Support elements for laminates including a layer of looped nonwoven fabric and laminates including such support elements

Abstract

The present invention relates to a nonwoven element, particularly a support element, comprising at least a portion consisting of a fiber and / or filament structure, wherein the fiber and / or filament structure extends between an upper and lower surface, and gas, particularly air and / or vapor, can pass through the structure from one surface to the other, and the fiber and / or filament is based on one or more materials selected from thermoplastic materials, and the density of the structure, measured under a pressure of 0.5 kPa according to standard NF ISO 9073-2 Method A of February 1997, is 155 kg / m³. 3 Larger, especially 200 kg / m 3 Larger, especially 250 kg / m 3 Regarding nonwoven elements characterized by being larger.

Description

[Technical Field]

[0001] The present invention relates to a support element, at least a portion thereof made of a structure of individual fibers and / or filaments that are non-repeatedly intertwined and / or entangled with one another. The present invention also relates to a laminate comprising such a support element and a loop element, particularly a loop-shaped nonwoven fabric layer, which is conventionally fixed to, particularly bonded or welded, a region of the diaper's landing zone, also known as the LZ, the central or abdominal grip zone, such that the loops of the loop element engage with hooks arising from a rear side attachment portion of the diaper to form a closure. [Background technology]

[0002] Traditionally, this type of support element has been made from film or nonwoven fabric. Film has the advantage of ensuring good grip of the laminate, especially in air vacuum systems, while placing the laminate onto the diaper on the production line. However, film is not breathable, is not flexible to the touch, and can be difficult to weld to the diaper.

[0003] Support elements made of nonwoven fabric layers have the disadvantage of being too permeable to gases, especially air and water vapor, which makes it difficult to use them to position laminates on diapers in the production line. Furthermore, support elements in the form of nonwoven fabric layers lack rigidity in the MD (machine direction) and easily constrict in the CD (cross direction or transverse direction) after stretching in the MD (known as the "neck-down" effect). Moreover, they are sensitive to pressure or compression, which makes them difficult to process in the production line, especially when used for positioning on diapers.

[0004] WO2018 / 060885A1 discloses a laminate comprising two loop-shaped layers and one support layer, all based on split yarn or short fibers (staple fibers), wherein the support layer is calendered by passing it between 150°C hot spot welding rollers before being assembled with the two loop-shaped layers. Herein, the density of the support layer is 100 to 300 kg / m³ 3 It is also stated that it is between [a certain range]. In this case, the density is calculated by dividing the surface density by the thickness of the support layer. However, it is not stated how much pressure is applied to the support layer when measuring the thickness. Furthermore, the permeability of each layer, especially the support layer, is equal to a maximum of 0.1 seconds in this case, according to the Gurley method.

[0005] WO2016 / 007431A1 discloses a laminate comprising one loop-shaped layer and one support layer, all based on carded fibers and short fibers, wherein the support layer is calendered before being assembled with the loop-shaped layer. In Example 1, the support layer is calendered between a metal roller and a cotton roller, and its density is 500 kg / m³. 3 This is equal to . In this case, the density is calculated by dividing the surface density by the thickness of the support layer. However, it is not stated how much pressure is applied to the support layer when measuring the thickness. Furthermore, the permeability of each layer, especially the support layer, is equal to a maximum of 0.1 seconds in this case, according to the Gurley method.

[0006] EP3812027A1 describes spunbond (filament)-based nonwoven fabrics intended for use as filters. Here, the density of the nonwoven fabric is 250 to 400 kg / m³. 3 It is also stated that it is between [a certain range]. In this case, the density is calculated by dividing the surface density by the thickness of the supporting layer. However, it is not stated how much pressure is applied to the supporting layer when measuring the thickness. The transmittance per unit of surface density is 40 liters / (m³) under a pressure of 125 Pa. 2 .sec) / (g / m 2) to 500 liters / (m 2 . second) / (g / m 2 ), that is, the minimum air permeability at a minimum surface density of 150 g / m 2 is 6,000 liters / (m 2 . second).

[0007] JP2001001698A describes a non-woven fabric having a density between 50 and 300 kg / m 3 for forming a support of wallpaper. However, it does not describe how the density is measured, especially how much pressure is applied to the support layer during measurement.

Summary of the Invention

Problems to be Solved by the Invention

[0008] The present invention aims to overcome the drawbacks of the prior art by proposing a non-woven type support element that is more suitable for a production line, particularly facilitating the processing of support elements in a production line and the gripping for positioning the support elements on a diaper.

Means for Solving the Problems

[0009] According to a first aspect of the present invention, an element of non-woven type, particularly an element forming a support element, includes at least a part composed of a structure of fibers and / or filaments, the structure extending between an upper surface and a lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other surface. The density of the structure, which is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa particularly according to the standard NF EN ISO 9073-2 method A in February 1997, is greater than 155 kg / m 3 , particularly greater than 170 kg / m 3 , particularly greater than 200 kg / m 3 , particularly greater than 250 kg / m 3 .

[0010] The present invention also relates to a female hook-and-loop fastener fastening element comprising a loop element, particularly a nonwoven fabric, and a nonwoven fabric type support element, wherein the support element comprises at least a portion made of a fibrous and / or filament structure, the structure extending between an upper and lower surface, and gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - In particular, the density of the structure, which is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa according to the standard NF EN ISO 9073-2 Method A of February 1997, is 155 kg / m³. 3 Larger, especially 170 kg / m 3 Larger, especially 200 kg / m 3 Larger, especially 250 kg / m 3 bigger The present invention relates to a female hook-and-loop fastener type fixing element characterized by the following features.

[0011] Preferably, the air permeability of the structure measured at a pressure difference of 200 Pa is 100 to 5,000 l / m³. 2 Between 100 and 3,100 l / m² / second 2 For example, between 500 and 3,100 l / m² per second. 2 Between 620 and 3,100 l / m² / second, in particular. 2 It is for a period of / seconds.

[0012] According to an advantageous embodiment, the present invention also relates to a female hook-and-loop fastener fastening element comprising a loop element, particularly a nonwoven fabric, and a nonwoven fabric type support element, wherein the support element comprises at least a portion made of a filament structure, particularly spunbond, the structure extending between an upper and lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - In particular, the density of the structure, which is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa according to the standard NF EN ISO 9073-2 Method A of February 1997, is 155 kg / m³. 3 Larger, especially 170 kg / m 3 Larger, especially 200 kg / m 3Larger, especially 250 kg / m 3 bigger The present invention relates to a female hook-and-loop fastener type fixing element characterized by the following features.

[0013] According to an advantageous embodiment, the present invention also relates to a female hook-and-loop fastener fastening element comprising a loop element, particularly a nonwoven fabric, and a nonwoven fabric type support element, wherein the support element comprises at least a portion made of a filament structure, particularly spunbond, the structure extending between an upper and lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - The air permeability of the structure measured at a pressure difference of 200 Pa is between 100 and 5,000 l / m³. 2 Between 100 and 3,100 l / m² / second 2 It is for a period of / seconds. The present invention relates to a female hook-and-loop fastener type fixing element characterized by the following features.

[0014] According to an advantageous embodiment, the present invention also relates to a female hook-and-loop fastener fastening element comprising a loop element, particularly a nonwoven fabric, and a nonwoven fabric type support element, wherein the support element comprises at least a portion made of a filament structure, particularly spunbond, the structure extending between an upper and lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - The structural surface density of the structure is 3 to 50 g / m³ 2 During that period, especially between 10 and 40 g / m 2 During that period, especially 15 to 30 g / m 2 During that period, especially 20 to 30 g / m 2 It is between, - The structure is undergoing calendar processing. The present invention relates to a female hook-and-loop fastener type fixing element characterized by the following features.

[0015] According to an advantageous embodiment, the present invention also relates to a nonwoven element, particularly an element forming a support element, which includes at least a portion of a filament structure, particularly made of spunbond, wherein the structure extends between an upper surface and a lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - In particular, the density of the structure, which is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa according to the standard NF EN ISO 9073-2 Method A of February 1997, is 155 kg / m³. 3 Larger, especially 170 kg / m 3 Larger, especially 200 kg / m 3 Larger, especially 250 kg / m 3 Larger, - The air permeability of the structure measured at a pressure difference of 200 Pa is between 100 and 5,000 l / m³. 2 Between 100 and 3,100 l / m² / second 2 It is for a period of / seconds. This relates to an element characterized by the following features.

[0016] According to an advantageous embodiment, the present invention also relates to a nonwoven element, particularly an element forming a support element, which includes at least a portion of a filament structure, particularly made of spunbond, wherein the structure extends between an upper surface and a lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - In particular, the density of the structure, which is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa according to the standard NF EN ISO 9073-2 Method A of February 1997, is 155 kg / m³. 3 Larger, especially 170 kg / m 3 Larger, especially 200 kg / m 3 Larger, especially 250 kg / m 3 Larger, - The thickness of the structure is less than 100 μm, especially less than 85 μm, especially between 20 μm and 100 μm, especially between 30 μm and 85 μm. This relates to an element characterized by the following features.

[0017] According to an advantageous embodiment, the present invention also relates to a nonwoven element, particularly an element forming a support element, which includes at least a portion of a filament structure, particularly made of spunbond, wherein the structure extends between an upper surface and a lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - In particular, the density of the structure, which is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa according to the standard NF EN ISO 9073-2 Method A of February 1997, is 155 kg / m³. 3 Larger, especially 170 kg / m 3 Larger, especially 200 kg / m 3 Larger, especially 250 kg / m 3 Larger, - The structural surface density of the structure is 3 to 50 g / m³ 2 During that period, especially between 10 and 40 g / m 2 During that period, especially 15 to 30 g / m 2 During that period, especially 20 to 30 g / m 2 It is between, - The structure is undergoing calendar processing. This relates to an element characterized by the following features.

[0018] Preferably, the density of the structure is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa, in particular according to the standard NF EN ISO 9073-2 Method A of February 1997, which is 500 kg / m³. 3 Larger.

[0019] According to another advantageous embodiment, the present invention also relates to a nonwoven element, particularly an element forming a support element, which includes at least a portion made of a structure of short fibers, particularly carded fibers, particularly spunlace nonwoven fabric, wherein the structure extends between an upper surface and a lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - In particular, the density of the structure, which is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa according to the standard NF EN ISO 9073-2 Method A of February 1997, is 500 kg / m³. 3 bigger This relates to an element characterized by the following features.

[0020] According to another advantageous embodiment, the present invention also relates to a nonwoven element, particularly an element forming a support element, which includes at least a portion made of a structure of short fibers, particularly carded fibers, wherein the structure extends between an upper surface and a lower surface, and a gas, particularly air and / or water vapor, can pass through the structure from one surface to the other. - In particular, the density of the structure, which is equal to the surface density divided by the thickness measured after 10 seconds under a pressure of 0.5 kPa according to the standard NF EN ISO 9073-2 Method A of February 1997, is 155 kg / m³. 3 Larger, especially 170 kg / m 3 Larger, especially 200 kg / m 3 Larger, especially 250 kg / m 3 Larger, especially 400 kg / m 3 Larger, - The air permeability of the structure measured at a pressure difference of 200 Pa is between 100 and 5,000 l / m³. 2 Between 620 and 3,100 l / m² / second, in particular. 2 It is for a period of / seconds. This relates to an element characterized by the following features.

[0021] Preferably, the fibers and / or filaments are selected from thermoplastic materials, particularly One or more polyesters, in particular polyester (PET) and / or biodegradable polyester and / or polyhydroxyalkanoate (PHA) and / or polylactic acid (PLA) and / or polybutylene adipate terephthalate (PBAT), and / or One or more polyolefins, particularly polypropylene (PP) and / or polyethylene (PE) and / or copolymers thereof, and / or One or more polyamides, and / or those mixtures Based on one or more materials selected from the following.

[0022] Preferably, the density of the structure is strictly less than the density of the material of the structure alone, particularly less than 90% of the density of the material alone, and more preferably less than 80% of the density of the material alone, particularly 1,200 kg / m³ 3 Less than 1,000 kg / m 3 Less than, more specifically, 950 kg / m³ 3 It is less than.

[0023] For example, the element consists of at least 50%, particularly at least 60%, particularly at least 70%, more specifically at least 80%, preferably at least 90% fiber and / or filament structures.

[0024] Preferably, the element consists entirely of a fibrous and / or filamentous structure.

[0025] For example, "based on ~" means that the material is primarily composed of, for example, at least 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, and in some cases 100% of this material.

[0026] For example, the remainder of the fibers and / or filaments, and / or the remainder of the material of the fibers and / or filaments, may include natural or synthetic materials, such as viscose, cotton, or the like.

[0027] For example, the fibers and / or filaments of a nonwoven fabric type element are produced from a wrap of fibers and / or filaments obtained by dry processing or fusion bonding.

[0028] In another example, nonwoven elements include pre-reinforcement zones arranged within and / or outside the structure of fibers and / or filaments.

[0029] For example, the preliminary reinforcement zone of the nonwoven element may be a dot, rectangle, dashed line, rhombus, parallelogram, ellipse, wave, or similar shape.

[0030] In another example, nonwoven elements do not have pre-reinforcement zones arranged within the fiber and / or filament structure, nor outside the fiber and / or filament structure.

[0031] For example, the fiber and / or filament structure is at least 25 mm 2 (5mm x 5mm), especially at least 50mm 2 (7.07mm x 7.07mm), especially at least 75mm 2 It extends over a surface area of ​​(8.66 mm × 8.66 mm).

[0032] For example, a fiber and / or filament structure extends continuously in the mechanical direction and / or transverse direction.

[0033] Preferably, the element is not a film.

[0034] According to a second aspect of the present invention, which itself constitutes an invention independent of other aspects of the present invention, but can be advantageously implemented in conjunction with each of the other aspects and with two or more combinations of the other aspects, the thickness of the structure is less than 100 μm, particularly less than 85 μm, particularly between 20 μm and 100 μm, and particularly between 30 μm and 85 μm.

[0035] According to a third aspect of the present invention, which itself constitutes an invention independent of other aspects of the present invention, but can be advantageously implemented in conjunction with each of the other aspects and with two or more combinations of the other aspects, the surface density of the structure is 3 to 50 g / m². 2 During that period, especially between 10 and 40 g / m2 During that period, especially 15 to 30 g / m 2 It is between these two points.

[0036] According to a fourth aspect of the present invention, which itself constitutes an invention independent of other aspects of the present invention, but can be advantageously implemented in conjunction with each of the other aspects and with two or more combinations of the other aspects, the air permeability of the structure is 100 to 3,100 l / m³ 2 The duration is between / seconds, and preferably not a nonwoven fabric containing a melt-blown layer, and in particular not a nonwoven fabric of the SMS type, i.e., a multilayer nonwoven fabric having at least one spunbond layer and at least one melt-blown layer.

[0037] According to a fifth aspect, which itself constitutes an invention independent of other aspects of the present invention, but can be advantageously implemented in conjunction with each of the other aspects and with two or more combinations of the other aspects, the present invention also comprises a method for manufacturing a support element, in particular an element according to the present invention, - A step of using a nonwoven fabric layer in the form of a wrap, wherein at least a portion of it forms a structure of fibers and / or filaments, and the structure has length and width. - The step of calendering, particularly heat calendering, a wrap of fibers and / or filaments over at least a portion of the width of a structure by passing it between two calender cylinders, each preferably having a smooth, particularly metallic, outer surface. This includes methods.

[0038] Preferably, the temperature of each cylinder, and / or the air gap between the two cylinders, and / or the speed of each cylinder, such that the density of the portion of the wrap that forms the fiber and / or filament structure upon appearance after calendering is 155 kg / m³ 3 Exceeding 200 kg / m³, especially 200 kg / m³ 3 Exceeding 250 kg / m³, especially 250 kg / m³ 3 Selected to exceed the limit.

[0039] Preferably, the density of at least a portion of the fiber and / or filament structure forming the nonwoven layer is 10 to 155 kg / m³ before calendering. 3 It is between these two points.

[0040] In particular, the ratio of the density after calendering to the density before calendering is between 1.3 and 15, especially between 1.5 and 8.

[0041] Preferably, the temperature of each cylinder, and / or the air gap between the two cylinders, and / or the speed of each cylinder are selected such that the thickness of the portion of the wrap that forms the structure of the fibers and / or filaments when emerging from the calendering process is less than 100 μm, particularly less than 85 μm, particularly between 20 μm and 100 μm, particularly between 30 μm and 85 μm.

[0042] In particular, the thickness of the portion of the wrap forming the fiber and / or filament structure before calendering is greater than 90 μm, especially greater than 100 μm, especially between 90 μm and 500 μm, especially between 100 μm and 500 μm.

[0043] In particular, the ratio of the thickness before calendering to the thickness after calendering is between 1.2 and 8.

[0044] Preferably, the temperature of each cylinder, and / or the air gap between the two cylinders, and / or the speed of each cylinder, such that the surface density of the portion of the wrap that forms the fiber and / or filament structure when emerging from the calendering process is 3 to 50 g / m². 2 During that period, especially between 10 and 40 g / m 2 During that period, especially 15 to 30 g / m 2 It is selected so as to be between the two.

[0045] Preferably, the temperature of each cylinder, and / or the air gap between the two cylinders, and / or the velocity of each cylinder, are such that the permeability of the portion of the wrap that forms the structure of fibers and / or filaments when emerging from the calendering process is 100 to 3,100 l / m 2 / second (or liters / (m) 2 During the interval of . seconds, especially between 500 and 3,100 l / m 2 Between 620 and 3,100 l / m² / second, in particular. 2 Selected to be within / seconds

[0046] In particular, the permeability of a portion of the wrap that forms the structure of the fibers and / or filaments before calendering is 1,000 to 7,000 l / m 2 For a duration of / second, preferably 1,500 to 7,000 l / m 2 For a period of / second, more preferably 2,000 to 7,000 l / m 2 For a duration of / second, and more preferably 3,000 to 7,000 l / m 2 It is for a period of / seconds.

[0047] In particular, the ratio of transmittance before calendering to transmittance after calendering is between 1.1 and 12, especially between 1.2 and 8.

[0048] In a preferred embodiment, the rotational peripheral speed of one calendar roller is faster than that of the other calendar roller. This allows for superior smoothness of the structure on the faster roller side.

[0049] According to a preferred embodiment, the product's moving speed is faster than the rotational peripheral speed of one of the calendar rollers. This allows for superior smoothness of the structure on the faster roller side.

[0050] In a preferred embodiment, a so-called deflection cylinder is provided upstream of the calender cylinder, and the deflection cylinder is intended to increase the contact area between a portion of the wrap forming the fiber and / or filament structure and the first calender cylinder before the portion of the wrap forming the fiber and / or filament structure contacts the calender cylinder before being directed between the calender cylinders so as to be preheated before passing between the cylinders.

[0051] Preferably, the roller is heated to a temperature above the HDT temperature (Method B) of the nonwoven material, particularly above 20°C, and in particular, the roller is heated to a temperature above the HDT temperature (Method B) of the nonwoven material having the lowest HDT temperature (Method B), particularly above 20°C.

[0052] The nonwoven fabric layer passing through the heated calendering equipment may be a web or wrap of nonwoven fabric that is pre-reinforced or not. If reinforced, this can be done in particular by heat bonding, mechanical needling, water jet, air jet, or the like, in particular according to a unit pattern, e.g., dots, ellipses, lines, columns, or a dashed pattern that can be arranged in a specific shape, e.g., hexagon or other.

[0053] According to the present invention, the fiber and / or filament structure maintains breathability upon emergence from calendering, is soft to the touch, has higher rigidity in the MD, and therefore is less susceptible to deformation in the MD during unwinding, less susceptible to tension fluctuations in the line, less susceptible in the CD, has less of a "neck-down" effect during stretching in the MD, is not too rough, is not too coarse, has a low coefficient of static and / or dynamic friction, is not too thick, so more material can be wound per coil of a given diameter, and is less susceptible to pressure, making it more stable when used for positioning on diapers in a production line.

[0054] In particular, after the nonwoven fabric layer passes between calender rollers, the percentage of free fibers and / or filaments in the upper and lower surfaces of the structure decreases. Conventionally, before passing between the rollers, the nonwoven fabric layer has, as a result of pre-reinforcement, 75% to 95% of the fibers and / or filaments forming the upper or lower surface of the structure that are free, i.e., can be individually separated from the structure, and especially removed therefrom. After passing between the rollers, this percentage becomes 0% to 25%, and especially 0% to 15%.

[0055] Furthermore, most of the fibers and / or filaments that are flush with the top and bottom surfaces of the structure are deformed, particularly by fusion, i.e., by melting into each other's tops or interiors, which results in a smoother texture and a glossy finish in these top and bottom regions.

[0056] The present invention also relates to a laminate comprising elements according to the present invention that form a support, fixed to one another by welding points or welding islands, particularly by calendering and / or ultrasonic welding, and loop elements, particularly loop-shaped nonwoven fabrics.

[0057] The present invention also relates to a diaper comprising elements according to the present invention that form a support, and in particular a laminate according to the present invention that forms a landing zone of the diaper.

[0058] The present invention also relates to a winding body in the form of a support element or a laminated coil according to the present invention.

[0059] Preferably, according to the present invention, the air permeability measured in accordance with ISO 9237 standard, ISSN 0335-3931, issued in August 1995, particularly at a pressure difference of 200 Pa, is greater than 100, particularly greater than 200, particularly greater than 300, particularly greater than 400, particularly greater than 500, particularly greater than 600, particularly greater than 700, particularly greater than 800, particularly greater than 900, particularly greater than 1,000, particularly greater than 1,100, particularly greater than 1,200, particularly greater than 1,300, particularly greater than 1,400, particularly greater than 1,500, particularly greater than 1,600. It is large and less than 5,000, especially less than 4,900, especially less than 4,800, especially less than 4,700, especially less than 4,600, especially less than 4,500, especially less than 4,400, especially less than 4,300, especially less than 4,200, especially less than 4,100, especially less than 4,000, especially less than 3,900, especially less than 3,800, especially less than 3,700, especially less than 3,600, especially less than 3,500, especially less than 3,400, especially less than 3,300, especially less than 3,200, especially less than 3,100. [Brief explanation of the drawing]

[0060] [Figure 1] This is a schematic diagram of an embodiment of the method according to the present invention.

[0061] [Figure 2] This is a perspective view of equipment for measuring the thickness of laminates and / or support elements and / or nonwoven fabrics.

[0062] [Figure 3] Figure 2 is a cross-sectional view of the equipment.

[0063] [Figure 4] This is a perspective view of a diaper including a landing zone made of a laminate containing support elements according to the present invention.

[0064] [Figure 5] from [Figure 16]These are photographs of the samples from Examples 1 to 12, viewed from above, before passing them between the calender rollers. The photographs were taken at 100x magnification.

[0065] [Figure 17] from [Figure 28] These are photographs of the samples from Examples 1 to 12, viewed from above after passing between the calender rollers. The photographs were taken at 100x magnification.

[0066] [Figure 29] and [Figure 30] This is a perspective view of an adapter used to measure the air permeability of a support element with a small surface area. [Modes for carrying out the invention]

[0067] The nonwoven fabric wrap 1 is unwound from a coil (not shown) and fed into the air gap between two metal calender cylinders 2 and 3. After passing around a deflection cylinder 4, it is heated to a temperature of 135°C or higher for wraps based on one or more thermoplastic materials. Once out of the air gap, the nonwoven fabric wrap 1 is allowed to cool over a sufficient distance before being wound up on a winding machine (not shown).

[0068] In particular, the air gap has a value greater than 10 micrometers, especially greater than 20 micrometers, especially greater than 30 micrometers, and less than 100 micrometers, especially less than 90 micrometers, especially less than 85 micrometers, generating a linear pressure on the lap between 10 and 150 N / mm, especially between 20 and 120 N / mm.

[0069] The outer surfaces of the two cylinders are smooth and do not have any engraved patterns.

[0070] Optionally, it may be useful to add a draw cylinder 5, for example a particularly cooled electric cylinder, to draw the product on the calendar cylinder 3. As a variant, the draw cylinder 5 shown in FIG. 1 can be arranged offset from the calendar cylinder 3.

Example

[0071] In this way, 12 wraps of non-woven fabric from Example 1 to 12 were passed between the two calendar rollers according to the above method. Example 1: 20 g / m 2 of 100% bio-based PLA spunbond, width 220 mm, reinforced with an elliptical pattern, available under the name PS1DW-P01 from Fitesa. Example 2: 20 g / m 2 of 100% bio-based PLA spunbond, width 300 mm, reinforced with an elliptical pattern, available under the name PS1DW-P01 from Fitesa. Example 3: 25 g / m 2 of 10% PP spunbond, width 240 mm, reinforced with an elliptical pattern, available under the name PS6-12G from Fitesa. Example 4: 25 g / m 2 of 100% PP HES spunbond, width 180 mm, having a calendar treatment pattern in the shape of a rectangular broken line on the CD, available under the name PS6KW-11G from Fitesa. Example 5: 13 g / m 2 of SMS type 100% polypropylene non-woven fabric, width 240 mm, reinforced with an elliptical pattern, available under the name PC51FW-111 from Fitesa. Example 6: 18 g / m 2 of 100% PP spunbond, width 170 mm, available under the name BLOWBOND SB ultrasoft from Texbond. Example 7: 20 g / m 2 [[ID=]]35 of 100% bio-based PLA spanlace, width 200 mm, available under the name 15.020.001 from Glatfelter (formerly Jacob Holm). Example 8: 10 g / m Example 8: 10 g / m2 100% PP spunbond, 100 mm wide, available under the name S 1000PH W from Union Industries S.p.A. Example 9: 22 g / m 2 100% PP heat - bonded card material, 165 mm wide, available under the name Sawabond 01408 - 001 from Sandler. Example 10: 30 g / m 2 100% PET (or 100% PES) spunlace, 180 mm wide, available from Eruslu. Example 11: 28 g / m 2 50% PET 50% PP spunlace, 180 mm wide, available under the name Sawasoft 01188 - 001 from Sandler. Example 12: 20 g / m 2 100% bio - based PLA spunbond, 220 mm wide, available under the name PS1DW - P01 from Fitesa.

[0072] For Examples 1 to 12, before and after passing between calendar rollers, the following parameters: coefficient of static friction, coefficient of dynamic friction, basis weight, transmittance, thickness, density, elongation in the MD at 5 N, elongation in the CD at 5 N, were measured by the method described below.

[0073] The results obtained are shown in the following table.

[0074] To measure the thickness of the support element, laminate, and / or non - woven fabric, the French and European standard NF EN ISO 9073 - 2 method A of February 1997 is used, and a thickness comparator can be used, in particular, a device titled "Precision Thickness Tester" sold under the product number D - 2005 - V by VVC.

[0075] This device 200 includes a disc 202, and the disc 202 has a surface area of 25 cm 2It has a circular surface and is located at the end of a cylindrical arm 203 that is vertically movable under the control of electronically controlled means incorporated into the device. The other end of the arm is located where element S has appropriate surface area dimensions, i.e., 25 cm². 2 If the surface area of ​​disk 202 is completely covered by the sample, the size is 25 cm². 2 An additional mass is used to apply a pressure of 0.5 kPa (after 10 seconds) to the base surface facing the disc 202. Conversely, as shown in Figure 3, the measurement can also be performed in accordance with the standard NF EN ISO 9073-2 Method A of February 1997, using the "Precision Thickness Tester" sold by VVC under product number D-2005-V and a 15 mm × 15 mm square palette 201 interposed between the base surface 204 and the disc 202, thereby applying a force, i.e., pressure, of 5.55 kPa to the surface of the sample S' (5.55 kPa = 0.5 kPa × (25 cm)). 2 / 2.25cm 2 Therefore, by placing the sample S' between the pallet and the disc, it is possible to measure its thickness in the pallet surface area by performing the steps described in Method A of the NF EN ISO 9073-2 standard of February 1997. 3 Exceeding 200 kg / m³, especially 200 kg / m³ 3 Exceeding 250 kg / m³, especially 250 kg / m³ 3 Nonwoven fabric elements exceeding a certain thickness have a thickness that does not show significant change after 10 seconds when the pressure is increased from 0.5 kPa to 5.5 kPa. As shown in Figure 2, for samples like sample S, that is, samples with a surface area that can completely cover the disc 202, it is also possible to use a square palette 201. Therefore, to measure large samples like S, it is possible to either use the palette shown in Figure 2, or to sandwich the sample S between the base surface 204 and the disc 202 without using a palette.

[0076] To measure the density of a support element and / or laminate and / or nonwoven fabric, measure its thickness as described above, multiply the obtained thickness by the surface density to determine the density of the support element, and the surface density can be calculated, as is well known, by weighing the sample using any commercially available scale and dividing the obtained mass by the surface area of ​​the sample.

[0077] To measure the air permeability of support elements and / or laminates and / or nonwoven fabrics, for example, a Textflix 3300 air permeability tester from Textest AG can be used with a test pressure of 125 Pa and a head test zone of 38 cm. 2 It is possible to use this.

[0078] According to the protocol defined in the standard ISO 9237, ISSN 0335-3931, issued in August 1995, at a pressure of 200 Pa, the surface area is 20 cm². 2 It is also possible to measure this transmittance using a sample. For example, it is possible to use the air permeability tester with model number "FX 3300" available from Textest AG.

[0079] In particular, it is necessary to test the air permeability of support elements, laminates, and / or nonwoven fabrics taken from diapers, and these themselves do not have dimensions suitable for testing by standard and / or selected testing machines, requiring samples with a larger surface area, for example, a product with a surface area of ​​20 cm². 2 The FX3000 from Textest AG, which requires the above-mentioned adapter, can be used with the adapter described in WO21009082A1 in the name of the present applicant.

[0080] The adapters shown in Figures 29 and 30 are for use with the aforementioned FX3000 test machine or another similar test machine.

[0081] As shown, the adapter 100 comprises two parts in the form of a substantially circular plate, namely an upper part 110 and a lower part 120, which are connected by a hinge 130. Part 110 has an inner surface 110i and an outer surface 110o. Part 120 has an inner surface 120i and an outer surface 120o.

[0082] The upper 110 and lower 120 each have through openings 112 and 122, respectively. The openings 112 and 122 each have circular edges with a diameter of 8 mm and are arranged facing each other, allowing air or fluid flow to pass through the adapter 100. The opening in the lower 120 is surrounded by a seal ring 124 located on the inner surface 120i of the lower 120. The seal ring 124 ensures airtightness when the upper 110 of the adapter 100 is folded down against the lower 120 with sufficient pressure, and the specimen under test is positioned between the upper 110 and lower 120 of the adapter 100, blocking the openings 112 and 122.

[0083] When the adapter is closed, does not contain the test sample, and the seal 124 is removed, the inner surface of the upper part 100 can substantially contact the inner surface 120i of the lower part 120.

[0084] The seal ring 124 can be positioned on the inner surface of the upper part 110 around the opening 112 provided in the upper part 110, or two seal rings can be provided in contact with each other, one around each opening.

[0085] The outer surface 120o of the lower part 120 may be provided with a seal ring 126 that facilitates, for example, the measurement of the flow passing through the adapter 100, i.e., the flow passing through the product under test, and especially the insertion of a tube protruding from the testing machine.

[0086] Sufficient pressure to ensure airtightness at the interface between the seal 124 and the upper inner surface is obtained by positioning the adapter between the test head, which is located at the end of the clamp arm of the air permeability tester, and the test stand. The arm, with the help of a spring, elastically presses the adapter against the test stand with sufficient force to ensure airtightness, and this force is the same as the force conventionally used without the adapter.

[0087] To measure the static and / or dynamic friction coefficients, elongation at 5N, and transmittance, the sample is conditioned for 24 hours in standard air as defined in standard ASTM D5170, at a temperature of 23°C ± 2°C and a relative humidity of 50% ± 5%.

[0088] The coefficients of dynamic and static friction can be measured according to the standard ASTM D1894 January 2014, for example, using a pallet with a mass of 205g, dimensions of 65mm x 65mm, and a travel speed of 150mm / min.

[0089] For elongation at 5N in CD or MD, a fracture elongation test can be performed on the sample using a dynamometer or other measuring instrument in accordance with standard EN 10002, with a speed of 100 mm / min, jaw distance of 50 mm, sample width of 50 mm, and preload of 0.1 N.

[0090] In the table below, the numbers in parentheses correspond to the nonwoven fabric before calendering.

[0091] [Table 1] TIFF2026512888000002.tif147154TIFF2026512888000003.tif147154

[0092] In this invention, nonwoven fabric is intended to mean a product obtained after forming a wrap of reinforced fibers and / or filaments. Wraps of fibers and / or filaments can be obtained by dry processing, fusion bonding, wet processing, or so-called “flash spinning.” Dry processing, e.g., carding, generally corresponds to fibers separated and arranged by carding. Fusion bonding (e.g., by spindle or called “spunlaid”) corresponds to a polymer that is melted, then extruded and spun to create a fibrous or filamentous wrap. In some cases, fusion bonding may or may not require additional strengthening steps. Wet processing (e.g., called “wet-laid”) is generally used with short synthetic cellulose fibers (rayon, viscose, etc.) dispersed in water, and then the fibers are deposited on a screen to form a wrap. “Flash spinning” is generally used with synthetic fibers dissolved in a solvent, and then sputtered onto a support under vacuum, forming a fiber wrap after solvent evaporation. Reinforcement can be mechanical, chemical, or thermal, creating bonds between fibers and / or filaments. This reinforcement can be direct, i.e., by welding, directly between fibers and / or filaments, or indirect, i.e., by an intermediate material between fibers and / or filaments, such as an adhesive or binder. The term "nonwoven fabric" refers to a structure in the form of a tape or wrap of fibers and / or filaments that are woven together unevenly, irregularly, or disorderly. Nonwoven fabrics can have a single-layer structure or a multi-layer structure. Nonwoven fabrics can be made from different synthetic and / or natural materials. Natural materials include, for example, cellulose fibers such as cotton, jute, paper pulp, hemp, or similar, and also regenerated cellulose fibers such as rayon or viscose (cellulose acetate). Natural fibers for nonwoven fabric materials can be prepared using various processes such as carding.Examples of synthetic materials include, but are not limited to, synthetic thermoplastic polymers known to form fibers and / or filaments, which include, but are not limited to, polyolefins such as polyethylene, polypropylene, polybutylene, and the like; polyamides such as polyamide 6, polyamide 6.6, polyamide 10, polyamide 11, polyamide 12, and the like; polyesters such as polyethylene terephthalate, polybutylene terephthalate, polylactic acid (PLA), and the like; polycarbonate, polystyrene, thermoplastic elastomers, vinyl polymers, polyurethanes, and mixtures and copolymers thereof. Some of these materials can be bioplastics, such as bio-derived (e.g., bio-PE, PLA, or PHA (polyhydroxyalkanoate), polyamide 11, viscose (cellulose acetate), and the like) and / or biodegradable (PLA and the like). Generally, fibers and filaments differ mainly in their length and manufacturing method.

[0093] A "continuous filament" refers to individual elements that are very long relative to their cross-sectional diameter, which can be continuously extruded to directly form a nonwoven fabric wrap, and then reinforced by heat bonding or any other means, enabling the achievement of desired performance and / or transport thereof. Preferably, the length of the continuous filament exceeds 120 mm.

[0094] "Fiber" is a general term referring to a reduced-length fabric material or fabric material element, less than the length of a continuous filament, that can be spun and / or used to form a nonwoven fabric. Two types of fibers are distinguished: short fibers, which are formed from discontinuous material and have a short length of less than 50 mm (preferably 25 mm to 50 mm), and long fibers, which are formed discontinuously and have a long length of more than 50 mm (preferably 60 mm to 120 mm).

[0095] Unlike continuous filaments, which are reinforced immediately after extrusion, fibers are typically oriented and organized into a wrap during a carding step, which is well known to those skilled in the art. This wrap can then be reinforced by heat bonding or any other means, enabling the achievement of desired performance and / or its transport.

[0096] According to the present invention, "film" means a sheet-like or wrap-like material whose length and width are much greater than its thickness (for example, by a ratio of 10 times, 50 times, or even 1000 times or more). Typically, the thickness of a film is less than 0.7 mm, especially less than 0.5 mm, or even thinner. In particular, a thread or bundle of threads, or a set of threads, is not a film.

[0097] The elements according to the present invention can be used, for example, as a support layer as described in document WO2015155150, in a lamination process for forming a laminate.

Claims

1. Nonwoven elements, particularly nonwoven elements forming support elements, comprising at least a portion consisting of a fiber and / or filament structure, the fiber and / or filament structure extending between an upper and lower surface, allowing gas, particularly air and / or water vapor, to pass through the structure from one surface to the other, the fiber and / or filament being based on one or more materials selected from thermoplastic materials, and the density of the structure being equal to the surface density divided by thickness measured after 10 seconds under a pressure of 0.5 kPa according to the NF EN ISO 9073-2 Method A of February 1997, is 155 kg / m³. ３ Larger, especially 200 kg / m ３ Larger, especially 250 kg / m ３ A nonwoven element characterized by being larger.

2. The structure has a flow rate of 100 to 3,100 l / m at a pressure difference of 200 Pa. ２ Between 500 and 3,100 l / min per second ２ The element according to claim 1, characterized by having an air permeability of / second.

3. The element according to claim 1 or 2, characterized in that the entire structure consists of fibers and / or filaments.

4. The element according to any one of claims 1 to 3, characterized in that the thickness of the structure is less than 100 μm, more particularly less than 85 μm, more particularly between 20 μm and 100 μm, and more particularly between 30 μm and 85 μm.

5. The surface density of the structure is 3 to 50 g / m². ２ During that period, especially between 10 and 40 g / m ２ During that period, especially 15 to 30 g / m ２ An element according to any one of claims 1 to 4, characterized in that it is between.

6. The element according to any one of claims 1 to 5, characterized in that the structure is a filament, particularly a spunbond structure.

7. An element, in particular a method for manufacturing an element according to any one of claims 1 to 6, - A nonwoven fabric layer in the form of a wrap, wherein at least a portion thereof forms a structure of fibers and / or filaments, and the structure has length and width, - A wrap of fibers and / or filaments is calendered, particularly heated calendered, over at least a portion of the width of the structure by passing it between two calender cylinders, each preferably having a smooth, particularly metallic, outer surface. A method that includes steps.

8. The density of a portion of the wrap that forms the structure of the fibers and / or filaments upon emergence from the calendar treatment is greater than 155 kg / m³ when each temperature of the cylinder, and / or the air gap between two cylinders, and / or each speed of the cylinder ３ exceeds, particularly exceeds 200 kg / m³ ３ exceeds, particularly exceeds 250 kg / m³ ３ The method according to claim 7, characterized in that it is selected to exceed.

9. The density of at least a portion of the fiber and / or filament structure of the nonwoven layer is 10 to 155 kg / m³ before calendering. ３ The method according to claim 7 or 8, characterized in that it is between.

10. The method according to any one of claims 7 to 9, characterized in that a cylinder called a deflection cylinder is provided upstream of the calender cylinder, and the deflection cylinder is intended to increase the contact area between a portion of the wrap forming the fiber and / or filament structure and a first calender cylinder that contacts it before it is directed between the calender cylinders, so that the portion of the wrap forming the fiber and / or filament structure is preheated before it passes between the cylinders.

11. The method according to any one of claims 7 to 10, characterized in that the roller is heated to a temperature exceeding the HDT temperature (Method B) of the nonwoven material or one of the materials, particularly exceeding 20°C, and in particular the roller is heated to a temperature exceeding the HDT temperature (Method B) of the nonwoven material having the lowest HDT temperature (Method B), particularly exceeding 20°C.

12. The method according to any one of claims 7 to 11, characterized in that the nonwoven fabric layer sent to a heated calender is a pre-reinforced nonwoven fabric web or wrap, particularly by heat bonding, mechanical needling, water jet, air jet, or similar, according to a unit pattern, such as lines, rows, or unit patterns in the form of points, ellipses, dashed lines, which can be arranged in a particular shape, such as hexagons or other specific shapes.

13. A laminate comprising elements according to any one of claims 1 to 6 that form a support, fixed to each other by welding points or welding islands, particularly by calendering and / or ultrasonic welding, and loop elements, particularly loop-shaped nonwoven fabrics.

14. A diaper comprising elements according to any one of claims 1 to 6 that form a support, particularly a laminate according to claim 13 that forms the landing zone of the diaper.

15. A winding body in the form of a coil of an element according to any one of claims 1 to 7 or a laminate according to claim 13.

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