2002 - Volume 1 - JEFF. Journal of Engineered Fibers and Fabrics
2002 - Volume 1 - JEFF. Journal of Engineered Fibers and Fabrics
2002 - Volume 1 - JEFF. Journal of Engineered Fibers and Fabrics
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lend. After extrusion, the film is heated<br />
<strong>and</strong> subjected to biaxial stretching,<br />
causing voids to form in the areas surrounding<br />
the filler particles. The voided<br />
film is characterized by thin polymer<br />
membranes <strong>and</strong> a fine pore network<br />
which permit the molecular diffusion <strong>of</strong><br />
water vapor through the film, but which<br />
block the passage <strong>of</strong> liquids. In essence,<br />
a tortuous path is created from one film<br />
surface to the other, which permits<br />
transfer <strong>of</strong> vapors but not liquids.<br />
Such breathable films are normally<br />
made from a thermoplastic polyolefin.<br />
The calcium carbonate filler is relatively<br />
easy to disperse in a polyolefin<br />
matrix, <strong>and</strong> the resulting film can have<br />
good breathability. However, calcium<br />
carbonate <strong>and</strong> other inorganic fillers<br />
have a disadvantage in that the filler<br />
tends to accumulate around the lip <strong>of</strong><br />
the extrusion die during manufacture <strong>of</strong><br />
the film. To alleviate this, a center layer<br />
filled with calcium carbonate can been<br />
coextruded with much thinner surface<br />
layers which contain little or no filler.<br />
This approach reduces filler build-up at<br />
the die, but <strong>of</strong>ten results in a less breathable<br />
product because the unfilled skin<br />
layers are less microporous than the<br />
filled core layer. Inorganic fillers are<br />
also somewhat expensive, due in part to<br />
their high density.<br />
Attempts have been made to make<br />
suitable breathable films using organic<br />
fillers, as such fillers can have less density<br />
<strong>and</strong> be less expensive. Organic<br />
fillers may also reduce the problem <strong>of</strong><br />
die build-up. However, organic fillers<br />
have a tendency to either agglomerate to<br />
form large particles, or to disperse too<br />
finely or actually dissolve in the polymeric<br />
medium.<br />
This patent discloses a process that<br />
uses an organic filler system which<br />
overcomes these problems. The organic<br />
filler has a higher melting point than the<br />
polymer matrix, <strong>and</strong> is preferably<br />
incompatible with the thermoplastic<br />
polymer, thereby preventing dissolution<br />
or excessive dispersion in the polymer<br />
matrix. A compatibizing agent is used<br />
with the organic filler, which agent has<br />
a tendency to prevent agglomeration <strong>of</strong><br />
the organic filler in the polymer matrix,<br />
<strong>and</strong> a tendency to break up existing<br />
agglomerates <strong>of</strong> the organic filler.<br />
To achieve these results, the inventors<br />
reveal that polystyrene particles are a<br />
suitable organic filler when used with a<br />
styrene-butadiene copolymer compatibilizing<br />
agent. The styrene-butadiene<br />
copolymer may be included in the polystyrene<br />
filler, <strong>and</strong> may be either chemically<br />
reacted to or blended with the<br />
polystyrene in the beads. The compatibilizing<br />
system should be present in an<br />
amount sufficient that the organic filler<br />
particles are at thermodynamic equilibrium<br />
in the polymer matrix in a dispersed<br />
particle phase having a mean<br />
particle diameter <strong>of</strong> about 0.1-2.5<br />
microns.<br />
U.S. 6,348,258 (February 19, <strong>2002</strong>);<br />
filed March 12, 1999. Assignee:<br />
Kimberly-Clark Worldwide, Inc.<br />
(Neenah, WI). Inventors: Vasily<br />
Aramovich Topolkaraev; Kevin Matthew<br />
Harrington; Glynis Allicia Walton;<br />
S<strong>and</strong>y Chi-Ching Ying; Kevin George<br />
Hetzler.<br />
Superabsorbent Polymer-impregnated<br />
Wetlaid Nonwoven with Smooth<br />
Surface<br />
The use <strong>of</strong> superabsorbent polymer<br />
(SAP) in disposable diapers <strong>and</strong> other<br />
sanitary protection products has been a<br />
significant innovation. It has resulted in<br />
design <strong>and</strong> product capabilities that<br />
would have been impossible otherwise.<br />
The typical way to use the SAP is to<br />
insert the solid powder into the<br />
absorbent woodpulp core <strong>of</strong> the product,<br />
while removing a substantial<br />
amount <strong>of</strong> the pulp absorbent. This<br />
<strong>of</strong>ten results in a core with 50% or higher<br />
loadings <strong>of</strong> particles <strong>of</strong> SAP.<br />
The resulting core thus formed has a<br />
rough texture, which can be felt in a disposable<br />
article having a topsheet. The<br />
rough texture is telegraphed through the<br />
article <strong>and</strong> may provide undesirable<br />
feeling for the user. Also, the particulate<br />
SAP material tends to shift <strong>and</strong> sift out<br />
<strong>of</strong> the selected position within the<br />
absorbent core. These problems can be<br />
solved to a degree by the use <strong>of</strong> SAP<br />
PATENT REVIEW<br />
fiber; however, such fiber is very expensive,<br />
limiting use <strong>of</strong> this form <strong>of</strong> SAP.<br />
This patent provides an economic<br />
way <strong>of</strong> obviating these problems, <strong>of</strong>fering<br />
an economic route to an SAPimpregnated<br />
structure that exhibits<br />
unexpected smooth texture <strong>and</strong> surprisingly<br />
good absorbency. This patent discloses<br />
a non-woven, wetlaid fibrous<br />
structure which is impregnated with<br />
SAP; it has a smooth surface texture <strong>and</strong><br />
is free <strong>of</strong> binder polymer.<br />
Typically, the structure comprises<br />
about 50 weight % <strong>of</strong> an ion-sensitive<br />
SAP having a particle size <strong>of</strong> less than<br />
250 microns, <strong>and</strong> about 40 weight % <strong>of</strong><br />
a fiber furnish <strong>and</strong> about 10 weight % <strong>of</strong><br />
an inorganic salt, preferably sodium sulfate.<br />
The fiber portion <strong>of</strong> the structure<br />
comprises about 80-95 weight % <strong>of</strong><br />
woodpulp fiber <strong>and</strong> 5-20 weight % cellulose<br />
acetate fiber (1.8 dpf, 0.25-inch<br />
length). A portion <strong>of</strong> the fiber furnish<br />
can also be composed <strong>of</strong> short-cut<br />
bicomponent binder fiber (PE/PET) or<br />
<strong>of</strong> short-cut polyester fiber (1.5 dpf, 0.5inch<br />
length).<br />
The slurry (0.2-2.5 g. solids/liter) can<br />
be formed into a wet web on a<br />
Fourdrinier wire or an inclined wire<br />
machine. The white water contains<br />
about 4% sodium sulfate, <strong>and</strong> the wet<br />
web has a composition <strong>of</strong> about 5-10 %<br />
solids. The wet web is then washed in<br />
an in-line curtain wash zone to reduce<br />
the salt content <strong>of</strong> the final web to about<br />
10-20 %. The weight <strong>of</strong> the final, dried<br />
wetlaid web is about 150 gsm. It shows<br />
an Absorbency Under Load (AUL) <strong>of</strong><br />
greater than 23 g./g. <strong>and</strong> has a very<br />
smooth surface texture.<br />
U.S. 6,348,133 (February 19, <strong>2002</strong>);<br />
filed August 3, 2001. “Smooth textured<br />
wet-laid absorbent structure.” Assignee;<br />
BASF Corporation (Mount Olive, NJ).<br />
Inventor: G. Thomas Woodrum.<br />
Coverstock With Separate Liquid<br />
Pervious <strong>and</strong> Impervious Regions<br />
Efforts have been made to prepare a<br />
nonwoven fabric that can serve as a diaper<br />
topsheet <strong>and</strong> possess regions <strong>of</strong> liquid<br />
permeability <strong>and</strong> liquid imperme-<br />
INJ Spring <strong>2002</strong> 51