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    • 专利摘要:
    FLEXIBLE COFORM NON-WOVEN Weft The present invention provides a flexible coform non-woven weave, which contains a matrix of meltblown fibers and an absorbent material. Meltblown fibers can comprise from about 2% by weight to about 40% by weight of the coform web. The absorbent material can comprise from about 60% by weight to about 98% by weight of the coform web. The cup crushing energy / thickness ratio of the nonwoven structure is desirably less than about 600. The coform web can be provided with a three-dimensional texture when, for example, using a three-dimensional forming surface. The coform web is suitable for forming absorbent articles, such as wipes and absorbent personal care products.
    公开号:BR112012014275B1
    申请号:R112012014275-5
    申请日:2010-11-18
    公开日:2020-10-13
    发明作者:Michael A. Schmidt；Kenneth B. Close；David M. Jackson；Lisa L. Nickel
    申请人:Kimberly-Clark Worldwide, Inc；
    IPC主号:
    专利说明:

    HISTORY OF THE INVENTION
    [001] Non-woven coform wefts, which are composites of a matrix of meltblown fibers and an absorbent material (eg pulp fibers), have been used as an absorbent layer in a wide variety of applications, including absorbent articles, dry absorbent wipes, wet wipes, and mops. Non-woven coform wefts can present a textured surface formed by placing the meltblown fibers in contact with a foraminous surface with three-dimensional surface contours. Softness and flexibility are important characteristics of coform wefts, for which improvements are continually sought.
    [002] As such, there is currently a demand for a non-woven coform web featuring improved softness and flexibility characteristics for use in a variety of applications. SUMMARY OF THE INVENTION
    [003] According to one embodiment, a non-woven coform weave is described, which includes a matrix of meltblown fibers and an absorbent material. The matrix includes a continuous region and a plurality of offset regions, the region continues to have a transversal direction, a machine direction and a thickness. The region continues to include a first side, which can be planar, extending in the transverse and machine direction, and a second side, which can be planar, opposite the first side. The first and second sides are separated by the thickness of the continuous region and the displacement regions extend outwards from the first side. The displacement regions can be positioned to define a plurality of first uninterrupted portions of the continuous regions, the first uninterrupted portions of the continuous region not being underlying any displacement regions. The first uninterrupted portions of the continuous region may extend in a first direction on the plane of the first side, the first direction may not intersect any regions of displacement, and the width of the uninterrupted portions divided by the width of the regions of displacement may be between about 0 , 3 and about 2.0. Widths are measured perpendicular to the first direction in the plane of the first side. In one embodiment, the continuous region can extend completely under the displacement regions.
    In one aspect, the thickness of the continuous region can be from about 0.01 mm to about 10.0 mm.
    In another aspect, the density of the continuous region is substantially equal to the density of the displacement regions.
    In an additional aspect, the weight of the continuous region may be less than the weight of the displacement regions.
    In an additional aspect, the displacement regions can extend from the first side by about 0.25mm to about 5.0mm.
    In one aspect, the first uninterrupted portions of the continuous region can extend in the first direction through at least two, three or four different displacement regions.
    In another aspect, the displacement regions can be positioned to define a plurality of second uninterrupted portions of the continuous region, the second uninterrupted portions of the continuous region extending infinitely in a second direction, without intercepting any displacement regions. The first direction can be orthogonal to the second direction.
    In one aspect, the meltblown fibers include a propylene / otolefin copolymer. In an additional embodiment, a-olefin can include ethylene.
    In another aspect, the absorbent material includes pulp fibers.
    In a still further aspect, meltblown fibers can comprise from 1% by weight to about 40% by weight of the web and the absorbent material can constitute from about 60% by weight to about 99% by weight of the web.
    In another aspect, the ratio of cup crushing energy to the thickness of the nonwoven coform web may be less than about 600 grams.
    In another embodiment, a handkerchief includes the non-woven weave described above. In a further aspect, the tissue can contain from about 150 to about 600% by weight of a liquid solution, based on the dry weight of the tissue.
    According to an additional embodiment, a nonwoven structure includes at least one fibrous meltblown material and at least one secondary fibrous material. The weight ratio of at least one secondary fibrous material to at least one meltblown fibrous material can be between about 40/60 to about 90/10. The cup crush energy / thickness ratio of the nonwoven structure can be less than about 600 grams.
    In another embodiment, the cup crush energy / thickness of the nonwoven structure can be in a range selected from the ranges consisting of about 200 grams to about 600 grams, from about 250 grams to about 600 grams, from about 276 grams to about 600 grams, from about 200 grams to about 580 grams, from about 250 grams to about 580 grams, from about 276 grams to about 580 grams, from about 200 grams to about 500 grams, from about 250 grams to about 500 grams, from about 276 grams to about 500 grams, from about 200 grams to about 400 grams, from about 250 grams to about 400 grams, from about 276 grams to about 400 grams, from about 200 grams to about 380 grams, from about 250 grams to about 380 grams, and from about 276 grams to about 380 grams.
    In one aspect, the fibrous meltblown material comprises a propylene / α-olefin copolymer. In a further aspect, a-olefin includes ethylene.
    In another aspect, the nonwoven structure can additionally include a continuous region and a plurality of displacement regions. The continuous region has a transverse direction, a machine direction and a thickness. The continuous region additionally includes a first side, which can be planar, extending in the transverse and machine direction, and a second side, which can be planar, opposite the first side. The first and second sides are separated by the thickness of the continuous region, the displacement regions extend outwardly from the first side, and the displacement regions are positioned to define a plurality of first uninterrupted portions of the continuous regions. The first unbroken portions of the continuous region are not underlying any displacement regions, the first unbroken portions of the continuous region extend in a first direction on the plane of the first side, and the first direction does not intersect any displacement regions.
    According to another embodiment, a method of forming a non-woven coform web is described, which comprises melting together a stream of an absorbent material, with a stream of meltblown fibers, to form a composite stream. After that, the composite stream is collected on a forming surface to form a non-woven coform web.
    Other features and aspects of the present invention are described in more detail below. BRIEF DESCRIPTION OF THE DRAWINGS
    A complete and enabling description of the present invention, including its best mode, addressed to a person skilled in the art, is shown more particularly in the rest of the specification, which makes reference to the attached figures, in which:
    Figure 1 is a schematic illustration of an embodiment of a method for forming the coform web of the present invention;
    Figure 2 is an illustration of certain features of the apparatus shown in Figure 1; and
    Figure 3 is a cross-sectional view of an embodiment of a textured coform web formed according to the present invention.
    Figure 4 is a plan view of a forming surface useful for forming the coform web of the present invention.
    Figure 5 is a schematic view of a load tester for testing a composite according to the present invention.
    Figure 6 is an exploded view of Figure 5.
    The repeated use of reference characters in the present specification and drawings is intended to represent the same elements or features or similar elements or features of the invention. DETAILED DESCRIPTION OF REPRESENTATIVE MODALITIES
    Reference will now be made in detail to various embodiments of the invention, one or more examples of which are shown below. Each example is provided by way of explanation, not limitation, of the invention. Indeed, it will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the scope and spirit of the invention. For example, features illustrated or described as part of one embodiment, can be used in another embodiment to provide yet another embodiment. Therefore, the present invention is intended to cover such modifications and variations.
    As used herein, the term "nonwoven weave" refers to a weave having a structure of individual fibers or filaments, which are intertwined, but not in an identifiable manner as in a knitted fabric. Examples of suitable nonwoven fabrics or wefts include, but are not limited to, meltblown wefts, spunbond wefts, linked carded wefts, air deposited wefts, coform wefts, hydraulically matted wefts, and so on.
    As used here, the term "meltblown weft", in general, refers to a non-woven weft, which is formed by a process, in which a molten thermoplastic material is extruded through a plurality of fine mold capillaries, usually circular, like fibers melted into high-speed, converging gas streams (for example, air) that attenuate the fibers of molten thermoplastic material to reduce their diameter, which can be up to the diameter of microfiber. After that, the meltblown fibers are carried by the high speed gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is described, for example, in U.S. Patent No. 3,849,241, to Butin et al. , which is incorporated herein, in its entirety, by reference to it, for all purposes. Generally speaking, meltblown fibers can be microfibers, which are substantially continuous or discontinuous, generally less than 10 micrometers in diameter, and which, in general, are sticky when deposited on a collecting surface.
    As used here, the term "spunbond weave" generally refers to a weave containing substantially continuous fibers of small diameter. The fibers are formed by extrusion of a fused thermoplastic material, from a plurality of fine capillaries, usually circular, from a spinner with the diameter of the extruded fibers, then, being quickly reduced according to, for example, extractive and / or other well-known spunbonding mechanisms. The production of spunbonding frames is described and illustrated, for example, in U.S. Patent Nos. 4,340,563 by Appel et al .; 3,692,618 to Dorschner et al .; 3,802,817 to Matsuki et al. ; 3,338,992 to Kinney; 3,341,394 to Kinney; 3,502,763 to Hartman; 3,502,538 to Levy; 3,542,615 to Dobo et al. and 5,382,400 by Pike et al., which are incorporated herein, in their entirety, by reference to them, for all purposes. Spunbond fibers are, in general, non-sticky when they are deposited on a collecting surface. Spunbond fibers can sometimes have diameters smaller than about 40 micrometers, and are often between about 5 and about 20 micrometers.
    Generally speaking, the present invention is directed to a coform nonwoven web, which contains a matrix of meltblown fibers and an absorbent material. Meltblown fibers suitable for use in the fibrous nonwoven structure comprise a thermoplastic composition, which may include polyolefins, for example, polyethylene, polypropyl, polybutylene and the like, polyamides, olefin copolymers and polyesters. According to one embodiment, the fibrous meltblown materials, used in the formation of the fibrous non-woven structure, are formed from a thermoplastic composition, which contain at least one propylene / a-olefin copolymer of a certain monomer content, density , melt flow rate, etc. In certain embodiments, the co-weft can be provided with texture using a three-dimensional forming surface.
    Several modalities will now be described in more detail.
    I. Thermoplastic Composition
    The thermoplastic composition desirably contains at least one propylene copolymer and an a-olefin, such as a C2-C2o-a-olefin, a C2-C12-a-olefin or a C2-C8-a-olefin. a- Suitable olefins can be straight or branched (for example, one or more branches of C 1 -C 3 -alkyl or an aryl group). Specific examples include ethylene, butene; 3-methyl-1-butene; 3,3-dimethyl-1-butene; pentene; pentene with one or more methyl, ethyl or propyl substituents; hexene with one or more methyl, ethyl or propyl substituents; heptene with one or more methyl, ethyl or propyl substituents; octene with one or more methyl, ethyl or propyl substituents; nonene with one or more methyl, ethyl or propyl substituents; decene replaced with ethyl, methyl or dimethyl; dodecene; styrene; and so on. Particularly desired a-olefin comonomers are ethylene, butene (for example, 1-butene), heptene and octene (for example, 1-octene or 2-octene). The propylene content of such copolymers can be from about 60 mol% to about 99.5 mol%, in additional embodiments, from about 80 mol% to about 99 mol%, and in still embodiments from about 85 mol% to about 98 mol%. The α-olefin content can also vary from about 0.5 mol% to about 40 mol%, in additional embodiments, from about 1 mol% to about 20 mol%, and in further embodiments additional, from about 2 mol% to about 15 mol%. The distribution of the α-olefin comonomer is typically random and uniform among the fractions of different molecular weights forming the propylene copolymer.
    The density of the propylene / α-olefin copolymer can be a function of both the length and the amount of α-olefin. In other words, the greater the length of α-olefin and the greater the amount of α-olefin present, the lower the density of the copolymer. Generally speaking, copolymers with a higher density are better able to retain a three-dimensional structure, while those with a lower density have better elastomeric properties. Therefore, in order to achieve an optimal balance between texture and stretch, the propylene / a-olefin copolymer is normally selected to have a density of about 0.860 grams per cubic centimeter (g / cm3) at about 0.900 g / cm3, in additional modalities, from about 0.861 to about 0.890 g / cm3, and, still in additional modalities, from about 0.862 g / cm3 to about 0.880 g / cm3. In addition, the density of the thermoplastic composition is normally selected to have a density of about 0.860 grams per cubic centimeter (g / cm3) to about 0.940 g / cm3, in additional embodiments, from about 0.861 to about 0.920 g / cm3, and, in still additional modalities, from about 0.862 g / cm3 to about 0.900 g / cm3.
    Any one of a variety of known techniques can generally be employed to form the propylene / α-olefin copolymer used in meltblown fibers. For example, olefin polymers can be formed using a free radical catalyst or a coordinating catalyst (for example, Ziegler-Natta). Preferably, the copolymer is formed from a single site coordination catalyst, such as a metallocene catalyst. Such a catalyst system produces propylene copolymers, in which the comonomer is randomly distributed within a molecular chain and uniformly distributed across different molecular weight fractions. Propylene copolymers catalyzed by metallocenes are described, for example, in U.S. Patent Nos. 7,105,609, by Datta, et al ■ ,; 6,500,563, by Datta, et al .; 5,339,056, by Yang, et al .; and 5,596,052, by Resconi, et al. , which are incorporated here in their entirety, by reference to them, for all purposes. Polymers prepared using metallocene catalysts typically have a narrow range of molecular weights. For example, metallocene-catalyzed polymers may show polydispersity indices (Mw / Mn) below 4, controlled short chain branch distribution and controlled tacticity.
    In particular embodiments, the propylene / a-olefin copolymer constitutes about 50% by weight or more, in additional embodiments, about 60% by weight or more, and yet in additional embodiments, about 75% by weight or more of the thermoplastic composition used to form the meltblown fibers.In other embodiments, the propylene / a-olefin copolymer constitutes at least about 1% by weight and less than about 49% by weight, in particular embodiments, of at least about 1% by weight and less than about 45% by weight, in additional embodiments, at least about 5% by weight and less than about 45% by weight, and, in yet additional embodiments, at least less than about 5% by weight and less than about 35% by weight of the thermoplastic composition used to form the meltblown fibers. Of course, other thermoplastic polymers can also be used to form the meltblown fibers, as long as they do not adversely affect the desired properties of the composite. For example, meltblown fibers can contain other polyolefins (for example, polypropylene, polyethylene, etc.), polyesters, polyurethanes, polyamides, block copolymers, and so on. In one embodiment, the meltblown fibers may contain an additional propylene polymer, such as homopolypropylene or a propylene copolymer. The additional propylene polymer can, for example, be formed from a substantially isotactic propylene homopolymer or a copolymer containing equal to or less than about 10% by weight of another monomer, i.e., at least about 90 % by weight of propylene. Such a polypropylene can be present in the form of a graft copolymer, random or in blocks and can be predominantly crystalline in that it has a clear melting point above about 110 ° C, in some embodiments, above about 115 ° C, and, in still additional modalities, above about 130 ° C. Examples of such additional polypropylenes are described in U.S. Patent No. 6,992,159, to Dattaetal., Which is incorporated herein in its entirety, by reference to it, for all purposes.
    In particular embodiments, the additional polymer (s) may comprise from about 0.1% by weight to about 50% by weight, in additional embodiments, from about 0.5% by weight. weight at about 40% by weight, and, in still further embodiments, from about 1% by weight to about 30% by weight of the thermoplastic composition. Likewise, the propylene / α-olefin copolymer described above can comprise from about 50% by weight to about 99.9% by weight, in additional embodiments, from about 60% by weight to about 99.5% by weight. weight, and, in still further embodiments, from about 75% by weight to about 99% by weight of the thermoplastic composition.
    In other embodiments, the additional polymer (s) may comprise more than about 50% by weight, in particular embodiments, from about 50% by weight to about 99% by weight , in selected modalities, from about 55% by weight to about 99% by weight, in additional modalities, from about 55% to about 95% by weight, and in still additional modalities, from about 65% in weight at about 95% by weight. Also, the propylene / otolefin copolymer described above can comprise from less than about 49% by weight, in particular embodiments, from about 1% by weight to about 49% by weight, in selected embodiments, from about 1% by weight to about 45% by weight, in additional embodiments, from about 5% by weight to about 45% by weight, and in still further embodiments, from about 5% by weight to about 35% by weight of the thermoplastic composition.
    The thermoplastic composition, used to form the meltblown fibers, can also contain other additives, as is known in the art, such as melt stabilizers, processing stabilizers, thermal stabilizers, light-based stabilizers, antioxidants, face stabilizers. thermal aging, bleaching agents, etc. Phosphite stabilizers (e.g., IRGAFOS, available from Ciba Specialty Chemicals, Tarrytown, New York, and DOVERPHOS, available from Dover Chemical Corp., Dover, Ohio) are exemplary melt mass stabilizers. In addition, hindered amine stabilizers (for example, CHIMASSORB, available from Ciba Specialty Chemicals) are exemplary thermal and light-based stabilizers. In addition, hindered phenols are commonly used as an antioxidant. Some suitable hindered phenols include those available from Ciba Specialty Chemicals under the trade name "Irganox®", such as Irganox® 1076, 1010 or E 201. When used, such additives (eg, antioxidant, stabilizer, etc.) can , each, be present in an amount of about 0.001% by weight to about 15% by weight, in additional embodiments, from about 0.005% by weight to about 10% by weight, and, in still further embodiments, by 0.01% to about 5% by weight of the thermoplastic composition used to form the meltblown fibers.
    Through the selection of certain polymers and their contents, the resulting thermoplastic composition can have thermal properties superior to those of polypropylene homopolymers conventionally used in meltblown wefts. For example, the thermoplastic composition is, in general, more amorphous in nature than the polypropylene homopolymers conventionally employed in meltblown wefts. For this reason, the crystallization rate of the thermoplastic composition is slower, as measured by its "crystallization half-time" - that is, the time required for half of the material to become crystalline. For example, the thermoplastic composition typically has a crystallization half-time greater than about 5 minutes, in additional embodiments, from about 5.25 minutes to about 20 minutes, and, in additional embodiments, about from 5.5 minutes to about 12 minutes, determined at a temperature of 125 ° C. In contrast, conventional polypropylene homopolymers often have a crystallization time of 5 minutes or less. In addition, the thermoplastic composition can have a melting temperature ("Tm") of about 100 ° C to about 250 ° C, in additional embodiments, from about 110 ° C to about 200 ° C, and in additional modalities, from about 140 ° C to about 180 ° C. The thermoplastic composition can also have a crystallization temperature ("Tc") (determined at a cooling rate of 10 ° C / min) from about 50 ° C to about 150 ° C, in additional modes, from about 80 ° C to about 140 ° C, and, in yet additional embodiments, from about 100 ° C to about 120 ° C. The crystallization half-time, the melting temperature and the crystallization temperature can be determined using differential scanning calorimetry ("DSC"), as is well known to those skilled in the art and described in greater detail below.
    The melt flow rate of the thermoplastic composition can also be selected within a certain range, to optimize the properties of the resulting meltblown fibers. The melt flow rate is the weight of a polymer (in grams), which can be forced through an extrusion rheometer orifice (0.21 cm (0.0825 inches) in diameter) when subjected to a force of 2,160 grams in 10 minutes, at 230 ° C. Generally speaking, the melt flow rate is high enough to improve the processability of the melt, but not so high that it adversely interferes with the binding properties of the fibers to the absorbent material. Therefore, in most embodiments, the thermoplastic composition has a melt flow rate of about 120 to about 6,000 grams for 10 minutes, in additional modalities, from about 150 to about 3,000 grams for 10 minutes, and , in still additional modalities, from about 170 to about 1,500 grams for 10 minutes, measured according to the test method ASTM D1238-E.
    II. Meltblown fibers
    Meltblown fibers can comprise from about 2% by weight to about 40% by weight, in additional embodiments, from 4% by weight to about 30% by weight, and, in still further embodiments, from about 5 % by weight at about 20% by weight of the coform web. Meltblown fibers can be single-component or multi-component. Mono-component fibers, in general, are formed from a polymer or combination of polymers extruded from a single extruder. Multicomponent fibers, in general, are formed from two or more polymers (for example, bicomponent fibers) extruded from separate extruders. The polymers can be arranged in distinct zones positioned substantially constant through the cross section of the fibers. The components can be arranged in any desired configuration, such as wrap-core, side by side, pie, island in the sea, three islands, porthole, or various other arrangements known in the art. Various methods for forming multicomponent fibers are described in U.S. Patent Nos. 4,789,592, by Taniguchi et al. ; 5,336,552, by Strack et al. ; 5,108,820, by Kaneko, et al .; 4,795,668, by Kruege, etal .; 5,382,400, by Pike, et al .; 5,336,552, by Strack, et al .; and 6,200,669, by Marmon, et al. ; which are hereby incorporated by reference, in their entirety, by reference to them, for all purposes. Multicomponent fibers having various irregular shapes can also be formed, as described in U.S. Patent Nos. 5,277,976, by Hogle, et al .; 5,162,074, from Hills, 5,466,410, from Hills, 5,069,970, from Largman, et al. ; and 5,057,368, by Largman, et al. , which are incorporated herein, in their entirety, by reference to them, for all purposes.
    III. Absorbent Material
    Any absorbent material can, in general, be used in the non-woven form of coform, such as absorbent fibers, absorbent particles, etc. The absorbent material may comprise from about 60% by weight to about 98% by weight, in additional embodiments, from 70% by weight to about 96% by weight, and in still further embodiments, from about 80 % by weight at about 95% by weight of the coform web. In one embodiment, the absorbent material includes fibers formed by a variety of pulping processes, such as kraft pulp, sulfite pulp, thermomechanical pulp, etc. Pulp fibers may include softwood fibers having an average fiber length greater than 1 mm and, in particular, about 2 to 5 mm, based on a length weighted average. Such softwood fibers may include, but are not limited to, northern softwood, southern softwood, redwood, red cedar, Canadian pine, pine (for example, southern pines), fir (for example, black fir), their combinations, and so on. Exemplary commercially available pulp fibers suitable for use include those available from Weyerhaeuser Company, Federal Way, Washington, under the designation "Weyco CF-405". Hard wood fibers, such as eucalyptus, maple, birch, poplar, and so on, can also be used. In certain instances, eucalyptus fibers may be particularly desired to increase the softness of the weft. Eucalyptus fibers can also enhance clarity, increase opacity and change the pore structure of the weft to increase its capacity for capillary action. In addition, if desired, secondary fibers obtained from recycled materials can be used, such as fiber pulp from sources, such as, for example, newspaper prints, reused cardboard, and office waste. In addition, other natural fibers can also be used, such as abaca, sabai herb, milkweed fibers, pineapple leaf, and so on. In addition, in some cases, synthetic fibers can also be used.
    In addition to or in conjunction with pulp fibers, the absorbent material may also include a superabsorbent, which is in the form of fibers, particles, gels, etc. Generally speaking, superabsorbents are water-swellable materials capable of absorbing at least about 20 times their weight, and in some cases at least about 30 times their weight in an aqueous solution containing 0.9 percent by weight of sodium chloride. The superabsorbent can be formed from modified, natural, synthetic and natural polymers and materials. Examples of synthetic superabsorbent polymers include the alkali metal and ammonium salts of poly (acrylic acid) and poly (methacrylic acid), polyacrylamides, poly (vinyl ethers), maleic anhydride copolymers with vinyl and alpha-olefins, poly (vinyl-pyrrolidone), poly (vinyl-morpholinone), poly (vinyl alcohol), and mixtures and copolymers thereof. In addition, superabsorbents include modified natural and natural polymers, such as starch grafted with hydrolyzed acrylonitrile, starch grafted with acrylic acid, methyl cellulose, chitosan, carboxymethyl-cellulose, hydroxy-propyl-cellulose, and natural gums, such as alginates, xanthan gum, locust bean gum and so on. Mixtures of natural and fully or partially synthetic superabsorbent polymers can also be used. Particularly suitable superabsorbent polymers are HYSORB 8800AD (BASF from Charlotte, North Carolina, and FAVOR SXM 9300 (available from Evonik Stockhausen, Greensboro, North Carolina).
    IV. Coform Preparation Technique
    The coform web, in general, is prepared by a process, in which at least one meltblown mold head (for example, two) is arranged, close to a chute through which the absorbent material is added while plot forms. Some examples of such coform preparation techniques are described in U.S. Patent Nos. 4,100,324, by Anderson, et al. ; 5,350,624, by Georger, et al. , and 5,508,102, by Georger, et al., as well as U.S. Patent Application Publications Nos. 2003/0200991, by Keck, et al. , 2007/0049153, by Dunbar, et al., And 2009/0233072, by Harvey, et al., All of which are incorporated herein, in their entirety by reference to them, for all purposes.
    Referring to Figure 1, for example, a modality of an apparatus for forming a coform web is shown. In this embodiment, the apparatus includes a pellet hopper 12 or 12 'from an extruder 14 or 14', respectively, into which a thermoplastic propylene / a-olefin composition can be introduced. Extruders 14 and 14 'each have an extrusion screw (not shown), which is driven by a conventional drive motor (not shown). As the polymer advances through extruders 14 and 14 ', it is progressively heated to a molten state, due to the rotation of the extrusion screw by the drive motor. Heating can be carried out in a plurality of discrete steps, with its temperature being progressively raised as it advances through discrete heating zones of extruders 14 and 14 ', towards two meltblowing molds16 and 18, respectively. The meltblowing molds16 and 18 can be yet another heating zone, where the temperature of the thermoplastic resin is maintained at a high level for extrusion.
    When two or more meltblowing mold heads are used, as described above, it should be understood that the fibers produced from the individual mold heads can be different types of fibers. In other words, one or more of the size, shape or polymeric composition may differ, and, in addition, the fibers may be single-component or multi-component fibers. For example, larger fibers can be produced by the first meltblowing mold head, such as those having an average diameter of about 10 micrometers or more, in additional modalities, about 15 micrometers or more, and, in yet additional modalities, from about 20 to about 50 micrometers, while smaller fibers can be produced by the second mold head, such as those having an average diameter of about 10 micrometers or less, in additional modalities, of about 7 micrometers or less, and, in yet additional modalities, from about 2 to about 6 micrometers. In addition, it may be desirable for each mold head to extrude approximately the same amount of polymer, such that the relative weight percentage of the coform nonwoven web material resulting from each meltblowing mold head is substantially the same. Alternatively, it may also be desirable to have the production of relative weight inclined, such that one mold head or the other is responsible for the majority of the coform web in terms of weight. As a specific example, for a fibrous meltblown nonwoven weft material having a weight of 1.0 oz per square yard or "osy" (34 grams per square meter or "g / m2"), it may be desirable for the first meltblowing mold head, produce about 30 percent of the weight of the meltblown fibrous nonwoven weft material, while one or more subsequent tblowing honey mold heads produce the remaining 70 percent of the weight of the nonwoven material fibrous meltblown fabric. Generally speaking, the overall weight of the coform nonwoven web is from about 10 g / m2 to about 350 g / m2, and, more particularly, from about 17 g / m2 to about 200 g / m2, and, even more particularly, from about 25 g / m2 to about 150 g / m2.
    Each tblowing honey mold 16 and 18 is configured so that two streams of attenuating gas per mold converge to form a single gas stream, which carries and attenuates fused filaments 20 as they come out of small holes or holes 24 in each meltblowing mold. The fused filaments 20 are formed in fibers, or, depending on the degree of attenuation, microfibers, of a small diameter, which are usually smaller than the diameter of the holes 24. Therefore, each meltblowing mold16 and 18 presents a corresponding single gas stream 26 and 28, containing carried thermoplastic polymer fibers. The gas streams 26 and 28, containing polymer fibers, are aligned to converge in an impingement zone 30. Typically, the meltblowing mold heads 16 and 18 are arranged at a certain angle with respect to the forming surface, such as as described in US Patent Nos. 5,508,102 and 5,350,624, by Georger, et al. Referring to Figure 2, for example, meltblown molds 16 and 18 can be oriented at an angle a, as measured from a plane "A" tangent to the two molds 16 and 18. As shown, plane "A" "is, in general, parallel to the formation surface 58 (Figure 1). Typically, each mold 16 and 18 is adjusted at an angle ranging from about 30 to about 75 degrees, in additional modes, from about 35 ° to about 60 °, and, in yet additional modes, about 45 ° at about 55 °. The molds 16 and 18 can be oriented at the same or different angles. In fact, the texture of the coform web can really be enhanced by orienting one mold at a different angle than the other mold.
    Referring again to Figure 1, absorbent fibers 32 (for example, pulp fibers) are added to the two streams 26 and 28 of thermoplastic polymer fibers 20 and 21, respectively, and in the impingement zone 30. The introduction of the absorbent fibers 32, in the two streams 26 and 28 of thermoplastic polymer fibers 20 and 21, respectively, is designed to produce a graduated distribution of absorbent fibers 32 within the combined streams 26 and 28 of thermoplastic polymer fibers. This can be done by melting a secondary gas stream 34, containing the absorbent fibers 32, between the two streams 26 and 28 of thermoplastic polymer fibers 20 and 21, so that all three gas streams converge in a controlled manner . Due to the fact that they remain relatively sticky and semi-melted after formation, meltblown fibers 20 and 21 can adhere and tangle simultaneously with absorbent fibers 32, when in contact with them, to form a coherent nonwoven structure.
    To carry out the fusion of the fibers, any conventional equipment can be employed, such as a collector roll arrangement 36 having a plurality of teeth 38 adapted to separate a mat or mat 40 of absorbent fibers in the individual absorbent fibers. When used, the sheets or mats 40 of fibers 32 are fed to the pick roller 36 by a roll arrangement 42. After the teeth 38 of the pick roller 36 have separated the fiber mat into separate absorbent fibers 32, the individual fibers they are transported towards the stream of thermoplastic polymer fibers through a nozzle 44. A compartment 46 encloses the collecting roller 36 and provides a passage or clearance 48 between the compartment 46 and the surface of the teeth 38 of the collecting roller 36 A gas, for example, air, is supplied to the passageway or clearance 48, between the surface of the collecting roller 36 and the compartment 46 via a gas duct 50. The gas duct 50 can enter the passageway or gap 48 at the junction 52 of the nozzle 44 and at the gap 48. The gas is supplied in sufficient quantity to serve as a means for transporting the absorbent fibers 32 through the nozzle 44. The gas supplied from the duct 50 also serves as an auxiliary in removing fib absorbent strips 32 from the teeth 38 of the pickup roller 36. The gas can be supplied by any conventional arrangement, such as, for example, an air blower (not shown). It is contemplated that additives and / or other materials can be added to or carried by the gas stream, to treat the absorbent fibers. Typically, the individual absorbent fibers 32 are carried through the nozzle 44 around the speed, at which the absorbent fibers 32 leave the teeth 38 of the pick roller 36. In other words, the absorbent fibers 32, when they leave the teeth 38 of the roller collector 3 6 and enter the nozzle 44, in general, they maintain their speed both in magnitude and in direction from the point, where they abandon the teeth 3 8 of the collector roller 36. Such an arrangement, which is discussed in more detail in US Patent No. 4,100,324, to Anderson, et al.
    If desired, the speed of the secondary gas stream 34 can be adjusted to achieve coform structures of different properties. For example, when the speed of the secondary gas stream is adjusted so that it is greater than the speed of each stream 2 6 and 28 of the thermoplastic polymer fibers 20 and 21, when in contact with the impingement zone 30, the absorbent fibers 32 will be incorporated into the coform nonwoven web in a gradient structure. In other words, the absorbent fibers 32 have a higher concentration between the outer surfaces of the coform nonwoven web than on the outer surfaces. On the other hand, when the speed of the secondary gas stream 34 is less than the speed of each stream 26 and 28 of the thermoplastic polymer fibers 20 and 21, upon contact with the impingement zone 30, the absorbent fibers 32 will be incorporated to the non-woven coform weave in a substantially homogeneous manner. In other words, the concentration of the absorbent fibers will be substantially the same over the entire coform nonwoven web. This is because the low speed absorbent fiber stream is drawn into a high speed thermoplastic polymer fiber stream, to intensify the turbulent mixing, which results in a consistent distribution of the absorbent fibers.
    To convert the composite stream 56, made of thermoplastic polymer fibers 20, 21 and absorbent fibers 32, into a non-woven structure of coform 54, a collecting device is positioned in the path of the composite stream 56. The collecting device can be a forming surface 58 (for example, belt, drum, yarn, fabric, etc.), driven by rollers 60 and rotating as indicated by arrow 62 in Figure 1. The molten streams of thermoplastic polymer fibers and absorbent fibers are collected as a matrix of coherent fibers on the surface of the forming surface 58, to form the nonwoven fabric form54. If desired, a vacuum box (not shown) can be employed to assist in drawing the meltblown fibers close to the molten state over the forming surface 58. The resulting textured coform structure 54 is coherent and can be removed from the forming surface 58 as a self-supporting non-woven material.
    It should be understood that the present invention is by no means limited to the modalities described above. In an alternative embodiment, for example, the first and second meltblowing mold heads can be used, which extend substantially across a forming surface, in a direction that is substantially transversal to the direction of movement of the forming surface. The mold heads can also be arranged in a substantially vertical, i.e., perpendicular, arrangement to the forming surface, so that the meltblown fibers thus produced are blown directly down over the forming surface. Such a configuration is well known in the art and is described in more detail, for example, in U.S. Patent Application Publication No. 2007/0049153, Dunbar, et al. In addition, although the modalities described above employ multiple meltblowing mold heads to produce fibers of different sizes, a single mold head can also be employed. An example of such a process is described, for example, in U.S. Patent Application Publication No. 2005/013 67 81, to Lassig, et al. , which is incorporated herein, in its entirety, by reference to it, for all purposes.
    As indicated above, in certain cases, it is desired to form a coform web that is textured. Referring again to Figure 1, for example, a modality employs a forming surface 58, which is foraminous in nature, so that the fibers can be extracted through the openings of the surface and form tufts similar to dimensional cloth, which protrude from the material surfaces, which correspond to the openings in the forming surface 58. The foraminous surface can be provided by any material that provides sufficient openings for penetration by some of the fibers, such as a highly permeable forming thread. Interwoven yarn geometry and processing conditions can be used to change the texture or tufts of the material. The particular choice will depend on the peak size, shape, depth, "density" of surface tuft (i.e., the number of peaks or tufts per unit area), etc., desired. In one embodiment, for example, the yarn may have an open area of about 35% to about 65%, in additional modalities, from about 40% to about 60%, and, in yet additional modalities, from about from 45% to about 55%. An exemplary high open area forming surface is FORMTECH ™ 6 forming wire manufactured by Albany International Co., of Albany, New York. Such a thread has a "mesh count" of about six strings per six strings per square inch (about 2.4 by 2.4 strings per square centimeter), that is, resulting in about 36 foramens or "holes" per square inch (about 5.6 per square centimeter) and therefore capable of forming about 36 tufts or peaks in the material per square inch (about 5.6 peaks per square centimeter). The FORMTECH ™ 6 yarn also has a warp diameter of about 1 millimeter of polyester, a shute diameter of about 1.07 millimeters of polyester, a nominal air permeability of approximately 41, 8 m3 / min (1,475 ft3 / min), a nominal caliber of about 0.2 centimeters (0.08 inches) and an open area of approximately 51%. Another example forming surface, available from Albany International Co., is the FORMTECH ™ 10 forming yarn, which has a mesh count of about 10 strings per 10 strings per square inch (about 4 by 4 strings per square centimeter) ), that is, resulting in about 100 foramina or "holes" per square inch (about 15.5 per square centimeter), and therefore capable of forming about 100 tufts or peaks per square inch (about 15, 5 peaks per square centimeter) in the material. Yet another suitable training thread is FORMTECH ™ 8, which has an open area of 47% and is also available from Albany International. Obviously, other forming wires and surfaces (eg drums, plates, mats, etc.) can be employed. For example, mats can be used with depressions etched on the surface, such that coform fibers fill the depressions, to result in tufts that correspond to the depressions. The depressions (tufts) can take various shapes, including, but not limited to, circles, squares, rectangles, spirals, ribs, lines, clouds, and so on. In addition, surface variations may include, but are not limited to, alternating twisting patterns, alternating string dimensions, release linings (eg, silicones, fluoro-chemicals, etc.), static dissipation treatments, and the like . Still other suitable foraminous surfaces, which can be employed, are described in U.S. Patent Application Publication No. 2007/0049153, by Dunbar, et al.
    Regardless of the particular texturing method employed, the tufts formed by the meltblown fibers including propylene / a-olefin copolymer are better able to retain the desired shape and surface contour. Namely, because meltblown fibers crystallize at a relatively low rate, they are soft when deposited over the forming surface, which allows them to drape over, and conform to, the contours of the surface. After the fibers crystallize, they are then able to maintain their shape and form tufts. The size and shape of the resulting tufts depend on the type of forming surface used, the types of fibers deposited on it, the vacuum volume of wire air used below to extract the fibers over and on the forming surface and other factors related. For example, tufts can project from the surface of the material in the range of about 0.25mm to at least about 9mm, and, in additional modalities, from about 0.5mm to about 3mm . Generally speaking, the tufts are filled with fibers and thus have desirable resilience, useful for wiping and scrubbing.
    Referring to Figures 3 and 4, a textured coform web 100 has a first outer surface 122 and a second outer surface 128. At least one of the outer surfaces has a three-dimensional surface texture. In Figure 3, for example, the first outer surface 122 has a three-dimensional surface texture, which includes tufts, peaks or displacement regions 124, which extend upwards from a continuous region 125, which extends continuously in the directions cross-section and the coform 100 machine. In a particular embodiment, the density of the continuous region can be substantially equal to the density of the displacement regions. An indication of the magnitude of the three-dimensionality on the textured outer surface (s) of the coform web is the peak-to-valley ratio, which is calculated as the ratio of the overall thickness "T" divided by the depth of is worth "D". When textured, the coform web typically has a peak-to-valley ratio of about 5 or less, in additional modalities, from about 0.1 to about 4, and in yet additional modalities, from about 0.5 to about 3. The continuous region 125 can have a thickness (TD) ranging from about 0.01mm to about 10.0mm, desirably, ranging from about 0.02 to about 6.0mm, and , most desirably, ranging from about 0.03 to about 3.0 millimeters. In a particular embodiment, the weight and / or thickness (T-D) of the continuous region may be less than the weight and / or thickness (D) of the displacement regions.
    In particular modalities that are more densely textured, the textured coform web will have about 2 to about 70 tufts per square centimeter, and in other modalities, about 5 and 50 tufts per square centimeter. In certain modalities, which are less densely textured, the textured coform web will feature from about 100 to about 20,000 tufts per square meter, and in additional modalities, it will feature from about 200 to about 10,000 tufts per square meter. The textured coform web can also exhibit a three-dimensional texture on the second web surface. This will be especially the case for lighter weight materials, such as those weighing less than about 70 grams per square meter, due to "mirroring", with the second surface of the material showing displacement of peaks or between peaks on the first external surface of the material. In this case, the valley depth D is measured for both outer surfaces, as above, and are then added together to determine an overall material valley depth.
    Referring again to Figures 3 and 4, in particular embodiments, the continuous region 125 comprises a plurality of uninterrupted regions 127, which continuously extend in at least one "Dx" direction without intercepting a displacement region 124. Another indication of the magnitude of the three-dimensionality of the texture is the ratio of the width "Wj." of the uninterrupted region 127 (measured as the largest width of the uninterrupted region in the direction perpendicular to the direction Dlz in which the uninterrupted region 127 extends without intercepting a displacement region) in relation to the width "W2" of the displacement regions 124 (measured as the greater dimension of the displacement regions in the direction perpendicular to the Dx direction). In particular embodiments, Wx can be in a range of about 0.0254 cm (0.01 inches) to about 1.905 cm (0.75 inches), desirably, in a range of about 1.127 cm (0.05 inches) ) at about 1.27 cm (0.5 inches), and, more desirably, in a range of about 0.203 cm (0.08 inches) to about 0.762 cm (0.3 inches). In particular modalities, the Wx / W2 ratio can be in a range of about 0.3 to 3.0, desirably in a range of about 0.5 to 2.0, and, more desirably, in a range of about 0.7 to about 1.5. In particular modes, there may additionally be a plurality of second uninterrupted regions, which continuously extend in a second direction "D2" without intercepting a region of displacement region. In a particular embodiment, D2 can be perpendicular to Dlz but other angles can also be used. The dimensions of the second uninterrupted regions, in relation to the dimensions of the displacement regions, can be as described above for the first uninterrupted regions.
    V. Articles
    The coform nonwoven fabric can be used on a wide variety of articles. For example, the web can be incorporated into an "absorbent article", which is capable of absorbing water or other fluids. Examples of some absorbent items include, but are not limited to, absorbent personal care items, such as diapers, training pants, absorbent underwear, incontinence items, feminine hygiene products (eg sanitary napkins), swimwear , baby wipes, handkerchiefs for gloves, and so on; medical absorbent articles, such as garments, fenestration materials, seat cushions, bed cushions, bandages, absorbent curtains and medical wipes; food service cloths; clothing items; purses, and so on. Suitable materials and processes for forming such articles are well known to those skilled in the art.
    In another particular embodiment, the coform weave is used to form a scarf. The scarf may be formed entirely from the coform weave or it may contain other materials, such as films, non-woven weaves (for example, spunbond weaves, meltblown weaves, carded weave materials, other coform weaves, weaves. dispersed by air, etc.), paper products, and so on. In one embodiment, for example, two layers of a textured coform web can be laminated together to form the scarf, as described in US Patent Application Publication No. 2007/0065643, by Kopacz, which is incorporated herein, in its entirety, by reference to it, for all purposes. In such embodiments, one or both layers can be formed from the coform web. In another embodiment, it may be desired to provide a certain amount of separation between a user's hands and a moisturizing or saturating liquid that has been applied to the tissue, or, when the tissue is supplied as a dry cleaner, to provide separation between the user's hands and a leak of liquid being cleaned by the user. In such cases, an additional film or nonwoven web may be laminated to a coform web surface to provide physical separation and / or to provide liquid barrier properties. Other fibrous wefts can also be included to increase the absorbent capacity, either for the purposes of absorbing more liquid leaks or for the purpose of providing a tissue with greater liquid capacity. When used, such additional materials can be fixed to the coform web using any method known to a person skilled in the art, such as laminating or thermal or adhesive bonding; with individual materials placed in face-to-face contact. Regardless of the materials or processes used to form the handkerchief, the weight of the handkerchief is typically about 20 to about 200 grams per square meter (g / m2), and in other embodiments, between about 35, and about 100 g / m2. Lighter weight products may be particularly well suited for use as wipes for light cleaning, while heavier weight products may be better adapted for use as industrial wipes.
    The scarf can take on a variety of shapes, including, but not limited to, generally circular, oval, square, rectangular or irregularly shaped. Each individual tissue can be arranged in a folded and stacked configuration on top of each other, to provide a stack of wet wipes. Such folded configurations are well known to those skilled in the art and include c-folded, z-folded, four-folded configurations, and so on. For example, the scarf can have an unfolded length of about 2.0 to about 80.0 centimeters, and, in additional embodiments, from about 10.0 to about 25.0 centimeters. The handkerchiefs can also have an unfolded width of about 2.0 to about 80.0 centimeters, and, in additional modalities, from about 10.0 to about 25.0 centimeters. The handkerchiefs can also have an unfolded bristle width of 2.0 to about 80.0 centimeters, and in additional modalities, from about 10.0 to about 25.0 centimeters. The stack of folded tissues can be placed inside a container, such as a plastic tube, to provide a package of tissues for eventual sale to the consumer. Alternatively, the tissues may include a strip of continuous material, which has perforations between each tissue and which can be arranged in a pile or wrapped in a roll for distribution. Various suitable dispensers, containers and systems for handkerchief delivery are described in U.S. Patent Nos. 5,785,179, by Buczwinski, et al .; 5,964,351, by Zander; 6,030,331, by Zander; 6,158,614, by Haynes, et al. ; 6,269,969, by Huang, et al .; 6,269,970, by Huang, et al .; and 6,273,359, by Newman, et al .; which are hereby incorporated by reference, in their entirety, by reference to them, for all purposes.
    In certain embodiments, the handkerchief is a "moistened" or "pre-humidified" handkerchief, due to the fact that it contains a liquid solution for cleaning, disinfecting, sanitizing, etc. Particular liquid solutions are not critical and are described in more detail in U.S. Patent Nos. 6,440,437, by Krzysik, et al. ; 6,028,018, by Amundson, et al. ; 5,888,524, to Cole; 5,667,635, to Win, et al. ; and 5,540,332, by Kopacz, et al. , which are incorporated herein, in their entirety, by reference to them, for all purposes. The amount of liquid solution used may depend on the type of tissue material used, the type of container used to store the tissues, the nature of the cleaning formulation, and the desired end use of the tissues. In general, each handkerchief contains from about 150 to about 600% by weight, and desirably from about 300 to about 500% by weight of a liquid solution based on the dry weight of the handkerchief.
    A measure of the flexibility of a nonwoven structure or tissue is the cup crushing energy / thickness ratio. Cup crush energy, measured as defined below, is a measure of the amount of energy required to crush a material that has been shaped into a cup shape for the purpose below. A low cup crush energy value is indicative of a highly flexible material. Thicker materials are desirable because thicker means less density, better absorbance and better cushioning and softness. Therefore, non-woven structures are desirable with lower glass crushing thickness / thickness ratios. Desirably, coform wefts have a cup crushing energy / thickness ratio of less than 600 grams. In various embodiments, the wipes and coform wefts can have a cup crushing energy / thickness ratio in a range selected from the ranges consisting of about 200 grams to about 600 grams, from about 250 grams to about 600 grams, from about 276 grams to about 600 grams, from about 200 grams to about 580 grams, from about 250 grams to about 580 grams, from about 276 grams to about 580 grams, of about 200 grams to about 500 grams, about 250 grams to about 500 grams, about 276 grams to about 500 grams, about 200 grams to about 400 grams, about 250 grams about 400 grams, about 276 grams to about 400 grams, about 200 grams to about 3 80 grams, about 250 grams to about 3 80 grams and about 276 grams to about 380 grams.
    The present invention can be better understood with reference to the following examples.
    Test Methods
    Cup Crush:
    Figures 5 and 6 show a cup crush testing system 1100, which includes a cup forming assembly 1102 and a force testing unit 1103. The force testing unit 1103 includes a force sensor 1104, which is a rigid rod 1105 is cantilevered. A hemispherical foot 1108 is positioned at the free end of the rod 1105. The force sensor 1104 includes electronic and mechanical devices for measuring the force experienced on the foot 1108 and transferred through the rigid rod 1105. The set 1102 includes conformable cups 1110 and 1112 in a top hat shape, that match, that grab a sheet 1202, in at least four points. The four corners 1106, of the sheet 1202, extend outside the assembly 1102. The cup 1112 is removed after forming the sheet 12 02 in a cup. A gripping ring 1114 holds shaped sheet 1202 in cup 1110 during testing.
    A measure of the softness of a 1202 non-woven fabric sheet is determined according to the "cup crush" test by the 1100 system. The cup crush test assesses the tissue stiffness by measuring the peak load (also called the peak load). "cup crush load" or just "cup crush") required for a 1108 foot, hemispherically shaped 4.5 cm in diameter, crush a 17.8 cm by 17.8 cm piece of fabric 12 02, shaped in a tall cup format of approximately 6.5 cm in diameter by 6.5 cm in height, while the fabric now shaped into a cup is surrounded by a cylindrical cup 1110 of approximately 6.5 cm in diameter, to maintain uniform deformation of the 1102 cup-shaped fabric. There may be gaps between the ring 1114 and the forming cup 1110, but at least four corners 1106 must be firmly tightened between them. The foot 1108 and the cylindrical cup 1110 are aligned to avoid contact between the walls of the cup and the foot, which could affect the readings. The load is measured in grams, and recorded a minimum of twenty times per second, while the foot is descending at a rate of about 406 mm per minute. The cup smash test provides a value for the total energy needed to smash a sample (the "cup smash energy"), which is the energy over a 4.5 cm range starting 0.5 cm below the top of the fabric cup, that is, the area under the curve formed by the load in grams, on one axis, and the distance that the foot travels in millimeters, on the other. In general, cup crushing energy is reported in gm-mm (or inch-pound). The peak cup crush load is determined over the same transit distance from the foot as the energy, and is usually reported in grams or pounds. A lower cup crush value (peak load or energy) indicates a softer material. A suitable device for measuring cup crush is a load cell model FTD-G-500 (500 gram range), available from Schaevitz Company, Pennsauken, NJ. Wet samples are tested with a 270% liquid supplement.
    Gauge / Thickness:
    The caliber of coform materials is a measure of thickness. The thickness is measured at 0.05 psi, with a standard bulk / tissue thickness tester, in millimeter units, using a 7.62 cm (3 inch) diameter plate (platen). This test is conducted on a finished wet wipe product and care must be taken to ensure that the plate does not fall on a fold or wrinkle that has resulted from packaging. Wetted samples are measured with a 270% liquid complement.
    EXAMPLES
    General Conditions for all Coform Samples: Several samples of coform wefts were formed from two heated streams of meltblown fibers and a single stream of fibrized pulp fibers, as described above and shown in Figure 1. The fibers of pulp was fully treated southern softwood pulp, obtained from Weyerhaeuser Co., Federal Way, Washington, under the designation "CF-405". The polymer from each meltblown stream was supplied to the respective meltblown molds at a rate of 0.9 kg (2.0 pounds) of polymer per inch of mold tip per hour, at 243.32C (470 ° F) in temperature melting mass. The distance from the impingement zone to the forming wire (that is, the forming height) was approximately 20.32 cm (8 inches) and the distance between the tips of the meltblown molds was approximately 12.7 cm (5 inches). The meltblown mold, positioned upstream from the pulp fiber stream, was oriented at an angle of 45 ° to the pulp stream, while the other meltblown mold (positioned downstream from the pulp stream) it was oriented around 45 °, in relation to the pulp stream. The samples had a grammage of 70 grams per square meter (g / m2) and a content of meltblown fibers of 30% by weight. The forming wire was FORMTECH ™ 8 (Albany International Co.). To achieve different types of tufts, rubber mats were laid out on the upper surface of the forming wire. A vacuum box was positioned below the forming wire to assist in weft deposition and was adjusted to 76.2 cm (30 inches) of water.
    Sample 1: The meltblown fibers were formed from Basell 650X Metocene MF650X, which is a propylene homopolymer with a density of 0.91 g / cm3 and a melt flow rate of 1,200 g / 10 minutes (23.0 ° C, 2.16 Kg), which is available from Basell Polyolefins. The standardized mat had the pattern shown in Figure 6 with round 0.635 cm (0.25 inch) holes, with a depth of 0.127 cm ( 0.05 inches), the holes then correspond to the displacement regions of 0.635 cm (0.25 inches) in diameter, extending about 0.127 cm (0.05 inches) from a surface of the coform material. In a first direction, the holes were arranged in lines with the centers of the displacement regions being spaced every 0.953 cm (0.37 5 inches). The lines were staggered as shown in Figure 6 with the displacement regions on one line being directly aligned between the nearest displacement regions on the adjacent lines. The lines were spaced every 0.953 cm (0.375 inches), resulting in an uninterrupted region between the lines having a width of 0.318 cm (0.125 inches).
    The test samples were moistened in the laboratory with the following solution:

    The solution was sprayed by hand to a complement level of 270%. A dry base sheet was weighed on a scale and then multiplied by 2.7 to determine the amount of solution to be added to the dry base sheet. After adding the solution, the wet wipes were covered and allowed to equilibrate at least 24 hours before testing. The cup crushing test and the thickness testing were performed for the samples. The ratio of cup crushing energy to thickness was calculated. The results are listed in Table 1.
    Samples 2: These samples were the same as Sample 1, except that the holes in the standardized mat had a depth of 0.254 cm (0.1 inches), resulting in the coform showing displacement regions extending about 0.2 54 cm (0 Inch) from the surface of the coform material.
    Sample 3: These samples were the same as Sample 1, except that the meltblown fibers were formed from a combination of 85% by weight of propylene homopolymer (Achieve 6936G1) and 15% by weight of propylene / ethylene copolymer (Vistamaxx 2330, density of 0.868 g / cm3, melt flow rate of 290 g / 10 minutes (230 ° C, 2.16 kg)), both of which are available from ExxonMobil Corp.
    Samples 4: These samples were the same as Sample 3, except that the holes in the standardized mat had a depth of 0.254 cm (0.1 inches), resulting in the coform showing displacement regions extending about 0.254 cm (0.1 inches) ) from the surface of the coform material.
    Commercial Products: Several commercial baby wipes were purchased and tested for comparison with the sample materials.
    As shown in Table 1, Samples 1-4, each, demonstrated a cup crushing energy ratio in relation to the lower thickness than commercial products. Table 1: Test Results

    Although the invention has been described in detail with respect to its specific modalities, it will be appreciated that those skilled in the art, when they reach an understanding of the above, will be able to readily conceive changes, variations and equivalents to these modalities. Consequently, the scope of the present invention must be assessed as that of the appended claims and any equivalents thereto. In addition, it should be noted that any given track, shown here, is intended to include any and all minor tracks included. For example, a range of 45-90 would also include 50-90; 45-80; 46-89 and the like.
    权利要求:
    Claims (7)
    [0001]
    1. Scarf, characterized by the fact that it comprises a non-woven coform weave, in which the non-woven coform weave comprises a matrix of meltblown fibers, each smaller than 10 micrometers in diameter, in which the meltblown fibers comprise a propylene / α-olefin copolymer and wherein α-olefin includes ethylene, said meltblown fibers entangled with an absorbent fibrous material wherein said absorbent fibrous materials contain pulp fibers, the coform matrix of meltblown fibers and absorbent fibrous material comprising a continuous region and a plurality of displacement regions in which the density of the continuous region is substantially equal to the density of the displacement regions, the region continues to have a transverse direction, a machine direction and a thickness of about 0.01 millimeters about 10.0 mm, the region still comprises a first planar side extending in the transverse direction and the machine direction and a second the planar side opposite the first side, the first and second sides being separated by the thickness of the continuous region, the displacement regions extending outward from the first side, in which the displacement regions are positioned to define a plurality of first uninterrupted portions of the continuous regions, in which the first uninterrupted portions of the continuous region do not underlie any displacement regions, additionally in which the first uninterrupted portions of the continuous region extend in a first direction in the plane of the first side, the first direction not intercepting any displacement regions , and in which additionally the width of the uninterrupted portions divided by the width of the displacement regions is between about 0.3 and about 2.0, the measured widths perpendicular to the first direction in the plane of the first side, and even more in that the continuous region extends completely over the displacement regions; wherein the meltblown fibers constitute from 1% by weight to about 40% by weight of the weft and the absorbent material constitutes from about 60% by weight to about 99-s by weight of the weft, and in which the energy ratio of cup crush / coform weft thickness is less than about 600 grams.
    [0002]
    2. Scarf according to claim 1, characterized by the fact that the base weight of the continuous region is less than the base weight of the displacement regions.
    [0003]
    3. Scarf according to claim 1, characterized by the fact that the displacement regions extend from the first side by about 0.25 mm to about 5.0 mm.
    [0004]
    4. Handkerchief according to claim 1, characterized by the fact that the first uninterrupted portions of the continuous region extend in the first direction passing at least two, three or four different displacement regions.
    [0005]
    5. Handkerchief according to claim 1, characterized by the fact that the displacement regions are additionally positioned to define a plurality of second uninterrupted portions of the continuous region, the second uninterrupted portions of the region continue to extend infinitely in a second direction without intercepting any displacement regions.
    [0006]
    6. Scarf according to claim 5, characterized by the fact that the first direction is orthogonal to the second direction.
    [0007]
    7. Handkerchief according to claim 1, characterized by the fact that it contains about 150 to about 600% by weight of a liquid solution based on the dry weight of the handkerchief.
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    同族专利:
    公开号 | 公开日
    BR112012014275A2|2017-04-04|
    IL219849D0|2012-07-31|
    MX336257B|2016-01-13|
    IL219849A|2015-09-24|
    US20110151196A1|2011-06-23|
    WO2011077278A3|2011-11-24|
    CO6660427A2|2013-04-30|
    AU2010334492B2|2015-01-22|
    AU2010334492A1|2012-06-14|
    KR101776973B1|2017-09-08|
    MX2012007156A|2012-07-03|
    EP2516711A2|2012-10-31|
    KR20120107092A|2012-09-28|
    EP2516711B1|2016-03-23|
    EP2516711A4|2014-01-08|
    WO2011077278A2|2011-06-30|
    US9260808B2|2016-02-16|
    SG181442A1|2012-07-30|
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    法律状态:
    2019-02-12| B06T| Formal requirements before examination|
    2019-12-10| B07A| Technical examination (opinion): publication of technical examination (opinion)|
    2020-05-26| B09A| Decision: intention to grant|
    2020-10-13| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 18/11/2010, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US12/643,123|US9260808B2|2009-12-21|2009-12-21|Flexible coform nonwoven web|
    US12/643,123|2009-12-21|
    PCT/IB2010/055251|WO2011077278A2|2009-12-21|2010-11-18|Flexible coform nonwoven web|
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