Uniform distribution of absorbents in a thermoplastic web
OwnerDarryl Franklin Clark, Yuelong Liu +1inventors
InventorsDarryl Franklin Clark, Yuelong Liu, David Michael Matela
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Abstract
A web of thermoplastic multicomponent substantially continuous fibers is thoroughly and evenly mixed with absorbent materials prior to deposition on the forming wire to result in superior adherence of the absorbents to the thermoplastic components and hence result in superior performance of the web. The multicomponent fibers have a low melting point sheath which can be fully activated to melt and wet the absorbent particles. The web can then be densified and cooled, securing the absorbents to the web with hardened flow joints and enabling the web to carry high loadings of absorbent while maintaining good web integrity.
Claims23
A method of making an absorbent nonwoven web, comprising:
- a) producing a mass of thermoplastic substantially continuous sheath-core or side-by-side multicomponent filaments by entraining molten thermoplastic polymers into a first air stream and drawing and containing the filaments in a fiber distribution unit;
- b) introducing an absorbent material via a second air stream into the fiber distribution unit at a point above a divergence zone of the mass of filaments in the fiber distribution unit;
- c) allowing the mass of filaments and absorbent material to mix in the fiber distribution unit and collecting the mixture onto a forming wire in a uniform distribution of filaments and absorbent material;
- d) running the collected mass of filaments and absorbent material through a heater at a time and temperature sufficient to soften the sheath of the filaments;
- and
- e) densifying the softened mass of filaments and the absorbent material.
An absorbent article comprising:
- a) a cover sheet serving as the exterior layer of the article;
- b) a top sheet serving as the interior layer of the article;
- c) a primary liquid retention layer having:
- i) a mass of thermoplastic substantially continuous at least partially sheath-core multicomponent filaments having a plurality of absorbent particles in a uniform distribution of filaments,
- ii) with a majority of the absorbent particles joined to sheaths of the multicomponent filaments by hardened flow joints;
- and
- iii) the primary liquid retention layer further being a densified web.
An absorbent nonwoven web comprising:
- a) a mass of thermoplastic, substantially continuous, at least partially sheath-core, multicomponent filaments having a plurality of absorbent particles in a uniform distribution throughout the mass of filaments;
- b) with a majority of the absorbent particles joined to sheaths of the multicomponent filaments by hardened flow joints;
- and
- c) the mass of thermoplastic, substantially continuous, at least partially sheath-core, multicomponent filaments with the plurality of absorbent particles in a uniform distribution throughout the mass of filaments further being densified.
Dependencies are inferred from the claim text.