material and the dry masterbatch into the polymer melt; (v) melt-extruding the polymer melt containing the pore-forming filler material and at least OCSA to form an intermediate membrane; and (vi) incrementally stretching the intermediate membrane in the longitudinal and / or transverse directions to form the breathable membrane. According to some embodiments, the method may include forming an impermeable membrane, wherein the addition of pore-forming filler may be excluded from the foregoing steps. Alternatively, the method for forming an impermeable membrane may exclude the step of incrementally stretching the membrane. In this respect, the method can provide an impermeable membrane with no or substantially no micropores.

[0087] According to certain embodiments of the invention, the dry masterbatch comprises a polymer matrix component (e.g., a carrier), and at least one OCSA is dispersed throughout the polymer matrix. For example, the polymer matrix may contain a matrix polymer corresponding to the polymer component of the polymer melt. By way of example only, the polymer melt may comprise a first polypropylene or a first polyethylene, and the matrix polymer may comprise a corresponding second polypropylene or a second polyethylene.

[0088] In another aspect, the present invention provides an absorbent article comprising: (i) a liquid-permeable top sheet (LPTS), such as a nonwoven fabric and / or a top-perforated membrane (TAF); (ii) a bottom sheet comprising a membrane, such as a breathable or non-breathable membrane as described and disclosed herein; and (iii) an absorbent core, wherein the absorbent core is located directly or indirectly between the LPTS and the bottom sheet. According to certain embodiments of the invention, the LPTS may comprise a TAF formed of a membrane, such as any of those comprising one or more OCSAs described and disclosed herein. According to certain embodiments of the invention, the absorbent article may further comprise an acquisition distribution layer (ADL) located directly or indirectly between the LPTS and the absorbent core. The ADL may, for example, comprise an open-pore membrane, a highly bulky nonwoven fabric, or a combination thereof. Alternatively or as another option, the ADL comprises an open-pore membrane comprising a second set of one or more OCSAs dispersed over the entire thickness of the open-pore membrane, applied to a top surface of the open-pore membrane, and / or applied to a bottom surface of the open-pore membrane. For example, one or more OCSAs may comprise salts of one or more fatty acids (such as ricinoleic acid), and / or one or more cucurbitacins (such as CB[5], CB[6], CB[7], CB[8], or any mixture thereof), and / or one or more zeolites, and / or one or more halogenated active aromatic sulfonamide compounds. Alternatively or according to certain embodiments of the invention, LPTS may comprise TAF, nonwoven fabric, or a combination thereof. LPTS may comprise TAF, including, for example, one or more OCSAs of a third group dispersed throughout the thickness of the TAF, applied to the top surface of the TAF, and / or applied to the bottom surface of the TAF. For example, one or more OCSAs comprise salts of one or more fatty acids (such as ricinoleic acid), and / or one or more cucurbitacins (such as CB[5], CB[6], CB[7], CB[8], or any mixture thereof), and / or one or more zeolites, and / or one or more halogenated active aromatic sulfonamide compounds. According to certain embodiments of the invention, one or more OCSAs, a second group of one or more OCSAs, and / or a third group of one or more OCSAs present in or on the backing plate may be the same as or different from each other. According to certain embodiments of the invention, the absorbent article may further comprise a substrate coating, such as the coating described above related to microporous membranes. The substrate coating may be disposed on the top surface of a substrate, wherein the substrate coating is located between the substrate and the absorbent core. Alternatively, the absorbent article may also comprise an ADL coating, such as the coating described above related to microporous membranes, disposed on the top and / or back surface of the porous membrane. Alternatively, the absorbent article may also comprise a TAF coating, such as the coating described above related to microporous membranes, disposed on the top and / or back surface of the TAF.

[0089] According to certain embodiments of the invention, the backsheet coating and / or ADL coating and / or TAF coating may contain about 0.0001% by weight to about 50% by weight of one or more salts of fatty acids (e.g., ricinoleic acid), for example at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8, 10, 15, 20 and 25% by weight of one or more salts of fatty acids (e.g., ricinoleic acid), and / or at most about any one of the following: 50, 40, 30 and 25% by weight of one or more salts of fatty acids (e.g., ricinoleic acid). Alternatively or as an alternative, about 0.0001% to about 50% by weight of one or more halogenated active aromatic sulfonamide compounds, for example at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8, 10, 15, 20 and 25% by weight of one or more halogenated active aromatic sulfonamide compounds, and / or at most about any one of the following: 50, 40, 30 and 25% by weight of said one or more halogenated active aromatic sulfonamide compounds. Alternatively or additionally, the backplate coating and / or ADL coating and / or TAF coating comprises about 0.0001% by weight to about 50% by weight of one or more cucurbituril compounds, for example at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8, 10, 15, 20 and 25% by weight of one or more cucurbituril compounds, and / or at most about any one of the following: 50, 40, 30 and 25% by weight of the one or more cucurbituril compounds. Alternatively, the backing coating and / or ADL coating and / or TAF coating may contain about 0.0001% by weight to about 50% by weight of one or more zeolites, for example at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8, 10, 15, 20 and 25% by weight of the one or more zeolites, and / or at most about any one of the following: 50, 40, 30 and 25% by weight of the one or more zeolites. Alternatively or as an option, the backsheet coating and / or the ADL coating and / or the TAF coating have a coating thickness of about 10 micrometers to about 2000 micrometers, for example at least about any one of the following thicknesses: 10, 15, 20, 25, 30, 35, 40, 45, 50, 80, 100, 150, 200, 250, 300, 500, 800 and 1000 micrometers, and / or at most about any one of the following: 2000, 1800, 1500, 1200 and 1000 micrometers.

[0090] According to certain embodiments of the invention, the membrane comprises a multilayer membrane, the multilayer membrane including breathable membranes, such as those described and disclosed herein. The multilayer membrane may include at least a first surface layer and a core layer, wherein the first surface layer has a first thickness, the core layer has a second thickness, and the first thickness is less than the second thickness. In some embodiments, the multilayer membrane further includes a second surface layer, wherein the core layer is located between the first surface layer and the second surface layer. Alternatively or as an alternative, at least one of the first surface layer and the core layer comprises a breathable membrane (e.g., a microporous membrane) as described and disclosed herein. Alternatively or as an alternative, the core layer comprises a monolithic membrane layer. For example, a monolithic membrane layer may comprise at least one highly breathable polymer. According to certain embodiments of the invention, the highly breathable polymer may comprise thermoplastic polyurethane (TPU), polyether block amide copolymer (e.g., from Arkema Group), etc. Or from Evonik E) or copolyester thermoplastic elastomers (e.g., from DSMEngineering Plastics) From EIDuPont de Nemours and Company At least one of the following. According to some embodiments of the invention, the monolithic film may comprise a polyether-block-ester copolymer comprising (i) soft blocks comprising polyethylene glycol and (ii) hard blocks comprising polybutylene terephthalate. According to some embodiments of the invention, the monolithic film may comprise a copolymer of isomeric polypropylene microcrystalline regions and random amorphous regions.

[0091] According to certain embodiments of the invention, a membrane (e.g., a single-layer or multi-layer membrane) is directly melt-extruded onto an absorbent core. As mentioned above, the membrane can be a breathable membrane (e.g., vapor-permeable) or an impermeable membrane. In this respect, the multi-layer membrane can be a co-extruded multi-layer membrane. Alternatively, the membrane can be directly thermally bonded and / or bonded to the absorbent core, for example, through a plurality of individual bonding sites that directly fuse adjacent portions of the absorbent core to the membrane.

[0092] Alternatively, the membrane, such as the breathable or non-breathable membranes described and disclosed herein, may be indirectly bonded to the absorbent core via an adhesive layer located between the membrane and the absorbent core. In this respect, the adhesive layer may be located between the absorbent core and the membrane and adhere the absorbent core to the membrane. According to certain embodiments of the invention, the adhesive layer may have a basis weight of about 0.2 to about 5 gsm, for example, at least about any one of the following: 0.2, 0.4, 0.5, 0.6, 0.8, 1, 1.2, 1.4, 1.5, 1.6, 1.8, 2, 2.2, 2.4, and 2.5 gsm, and / or at most about any one of the following: 5, 4.5, 4, 3.5, 3, and 2.5 gsm. According to certain embodiments of the invention, the adhesive layer may include a discontinuous layer comprising a plurality of separate adhesive deposition sites. Additionally or alternatively, the adhesive layer may comprise one or more continuous stripes, one or more discontinuous stripes, or a combination thereof. For example, according to some embodiments, the adhesive layer includes one or more non-overlapping continuous stripes. Alternatively, the adhesive layer may include one or more continuous stripes, wherein a first plurality of continuous stripes define an intersecting region defined by the overlapping portions of the first plurality of continuous stripes. Or, the adhesive layer may include a continuous layer.

[0093] According to certain embodiments of the invention, absorbent articles include diapers, such as adult diapers or baby diapers, or feminine care products, such as pads or linings, or pet pads, such as puppy pads.

[0094] For example, Figure 1 An absorbent article 1 is shown, comprising a nonwoven top sheet 10 that can be positioned closest to the user's skin and a bottom sheet 20 that can be positioned further away from the user's skin during use, such as those described and disclosed herein. The absorbent article 1 also includes an absorbent core 30 located between the top sheet 10 and the bottom sheet 20. Figure 2 An absorbent article 1 is shown, comprising a nonwoven top sheet 10 positioned closest to the user's skin and a bottom sheet 20 positioned further away from the user's skin during use, as described and disclosed herein. The absorbent article 1 includes an absorbent core 30 and an adhesive layer 40, wherein the bottom sheet is indirectly bonded to the absorbent core via the adhesive layer. Figure 3An absorbent article 1 according to certain embodiments of the invention is shown, comprising a collection distribution layer 50 located between a top sheet 10 and an absorbent core 30. The absorbent article 1 also includes a backing sheet 20 bonded to the absorbent core 30 such that the absorbent core is located between the collection distribution layer and the backing sheet. In this respect, the collection distribution layer may comprise a nonwoven fiber web or fabric formed of spunbond fibers, meltblown fibers, short fibers, cellulose fibers (e.g., natural and / or synthetic cellulose fibers) and / or the open-cell membranes mentioned herein. According to certain embodiments of the invention, the collection distribution layer comprises a highly bulky nonwoven fiber web or fabric and / or an open-cell membrane. For example, the collection distribution layer may receive fluid from the top sheet and distribute the fluid over a larger area, and transfer the fluid to the absorbent core over a larger area. As described above, the collection distribution layer may comprise a highly bulky material to prevent rewetting (e.g., liquid flowing from the absorbent article back to the user).

[0095] In another aspect, the present invention provides a method for manufacturing an absorbent article, the method comprising the steps of: (i) providing or forming a liquid-permeable topsheet (LPTS), such as a nonwoven fabric and / or TAF; (ii) providing or forming a backsheet comprising a membrane, such as a breathable or non-breathable membrane described and disclosed herein; (iii) providing or forming an absorbent core, wherein the absorbent core is located directly or indirectly between the LPTS and the backsheet; and (iv) bonding the backsheet directly or indirectly to the absorbent core. According to certain embodiments of the invention, the step of bonding the backsheet directly or indirectly to the absorbent core includes bonding the backsheet directly to the absorbent core by forming one or more thermal bonds between the backsheet and the absorbent core, by directly melt-extruding a precursor membrane onto the absorbent core before or after incrementally stretching a precursor membrane to form a microporous membrane, or by directly melt-extruding a membrane onto the absorbent core. Alternatively, the step of bonding the backsheet directly or indirectly to the absorbent core includes indirectly bonding the backsheet to the absorbent core by adding an adhesive layer between the backsheet and the absorbent core.

[0096] According to certain embodiments of the invention, the method may include providing or forming an ADL and placing the ADL directly or indirectly between the LPTS and the absorbent core. As described above, the ADL may include an open-cell membrane, a highly bulky nonwoven fabric, or a combination thereof. According to certain embodiments of the invention, the ADL includes an open-cell membrane comprising a second set of one or more OCSAs dispersed throughout the thickness of the open-cell membrane, applied to the top surface of the open-cell membrane, and / or applied to the bottom surface of the open-cell membrane. Alternatively or additionally, according to certain embodiments of the invention, the LPTS may include a nonwoven fabric and / or a TAF. The LPTS may include a TAF comprising, for example, a third set of one or more OCSAs dispersed throughout the thickness of the TAF, applied to the top surface of the TAF, and / or applied to the bottom surface of the TAF. For example, one or more OCSAs may comprise salts of one or more fatty acids (such as ricinoleic acid), and / or one or more cucurbituril compounds (such as CB[5], CB[6], CB[7], CB[8], or any mixture thereof), and / or one or more halogenated active aromatic sulfonamide compounds of formula (I). According to certain embodiments of the invention, one or more OCSAs, a second group of one or more OCSAs, and / or a third group of one or more OCSAs existing in or on the back panel may be the same as or different from each other.

[0097] Example

[0098] This disclosure is further illustrated by the following embodiments and should in no way be construed as limiting. That is, the specific features described in the following embodiments are merely illustrative and not limiting.

[0099] Materials list

[0100] Traditional plastic CF707030PE: is a masterbatch containing calcium carbonate (i.e., CaCO3).

[0101] Westlake EC474AA (WL 474): is a low-density polyethylene resin.

[0102] ExxonMobil Exceed TM 3518PA (EM 3518): A linear low-density polyethylene resin prepared from ethylene-1-hexene copolymer.

[0103] Chevron Phillips HMN 6060 (CPC 6060): is a high-density polyethylene resin made from ethylene-hexene copolymer.

[0104] AMPACET 1001102-N: is an odor control masterbatch designed to absorb odor-generating molecules containing nitrogen and sulfur.

[0105] Instance set

[0106] Various sample membranes were prepared for testing and comparison, such as for odor isolation. Table 1 provides a summary of the formation and testing of each sample membrane (i.e., Examples 1-8).

[0107]

[0108] Table 1

[0109] Although summarized in Table 1 above, Example 1 (membrane number M16-5123) is a base membrane that does not contain odor control masterbatch and filler (i.e., calcium carbonate).

[0110] Example 2 (membrane number M16-5123A) is formed from the same composition as Example 1. However, Example 2 undergoes an activation step (e.g., incremental stretching). Similar to Example 1, Example 2 is also an air-impermeable membrane.

[0111] Example 3 (membrane number M16-5124) includes an odor control masterbatch. This membrane is filler-free and undergoes an activation step (e.g., incremental stretching). Example 3 is an impermeable membrane.

[0112] Example 4 (membrane number M16-5124A) is formed from the same composition as Example 3, but without the activation step (e.g., incremental stretching). This membrane is non-permeable.

[0113] Example 5 (membrane number M16-5125) is a breathable membrane comprising a calcium carbonate masterbatch. This membrane does not contain an odor control masterbatch and undergoes an activation step (e.g., incremental stretching).

[0114] Example 6 (membrane number M16-5125A) is formed from the same composition as Example 5, but without the activation step (e.g., incremental stretching). Example 6 is an impermeable membrane.

[0115] Example 7 (membrane number M16-5126) is a breathable membrane that includes both an odor control masterbatch and a calcium carbonate masterbatch. The membrane also undergoes an activation step (e.g., incremental stretching).

[0116] Example 8 (film code M16-5126A) is formed from the same composition as Example 7, but the film has not undergone an activation step (e.g., incremental stretching). The film is non-permeable.

[0117] Test plan:

[0118] Headspace samples were prepared in 10-LTedlar air sample bags.

[0119] 1 mL of real human urine was added to the weighing pan.

[0120] A thin film material covers a tent-shaped stainless steel screen material.

[0121] Keep the samples in a 98°F oven for 1 to 5 hours.

[0122] Separate sample preparation time points: 1 hour and 5 hours.

[0123] The headspace was presented at multiple dilution levels using an olfactory meter.

[0124] Study I: Objective - To study the effects of odor control masterbatch CaCO3 and activation on reducing urine odor.

[0125] In this study, the four-layer membranes 5124A, 5126A, 5124 and 5126 were compared with the 5123 membrane, which served as a reference.

[0126] Adding the odor control masterbatch alone did not reduce urine odor during the 1-hour and 5-hour test intervals, as shown in Figure 30. This may potentially be attributed to the resin coating on the odor-active material, which may have a negative impact on its efficacy (5124A film vs. 5123 film).

[0127] When the odor control masterbatch was mixed with CaCO3, signs of odor reduction were observed after 1 hour, as shown in Figure 31. A significant reduction in odor was observed after 5 hours (5126A film vs. 5123 film). This phenomenon may be due to the adsorption of odor molecules by the pores in CaCO3; however, we do not wish to be bound by this theory. As shown in Figure 32, a similar trend was observed with the addition of the odor control masterbatch and activation (5124 film vs. 5123 film). Although we do not wish to be bound by the following theory, it is believed that activation methods including film stretching contribute to the exposure of odor-active substances embedded within.

[0128] As shown in Figure 33, the addition of CaCO3 and activation at 1 hour and 5 hours both resulted in a reduction in odor, especially at lower dilution levels (5126 film vs. 5123 film).

[0129] When the three membranes 5126A, 5124 and 5126 were compared with the membrane containing the odor control MB (5124A), the results were similar, as shown in Figures 34, 35 and 36, respectively.

[0130] Study II: Objective - to evaluate the necessity of combining odor control masterbatch with CaCO3 and activation to effectively reduce odor.

[0131] In this study, three membranes, 5125A, 5123A and 5125, were compared with membrane 5123.

[0132] In some cases, CaCO3 and activation successfully reduced minor urine odors, with potential factors discussed in the previous section likely contributing to this effect, as shown in Figures 37 and 38. However, for significant odor reduction, the inclusion of an odor-controlling masterbatch appears necessary, as shown in Figure 39. A synergistic effect was demonstrated using all three components—odor-controlling masterbatch, CaCO3, and activation—resulting in the most effective odor-reducing performance.

[0133] These and other modifications and variations can be made to the invention by those skilled in the art without departing from the spirit and scope of the invention, which is more specifically set forth in the appended claims. Furthermore, it should be understood that aspects of the various embodiments can be interchanged, in whole or in part. Moreover, those skilled in the art will understand that the foregoing description is merely exemplary and is not intended to limit the invention as further described in these appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary descriptions of the versions contained herein.

Claims

1. A breathable membrane, comprising: A vapor-permeable and liquid-impermeable (VPLI) membrane comprising a microporous membrane containing a plurality of micropores, wherein the microporous membrane comprises (a) a first outermost surface, (b) a second outermost surface, (c) a thickness extending between the first outermost surface and the second outermost surface, and (d) at least one odorous compound barrier agent (OCSA) dispersed throughout the thickness of the membrane, wherein the at least one OCSA comprises (i) one or more ricinoleates, and / or (ii) one or more cucurbituril compounds, and / or (iii) one or more zeolites, and / or (iv) one or more halogenated active aromatic sulfonamide compounds.

2. The breathable membrane according to claim 1, wherein the one or more castor oil salts comprise transition metals and / or post-transition metals.

3. The breathable membrane according to claim 1, wherein the one or more ricinoleates include zinc ricinoleate.

4. The breathable membrane according to claims 1-3, wherein the salts of one or more ricinoleic acids constitute from about 0.0001% by weight to about 40% by weight of the microporous membrane, such as at least about any one of the following: 0.0001, 0.001, 0.01, 0.02, 0.05, 0.08, 0.1, 0.5, 0.2, 0.5, 0.8, 1, 2, 5, 8 and 10% by weight of the microporous membrane, and / or at most about any one of the following: 40, 30, 20, 18, 15, 12 and 10% by weight of the microporous membrane.

5. The breathable membrane according to claims 1-4, wherein the microporous membrane comprises a single-layer membrane or a multilayer membrane, the multilayer membrane comprising 2 to about 10 individual microporous membrane layers bonded together, for example 2, 3, 4 or 5 individual microporous membrane layers bonded together, and / or up to about any one of the following: 10, 9, 8, 7, 6 and 5 individual microporous membrane layers bonded together.

6. The breathable membrane according to claims 1-5, wherein the thickness of the microporous membrane comprises from about 10 micrometers to about 500 micrometers, such as at least about any one of the following: 10, 20, 30, 40, 50, 60, 80, 100, 150, 200 and 250 micrometers, and / or at most about any one of the following: 500, 450, 400, 350, 300 and 250 micrometers.

7. The breathable membrane according to claims 1-6, wherein the microporous membrane comprises a polymer component and an additive component, wherein the additive component comprises (i) one or more castor oil salts, and / or one or more cucurbituril compounds, and / or one or more zeolites, and / or one or more halogenated active aromatic sulfonamide compounds, and (ii) a pore-forming filler material comprising a plurality of filler particles; and wherein the polymer component of the microporous membrane comprises a polyolefin, such as polyethylene or a copolymer thereof or polypropylene or a copolymer thereof or a blend of a first polyolefin and a second polyolefin.

8. The breathable membrane according to claims 1-7, wherein the microporous membrane has a microporous density of 200-20000 g / m³ as determined according to WSP 70.4(08). 2 / 24-hour MVTR.

9. A method for forming a breathable membrane, comprising: (i) Formation of a polymer melt; (ii) Adding a pore-forming filling material to the polymer melt; (iii) Adding a dry masterbatch to the polymer melt, wherein the dry masterbatch contains at least one odorous compound separator (OCSA), the OCSA containing (a) one or more ricinoleate salts, and / or (b) one or more cucurbituril compounds, such as CB[5], CB[6], CB[7], CB[8] or any mixture thereof, and / or (c) one or more zeolites, and / or (d) one or more halogenated active aromatic sulfonamide compounds; (iv) Mix the pore-forming filler material and the dry masterbatch into the polymer melt; (v) Melt extrusion of the polymer melt comprising the pore-forming filler material and at least OCSA to form an intermediate film; (vi) Incrementally stretch the intermediate membrane in the longitudinal and / or transverse directions to form the breathable membrane.

10. The method of claim 9, wherein the dry masterbatch comprises a polymer matrix component, and the at least one OCSA is dispersed throughout the polymer matrix.

11. The method of claim 10, wherein the polymer matrix comprises a matrix polymer corresponding to the polymer component of the polymer melt.

12. An absorbent article, comprising: (i) Liquid permeable topsheets (LPTS), such as nonwoven fabrics or membranes with openings at the top (TAF); (ii) a film comprising a membrane, such as a breathable membrane according to any one of claims 1-8; (iii) an absorbent core, wherein the absorbent core is located directly or indirectly between the LPTS and the substrate.

13. The absorbent article according to claim 12 further includes an acquisition distribution layer (ADL) located directly or indirectly between the LPTS and the absorbent core.

14. A method for preparing an absorbent article, the method comprising: (i) Providing or forming a liquid-permeable top sheet (LPTS), such as a nonwoven fabric or a membrane with openings at the top (TAF); (ii) Providing or forming a substrate comprising a membrane, such as a breathable membrane according to any one of claims 1-8; (iii) Providing or forming an absorbent core, wherein the absorbent core is located directly or indirectly between the LPTS and the substrate; and (iv) Bond the substrate directly or indirectly to the absorbent core.

15. The method of claim 14, wherein the step of directly or indirectly bonding the substrate to the absorbent core comprises bonding the substrate directly to the absorbent core by forming one or more thermal bonds between the substrate and the absorbent core, by directly melt-extruding the precursor film onto the absorbent core before or after incrementally stretching the precursor film to form a microporous film, or by directly melt-extruding the film onto the absorbent core.

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