Absorbent composites
AssigneeMagnera Corporation
InventorsLei Wang, Nyle Bishop, Gregory Wagner Farell, Pierre Grondin
Life of this patent
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Abstract
Absorbent composites are provided that include a nonwoven top layer having hydrophilic fibers and an absorbent core layer directly or indirectly attached to the nonwoven top layer, wherein the absorbent core layer comprises a through-air-bonded nonwoven. The absorbent composites may include a combination of (i) a composite-run-off value of less than 50% as determined by ISO 9073-11, (ii) a composite-absorption capacity of at least 600% as determined by ISO 9073, and (iii) a composite-rate of absorption of less than 10 seconds for a 5 ml liquid sample as determined by D824-94. The absorbent composites may include an optional film layer attached to the absorbent core layer.
Claims25
An absorbent composite, comprising:
- (a) a nonwoven top layer comprising hydrophilic fibers;
- (b) an absorbent core layer consisting of a plurality of crimped multi-component continuous spunbond filaments directly bonded to the nonwoven top layer via a plurality of ultrasonic bonds or thermal bonds, wherein the absorbent core layer is a high-loft through-air-bonded nonwoven having a basis weight from 10 gsm to 200 gsm;
- and
- (c) a water impermeable film, wherein the absorbent core layer is directly sandwiched between the nonwoven top layer and the water impermeable film;
- wherein the water impermeable film is extrusion coated directly onto the through-air-bonded nonwoven or adhesively bonded directly onto the through-air-bonded nonwoven;
- wherein the absorbent composite includes (i) a composite-run-off value of less than 50% as determined by ISO 9073-11;
- (ii) a composite-absorption capacity of at least 600% as determined by ISO 9073;
- and (iii) a composite-rate of absorption of less than 10 seconds for a 5 ml liquid sample as determined by D824-94;
- where the high-loft through air bonded nonwoven is a material that is compressible by 20% or more when an applied pressure changes from 0.1 kPa to 0.5k Pa according to BS EN ISO 9703-2 (1995).
An absorbent composite, comprising:
- (a) a nonwoven top layer comprising hydrophilic fibers;
- (b) a high-loft through-air-bonded nonwoven comprising a plurality of absorbent core fibers, the high-loft through-air-bonded nonwoven is directly bonded to the nonwoven top layer via a plurality of ultrasonic bonds or thermal bonds, wherein the high-loft through-air-bonded nonwoven consists of crimped continuous fibers, crimped staple fibers, or a combination thereof, and the high lott through-air-bonded nonwoven has a basis weight from 10 gsm to 200 gsm;
- (c) a water impermeable film, wherein the through-air-bonded nonwoven is directly sandwiched between the nonwoven top layer and the water impermeable film;
- wherein the water impermeable film is extrusion coated directly onto the high-loft through-air-bonded nonwoven;
- wherein the high-loft through air bonded nonwoven is a material that is compressible by 20% or more when an applied pressure changes from 0.1 kPa to 0.5 kPa according to BS EN ISO 9703-2 (1995),
- wherein the absorbent composite includes (i) a composite-run-off value of less than 50% as determined by ISO 9073-11;
- (ii) a composite-absorption capacity of at least 600% as determined by ISO 9073;
- and (iii) a composite-rate of absorption of less than 10 seconds for a 5 ml liquid sample as determined by D824-94.
Dependencies are inferred from the claim text.