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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

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