Patent Application
20130144238
The present invention relates to an acquisition distribution layer for absorbent hygiene products produced from continuous tow bands, and to apparatuses, systems, and methods related thereto.
Absorbent hygiene products (“AHP”), such as infant diapers, feminine hygiene pads, adult incontinence products, and the like, have traditionally utilized absorbent structures with various configurations to provide the requisite absorbency performance. Generally, to manage liquid waste, components of an AHP provide for first uptake of a liquid into the absorbent product (typically with a topsheet), then distribution of the liquid within the absorbent product (typically with an acquisition distribution layer), and finally retention of the liquid within the absorbent product (typically in an absorbent core comprising fluff cellulose fibers and superabsorbent polymers). Generally, the various AHP manufacturers use unique topsheets, acquisition distribution layers (“ADL”), and absorbent cores.
An ADL is generally a polyester nonwoven material produced from carding processes with additional filament-to-filament bonding steps to hold the nonwoven material together. Further, to produce ADL materials with complex structures, e.g., a layered structure, the carding processes may require additional steps and apparatuses that can significantly increase cost.
AHP manufacturers typically use third-party manufacturers, which increases cost, to produce the ADL materials due, at least in part to, the high equipment cost and large footprint of carding processes. Further, for a ADL material to integrate into AHP manufacturing lines, third-parties typically provide the ADL materials as large rolls. As a consequence of having to transport the ADL nonwoven materials in the large roll format, a nonwoven material is generally produced with a higher tensile strength so that the integrity and thickness of the nonwoven material is maintained during collection, transportation, and integration into an AHP manufacturing line.
A higher tensile strength is generally achieved during the filament-to-filament bonding steps by using acrylic latex emulsions, ethylene vinyl acetate copolymer latex emulsions, or bicomponent fibers followed by thermal processes to set the filament-to-filament bonding. These extra steps increase expense not only because of the additional steps, but also because acrylic latex emulsions or bicomponent fibers are expensive.
Further, the use of nonwoven materials having higher tensile strength may translate to an ADL with less flexibility, which in an AHP application is not a desirable quality.
Accordingly, systems and methods capable of producing nonwoven materials suitable for use as an ADL that allow for AHP manufacturers to integrate ADL production directly into AHP manufacturing lines would be of benefit to one skilled in the art. Further, systems and methods that provide additional capabilities, like the production of complex structures, without significantly increasing the footprint and/or cost of ADL production would be a further benefit to one skilled in the art.
The present invention relates to an acquisition distribution layer for absorbent hygiene products produced from continuous tow bands, and to apparatuses, systems, and methods related thereto.
In one embodiment, the present invention may provide for a system comprising: a tow band processing line; and a master air jet operably connected to the tow band processing line to receive a processed tow band from the tow band processing line so as to produce an acquisition distribution layer for an absorbent article.
In another embodiment, the present invention may provide for a system comprising: a plurality of tow band processing lines; a master air jet in communication with the tow band processing lines to receive a plurality of processed tow bands from the tow band processing lines to form an acquisition distribution layer; and an absorbent hygiene product manufacturing line in communication with the master air jet for receiving the acquisition distribution layer.
In yet another embodiment, the present invention may provide for a method comprising: producing an acquisition distribution layer from a plurality of processed tow bands; and forming an absorbent hygiene product that includes the produced acquisition distribution layer.
In another embodiment, the present invention may provide for a method comprising: processing a plurality of tow bands along at least one tow band processing line to form a plurality of processed tow bands; and combining the plurality of processed tow bands using a master air jet to form an acquisition distribution layer for an absorbent article.
In one embodiment, the present invention may provide for a method comprising: forming a plurality of processed tow bands along a plurality of tow band processing lines; combining in a master air jet the plurality of processed tow bands to form an acquisition distribution layer; adding the acquisition distribution layer to an absorbent hygiene product manufacturing line; and producing an absorbent hygiene product comprising the acquisition distribution layer.
In another embodiment, the present invention may provide for an acquisition distribution layer comprising a plurality of continuous filaments.
In yet another embodiment, the present invention may provide for an absorbent hygiene product comprising, in order: a topsheet; an acquisition distribution layer comprising a plurality of continuous filaments; an absorbent core; and a backsheet.
In another embodiment, the present invention may provide for an absorbent hygiene product comprising: a topsheet; a backsheet; an acquisition distribution layer disposed about an absorbent core; and wherein the acquisition distribution layer is disposed between the topsheet and the backsheet.
The features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the preferred embodiments that follows.
The following figures are included to illustrate certain aspects of the present invention and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, as will occur to those skilled in the art and having the benefit of this disclosure.
The present invention relates to an acquisition distribution layer for absorbent hygiene products produced from continuous tow bands, and to apparatuses, systems, and methods related thereto.
The systems described herein enable the production of an acquisition distribution layer (“ADL”) from a continuous tow band. As illustrated in the nonlimiting examples of
A system of the present invention may, in some embodiments, allow for straightforward production of an ADL with a desired structure and/or composition, which may yield improvements in the performance of an AHP. For example, a system of the present invention may, in some embodiments, allow for the incorporation of additives into an ADL that enhance absorbency and/or reduce odor in an AHP. Additionally, a system of the present invention may, in some embodiments, enable the production of an ADL with a unique structure, as described further in relation to
It should be noted that when “about” is provided below in reference to a number in a numerical list, the term “about” modifies each number of the numerical list. It should be noted that in some numerical listings of ranges, some lower limits listed may be greater than some upper limits listed. One skilled in the art will recognize that the selected subset will require the selection of an upper limit in excess of the selected lower limit.
Generally, an ADL of the present invention may comprise continuous filaments as opposed to staple fibers used in traditional carding processes described above. The use of continuous filaments and a system that includes a master air jet may advantageously, in some embodiments, provide for an ADL having the necessary integrity without the use of expensive acrylic latex emulsions or bicomponent fibers to enhance filament-to-filament bonding.
In some embodiments of the present invention, an ADL may comprise more than one type of filament as characterized by, inter alia, composition, cross-sectional shape, denier per filament, any other suitable characteristic, or any combination thereof. Production of an ADL comprising more than one type of filament may be as a result of using more than one tow band and/or using at least one tow band having more than one type of filament. A continuous tow band suitable for use in conjunction with the present invention may, in some embodiments, comprise more than one type of filament as characterized by, inter alia, composition, cross-sectional shape, denier per filament, any other suitable characteristic, or any combination thereof. In some embodiments, tow band processing lines for use in conjunction with the present invention may process more than one type of tow bands. In some embodiments, tow band processing lines for use in conjunction with the present invention may process more than one tow band as characterized by, inter alia, filament composition, filament cross-sectional shape, denier per filament, total denier, any other suitable characteristic, or any combination thereof.
Examples of suitable continuous tow bands for use in conjunction with the present invention may include, but not be limited to, continuous tow bands that include carbon filaments, activated carbon filaments, natural fibers, synthetic filaments, bicomponent fibers, or any combination thereof. Suitable continuous tow bands for use in conjunction with the present invention may also comprise filaments that comprise polyolefins, polyethylenes, polypropylenes, polyesters, polyethylene terphalate (PET), lyocells (e.g., TENCEL®, a lyocell, available from The Lenzing Group), viscose, rayons, polyamines, polyamides, polypropylene oxides, polyethylene sulfides, polyphenylene sulfide, liquid crystalline polymeric substances capable of being formed into fibers, silks, wools, cottons, rayons, polyacrylates, polymethacrylates, cellulose acetates, cellulose diacetates, cellulose triacetates, cellulose propionates, cellulose butyrates, cellulose acetate-propionates, cellulose acetate-butyrates, cellulose propionate-butyrates, starch acetates, acrylonitriles, vinyl chlorides, vinyl esters, vinyl ethers, and the like, any derivative thereof, any blend polymer thereof, any copolymer thereof, or any combination thereof.
While the systems and methods of the present invention may not require a bicomponent fiber for, inter alia, bonding processes, bicomponent fibers may be used in conjunction with the present invention for bonding processes or to enhance other properties of an ADL. Suitable configurations for bicomponent fibers for use in conjunction with the present invention may include, but not be limited to, side-by-side, sheath-core, segmented-pie, islands-in-the-sea, tipped, segmented-ribbon, or any hybrid thereof, nonlimiting examples of which are illustrated in
In some embodiments, a continuous tow band, or at least some filaments thereof, may comprise additives. Additives may be integral to the filaments of a continuous tow band (e.g., included in the production of the filaments) or applied to the surface of filaments of a continuous tow band. Suitable additives are detailed further herein and additive application methods are detailed above.
Filaments of a continuous tow band may, in some embodiments, have any suitable cross-sectional shape, including, but not limited to, circular, substantially circular, crenulated, ovular, substantially ovular, polygonal, substantially polygonal, dog-bone, “Y,” “X,” “K,” “C,” multi-lobe, and any hybrid thereof. As used herein, the term “multi-lobe” refers to a cross-sectional shape having a point (not necessarily in the center of the cross-section) from which at least two lobes extend (not necessarily evenly spaced or evenly sized).
In some embodiments, continuous tow bands for use in conjunction with the present invention may have a denier per filament (dpf) ranging from a lower limit of about 1, 2, 3, 5, 10, 12, 15, or 16 to an upper limit of about 50, 40, 30, 20, 15, 12, 10, 7, or 5, and wherein the denier per filament may range from any lower limit to any upper limit and encompass any subset therebetween. In some embodiments, continuous tow bands may have a denier per filament of about 50 or less, and most preferably 10 or less.
While a system of the present invention may be capable of processing a continuous tow band having a total denier of about 10,000 to about 3,000,000, a continuous tow band for use in conjunction with the production of an ADL with a system of the present invention may preferably process a tow band having a total denier ranging from about 25,000 to about 150,000, or more preferably about 25,000 to about 100,000, or most preferably about 25,000 to about 50,000, including any subset therebetween. By way of nonlimiting example, a continuous tow band for use in conjunction with the present invention may comprise cellulose acetate filaments and have a total denier of 100,000 or less and a dpf of about 10 or less. By way of another nonlimiting example, a continuous tow band for use in conjunction with the present invention may comprise polyester filaments and have a total denier of about 60,000 or less and a dpf of about 10 or less.
While a system of the present invention may be capable of processing a continuous tow band with a width of about 60 cm or less, a continuous tow band for use in conjunction with the production of an ADL with a system of the present invention may preferably process a tow band having a width of about 1 cm to about 10 cm, or more preferably about 1 cm to about 5 cm, including any subset therebetween.
While a system of the present invention may be capable of processing a processed tow band having a caliper of about 0.1 mm to about 100 mm, a process tow band for use in conjunction with the production of an ADL with the system of the present invention may preferably process the process tow band having a caliper of about 0.1 mm to about 5 mm, or more preferably about 0.1 mm to about 2 mm, including any subset therebetween.
In some embodiments, a system of the present invention may be configured to produce an ADL from tow bands such that the ADL has a caliper and/or complex cross-sectional make-up not previously realized.
Some embodiments of the present invention may involve combining two or more processed tow bands using a master air jet to produce an ADL. Said processed tow bands may be the same or different. In some embodiments of the present invention, the plurality of tow band processing lines may produce the same processed tow bands. In some embodiments of the present invention, the plurality of tow band processing lines may produce more than one type of processed tow band as characterized by, inter alia, composition, cross-sectional shape of the filaments, dpf of the filaments, total denier of the continuous tow bands, caliper of the processed tow bands, bulk density of the processed tow bands, any other suitable characteristic, or any combination thereof.
In some embodiments of the present invention, the master air jet may be configured to receive the processed tow bands side-by-side with minimal to no overlap, stacked with substantial overlap, or any combination thereof. In some embodiments, the master air jet may be configured to receive a plurality of processed tow bands to produce an ADL with a cross-sectional make-up that substantially resembles the compositional and positional relationship of the plurality of processed tow bands introduced into the master air jet, for example as shown in
An ADL of the present invention may, in some embodiments, have a variety of cross-sectional make-ups based on the configuration in which processed tow bands are introduced into master air jet.
In some embodiments, an ADL of the present invention may have a caliper ranging from about the height of to about 20% greater than the height of the outlet of the master air jet. While a system of the present invention may be capable of producing an ADL or ADL-like material having a caliper ranging from about 0.1 mm to about 100 mm, an ADL of the present invention may preferably have a caliper of about 0.1 mm to about 10 mm, or more preferably about 0.1 mm to about 2 mm, including any subset therebetween. By way of nonlimiting example, an ADL of the present invention having a caliper of about 5 mm may be utilized in a diaper. By way of another nonlimiting example, an ADL of the present invention having a caliper of about 1 mm may be utilized in a feminine hygiene product.
In some embodiments, an ADL of the present invention may have a bulk density of about 0.05 g/cm3 or less. In some embodiments, an ADL of the present invention may have a bulk density ranging from a lower limit of about 0.005 g/cm3 or 0.01 g/cm3 to an upper limit of about 0.1 g/cm3, 0.05 g/cm3, or 0.01 g/cm3, and wherein the bulk density of an ADL may range from any lower limit to any upper limit and encompass any subset therebetween.
In some embodiments, an ADL of the present invention may have a width substantially the same as the width of the widest processed tow band(s) from which it is formed. In some embodiments, an ADL of the present invention may have a width substantially the same as the sum of the width of processed tow bands from which it is formed. While a system of the present invention may be capable of producing an ADL or ADL-like material having a width ranging from about 5 cm to about 10 m, an ADL of the present invention may preferably have a width of about 2 cm to about 10 cm, or more preferably about 4 cm to about 8 cm, including any subset therebetween. By way of nonlimiting example, a polyester tow having 55,000 total denier and an initial width of about 2 cm may be run through a tow band processing line having three spreaders and a delivery roll and then introduced to a master air jet at width of about 10 cm to produce an ADL having a caliper of about 1 cm and a width of about 10 cm.
In some embodiments, a system of the present invention for producing an ADL from a tow band may comprise at least one tow band processing line operably connected to at least one master air jet so as to receive a processed tow band therefrom, nonlimiting examples of which are illustrated in
In some embodiments, tow band processing lines may include apparatuses and/or machinery to spread tow bands, uncrimp tow bands, open tow bands, bulk tow bands, apply additives to tow bands, or any combination thereof. One skilled in the art should understand the apparatuses and/or machinery needed to spread tow bands, uncrimp tow bands, bulk tow bands, apply additives to tow bands, or any combination thereof. Nonlimiting examples of suitable apparatuses and/or machinery may include spreaders, tension rollers, guide rollers, air bulking jets, sprayers, steamers, and the like, or any combination thereof. For example, a rod maker from HAUNI may be modified so as to provide the spreaders and tension rollers for opening the tow bands prior to introduction into a master air jet. Examples of air bulking jets are described in more detail herein and can be found in U.S. Pat. Nos. 6,253,431 and 6,543,106, the entire disclosures of which are incorporated herein by reference.
A system of the present invention may, in some embodiments, include at least one tow band processing line operably connected to a master air jet. A master air jet generally uses an air jet to create a Venturi that moves processed tow bands through the master air jet apparatus. The Venturi may further act to entangle filaments of adjacent processed tow bands as they pass through the master air jet. In some embodiments, the master air jet of the present invention may be configured to received a plurality of processed tow bands.
Referring now to a nonlimiting example illustrated in
Referring now to a nonlimiting example illustrated in
Referring now to another nonlimiting example illustrated in
It should be noted that in
In some embodiments, producing an acquisition distribution layer from a continuous tow band(s) may comprise processing at least one continuous tow band to form processed tow bands and forming the processed tow band(s), e.g., by combining the processed tow band(s), into an acquisition distribution layer using a master air jet.
One skilled in the art with the benefit of this disclosure should understand that the desired configuration and composition of an ADL will, at least in part, dictate the design of a system of the present invention. Accordingly, an ADL with a complex configuration and/or composition may require a plurality of tow band processing lines (e.g., six or more).
Referring now to
At one end, master air jet 440 includes inlet opening 444. As best seen as an example in
As best seen in
Accumulating chamber 462 may be located adjacent the outlet end of housing 442 and downstream of forming chamber 460 and may have a vertical dimension which is greater than outlet opening 446 of forming chamber 460. Accumulating chamber 462 may also be preferably formed with a rectangular configuration to permit the continuous tow band to pass into accumulating chamber 462 from forming chamber 460 to accumulate within accumulating chamber 462. Ultimately the processed tow bands may be withdrawn from housing 442 through outlet opening 446 at different flow rates yielding an acquisition distribution layer.
As best seen in
The relative size of forming chamber 460 and accumulating chamber 462 may help determine the caliper of the acquisition distribution layer produced from master air jet 440. Sizing guides 478 along side plates 474 allow for increasing or decreasing the size of forming chamber 460 to change this effect. It should be noted that the configuration of sizing guides 478 along side pates 474 may allow for changing the size of forming chamber 460 by different amounts by angling top plate 480 relative to bottom plate 482. Varying the shape and/or positions of perforated plates 468 the size of accumulating chamber 462 may be varied.
Similarly, the size of inlet opening 444 and outlet opening 446 may be adjusted using sizing guides 478 along side plates 474 or varying the position and/or shape of perforated plates 468. Variable sizing of inlet opening 444 may advantageously allow for receiving higher caliper processed tow bands into master air jet 440. Also variable sizing of outlet opening 446 may advantageously allow for producing higher caliper an acquisition distribution layer.
As seen best in
As seen best in
While some of the carrier air may be discharged through perforations 476 in side plates 474, a substantial portion of the carrier air is believed to move the processed tow band through the spacing between perforated plates 468 and passes outwardly through perforations 470 in perforated plates 468. In so doing, it is believed that the air passing outwardly through perforations 470 urges the processed tow band into frictional engagement with the facing inner surfaces of perforated plates 468. It is believed that this frictional engagement creates a braking action on the processed tow band, which should retard the movement of the processed tow band through accumulating chamber 462. Further, it is believed that the breaking action causes the tow to accumulate in accumulating chamber 462 at a density greater than the processed tow band had in forming chamber 460. Then, the bulked and densified processed tow band exits the accumulating chamber 462 as an acquisition distribution layer through the outlet opening 446 at different flow rates.
It is believed that the flow rate of the carrier air may determine the retarding or braking action applied to the continuous tow band as it passes between perforated plates 468. If the flow rate of the carrier air is increased, the carrier air passing outwardly through perforations 470 in perforated plates 468 will urge the processed tow band into engagement with perforated plates 468 with a greater force, and may thereby increase the retarding or braking action that is applied to the processed tow band. Conversely, if the flow rate of the carrier air is decreased, there will be a smaller braking action applied to the processed tow band. Therefore, a high degree of regulation of the braking action may be obtained by the simple expedient of operating the control valve to provide a flow of carrier air that provides the desired braking action imposed on the processed tow band, which is believed to control the density and caliper of the acquisition distribution layer as it leaves housing 442.
In some embodiments, master air jets of the present invention may having hinged side plates. Hinged side plates may advantageously allow for physically pulling processed tow bands through the master air jet then closing the hinged side plates with the air jets operating so as to create the Venturi that then operates to transport the processed tow bands through the master air jet. By way of nonlimiting example, this pulling action may be desirable when processing high total denier and high denier per filament processed tow bands.
Referring now to
The side plates may have side plate guides 1096 operably attached to either side plate top half 1090 and side plate bottom half 1092 (not shown) to ensure proper alignment when the side plates are closed. To keep the side plate halves 1090 and 1092 closed during operation, at least one side plate guide 1096 may be capable of operably attaching to both side plate halves 1090 and 1092. As shown in
One skilled in the art should recognize the plurality of modifications to hinged side plates that achieve the same function of the master air jet, e.g., side plate halves with grooves rather than side plate guides to ensure proper alignment. Further, one skilled in the art should recognize that during operation a processed tow band passing through the master air jet may snag on some imperfections (e.g., burs or gaps) in the side plates, especially at high air jet speeds. Snagging has the potential to adversely affect the edges of the acquisition distribution layer produced and, in some cases, may cause inoperability of the master air jet.
In some embodiments, master air jets of the present invention may have a sizeable outlet opening. Referring now to
One skilled in the art should recognize the plurality of modifications to hinged perforated plates that achieve the same function of the master air jet, e.g., vertical screws to adjust the location of the perforated plates and consequently the size of the outlet opening on the fly. One skilled in the art should recognize the modifications should maintain the intended purpose of the perforated plates, i.e., provide a brake for the processed tow bands passing therethrough so as to create the bulk of the subsequent acquisition distribution layer.
In some embodiments, master air jets of the present invention may have any combination of the features including, but not limited to, adjustable side plates, hinged side plates, a sizeable inlet opening, and a sizeable outlet opening. In some embodiments, the present invention provides a master air jet that comprises an inlet opening to a central passageway, the inlet opening having a width of about 5 cm to about 10 m and a height of about 0.5 cm to about 5 cm; an air jet capable of forming a Venturi in a central passageway; a forming chamber along the central passageway disposed after the air jet; an accumulation chamber formed by at least two perforated plates and at least two side plates, the accumulation chamber being disposed along the central passageway after the forming chamber; and an outlet opening to the central passageway, the outlet opening having a width of about 5 cm to about 10 m and a height of about 2 mm to about 500 mm. In some embodiments said master air jet may have a sizeable inlet opening and/or a sizeable outlet opening.
While a master air jet may be configured to have an inlet opening with a width ranging from about 5 cm to about 10 m, a master air jet for use in conjunction with the production of an ADL may preferably have an inlet opening having dimensions of width of about 5 cm to about 15 cm, more preferably about 5 cm to about 10 cm, including any subset therebetween.
While a master air jet may be configured to have an inlet opening with a height ranging from about 0.5 cm to about 5 m, a master air jet for use in conjunction with the production of an ADL may preferably have an inlet opening having dimensions of height of about 0.5 cm to about 3 cm, more preferably about 0.5 cm to about 1 cm, including any subset therebetween.
While a master air jet may be configured to have an outlet opening with a width ranging from about 5 cm to about 10 m, a master air jet for use in conjunction with the production of an ADL may preferably have an outlet opening having dimensions of width of about 5 cm to about 15 cm, more preferably about 5 cm to about 10 cm, including any subset therebetween.
While a master air jet may be configured to have an outlet opening with a height ranging from about 2 mm to about 500 mm, a master air jet for use in conjunction with the production of an ADL may preferably have an outlet opening having dimensions of height of about 2 mm to about 20 mm, more preferably about 2 mm to about 10 mm, including any subset therebetween.
In some embodiments, a system of the present invention may include an additive application area. Suitable additives for use in conjunction with the present invention are detailed further herein. In some embodiments, the system of the present invention may include at least one additive application area. Additive application areas may, in some embodiments, be disposed along at least one tow band processing line, between at least one tow band processing line and a master air jet, and/or after a master air jet. It should be noted that applying includes, but is not limited to, dipping, immersing, submerging, soaking, rinsing, washing, painting, coating, showering, drizzling, spraying, placing, dusting, sprinkling, affixing, and any combination thereof. Further, it should be noted that applying includes, but is not limited to, surface treatments, infusion treatments where the additive incorporates at least partially into filaments, and any combination thereof. One skilled in the art, with the benefit of this disclosure, should understand that an additive should be utilized in a concentration and manner so as to not render the master air jet inoperable for forming an ADL. By way of nonlimiting example, some adhesives and plasticizers should be used in limited quantities as these additives may cause the continuous filaments to stick to a master air jet or not have sufficient mechanical strength to properly form an ADL in the master air jet.
In some embodiments, the application of additives to a tow band (or a processed tow band) may be homogeneous or heterogeneous across the tow band (or a processed tow band). By way of nonlimiting example, along a tow band processing line, an adhesive additive may be applied to the edges of the tow band and an ion exchange resin additive may be applied to the central portion of the tow band. Such a tow band may be used to produce an ADL with adhesive bands at the edges that enhances adhesion to layers above and below the ADL in an AHP and an ion exchange resin additive in the central portion of the ADL that exchanges salt ions and consequently enhances the absorbent capacity of an absorbent core in an AHP. Incorporation of ion exchange resins into an ADL may advantageously exchange salt ions from bodily fluids, which may reduce the level of salt poisoning to the absorbent core and consequently may increase the absorbent capacity of the absorbent core.
Some embodiments of the present invention may involve passing heated gases through the master air jet during formation of the ADL. Some embodiments of the present invention may involve passing inert gases through the master air jet, which may advantageously reduce oxidation of the filament surfaces, especially if the gas is heated. Some embodiments of the present invention may involve passing a heated gas comprising a liquid (e.g., steam) through the master air jet, which may advantageously, for some filament compositions like cellulose acetate, plasticize the filaments and/or increase filament-to-filament bonding.
Some embodiments of the present invention may involve collecting the ADL for storage and/or transporting (e.g., shipping). In some embodiments, a system for producing an ADL of the present invention from tow bands may comprise at least one tow band processing line, at least one master air jet, and a collection area.
Some embodiments of the present invention may involve cutting an ADL into pieces of a desired shape and/or size. In some embodiments, a cut ADL may be continuously produced and fed to an AHP manufacturing line or continuously produced and collected for storage and/or transportation.
In some embodiments, a system of the present invention may be operably connected to an AHP manufacturing line. In some embodiments, an ADL produced from a system of the present invention may be added to an AHP manufacturing line as a continuous ADL. In some embodiments, an ADL produced from a system of the present invention may be cut before addition to an AHP manufacturing line, e.g., a continuous process of production of an ADL using a system of the present invention, cutting the ADL to desired length, and placing the cut ADL on an AHP manufacturing line.
One skilled in the art, with the benefit of this disclosure, will recognize the apparatuses or machinery capable for properly operably connecting (e.g., transporting to, between, and/or from) a tow band processing line, a master air jet, optionally an AHP manufacturing line, or and any additional processing areas or lines (e.g., collection areas, cutting areas, additive application areas, and the like). By way of nonlimiting examples, suitable apparatuses and/or machinery may include guides, rollers, reels, gears, conveyors, transfer belts, vacuums, air jets, and the like, any hybrid thereof, or any combination thereof. By way of nonlimiting example, a system of the present invention may, in some embodiments, include a conveyor for transporting an ADL to a collection area. By way of another nonlimiting example, a system of the present invention may, in some embodiments, include a series of guides and rollers for transporting an ADL from the system directly to an AHP manufacturing line.
In some embodiments, an ADL of the present invention that comprises continuous filaments may be incorporated as a part of an AHP. Suitable AHP may include, but are not limited to, infant diapers, feminine hygiene pads, adult incontinence products, and the like.
One skilled in the art with the benefit of this disclosure should understand the plurality of AHP configurations in which an ADL of the present invention may be incorporated.
In some embodiments, an AHP may comprise in order: a topsheet, an ADL of the present invention, an absorbent core, and a backsheet. In some embodiments, an AHP may further comprise an adhesive such that the backsheet is disposed between the absorbent core and the adhesive. By way of nonlimiting example, a diaper or incontinence product may comprise in order: a topsheet, an ADL of the present invention, an absorbent core, and a backsheet. By way of another nonlimiting example, a feminine hygiene pad may comprise in order: a topsheet, an ADL of the present invention, an absorbent core, a backsheet, and an adhesive.
In some embodiments, an AHP may comprise an ADL of the present invention disposed about an absorbent core. In some embodiments, an AHP may further comprise a topsheet in a backsheet such that the ADL disposed about the absorbent core is disposed between the topsheet and the backsheet. By way of nonlimiting example, a disposable diaper insert may comprise one surface of the topsheet, an opposing surface of a backsheet, and an ADL of the present invention disposed about the absorbent core that is together disposed between the topsheet and backsheet.
Suitable topsheets for use in conjunction with the present invention may be liquid pervious, permitting liquids to readily penetrate through its thickness, and may be woven materials, nonwoven materials, or films. In some embodiments, for example those that come in contact with the skin, a topsheet for use in conjunction with the present invention may have the characteristics of compliant, soft feeling, and non-irritating to the wearer's skin. Suitable topsheets for use in conjunction with the present invention may comprises materials that include, but are not limited to, porous foams, reticulated foams, apertured plastic films, natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers) or from a combination of natural and synthetic fibers. In some embodiments, topsheets for use in conjunction with the present invention may be made of a hydrophobic material to isolate a consumer's skin from liquids in the absorbent core. In some embodiments, topsheets for use in conjunction with the present invention may comprise one or more openings to receive the bodily fluids. In some preferred embodiments, topsheets comprises a compound to adjust hydrophilicity of the material, like a surfactant. In some preferred embodiments, topsheets may comprises a nonwoven material made using means well known to those skilled in the fabrics art.
Preferable topsheets for use in diaper applications may, in some embodiments, have a basis weight from about 10 to about 25 g/m2, a minimum dry tensile strength of at least about 150 g/cm in the machine direction, and a strikethrough of less than about 3 seconds according to European Disposables and Nonwovens Association Standard Method 150.4-99. By way of nonlimiting example, one suitable topsheet may comprise a polypropylene spunbonded nonwoven comprises fibers of less than 3 denier per filament having a basis weight of about 18 g/m2.
Suitable backsheets for use in conjunction with the present invention may prevent liquids from passing therethrough. For example in diapers and feminine hygiene products, backsheets may prevent fluids absorbed by an absorbent layer and contained within the article from soiling other external articles that may contact the article, such as bed sheets and clothing. Suitable backsheets for use in conjunction with the present invention may include, but are not limited to, thin polymer films of hydrophobic polymers like polypropylene and polyethylene. By way of nonlimiting example, a backsheet for use in conjunction with the present invention may comprise a layer of polyethylene film having a basis weight between about 10 g/m2 and about 30 g/m2, although other flexible, liquid impervious materials can be used. In some embodiments, backsheets for use in conjunction with the present invention are breathable (e.g., via micropores) so as to permit vapors to escape from the diaper while still preventing fluids (e.g., exudates) from passing therethrough. In some embodiments, backsheets for use in conjunction with the present invention may have a nonwoven laminated to the film layer so as to make backsheet more “cloth-like”. Such a nonwoven layer may, in some embodiments, comprise a nonwoven material (e.g., one having a spunbonded or other suitable structure) with a basis weight between about 15 g/m2 and about 25 g/m2.
Suitable adhesives for use in conjunction with the present invention may include, but are not limited to, pressure sensitive adhesives, glue, gelatin, caesin, starch, cellulose esters, aliphatic polyesters, poly(alkanoates), aliphatic-aromatic polyesters, sulfonated aliphatic-aromatic polyesters, polyamide esters, rosin/polycaprolactone triblock copolymers, rosin/poly(ethylene adipate) triblock copolymers, rosin/poly(ethylene succinate) triblock copolymers, poly(vinyl acetates), poly(ethylene-co-ethylacrylate), poly(ethylene-co-methyl acrylate), poly(ethylene-co-propylene), poly(ethylene-co-1-butene), poly(ethylene-co-1-pentene), poly(styrene), acrylics, polyurethanes, sulfonated polyester urethane dispersions, nonsulfonated urethane dispersions, urethane-styrene polymer dispersions, non-ionic polyester urethane dispersions, acrylic dispersions, silyl anionic acrylate-styrene polymer dispersions, anionic acrylate-styrene dispersions, anionic acrylate-styrene-acrylonitrile dispersions, acrylate-acrylonitrile dispersions, vinylchloride-ethylene emulsions, vinylpyrrolidone/styrene copolymer emulsions, carboxylated and noncarboxylated vinyl acetate ethylene dispersions, vinyl acetate homopolymer dispersions, polyvinyl chloride emulsions, polyvinylidene fluoride dispersions, ethylene acrylic acid dispersions, polyamide dispersions, anionic carboxylated or noncarboxylated acrylonitrile-butadiene-styrene emulsions and acrylonitrile emulsions, resin dispersions derived from styrene, resin dispersions derived from aliphatic and/or aromatic hydrocarbons, styrene-maleic anhydrides, gamma-chloropropylmethoxysilane, vinyltrichlorosilane, vinyltriethoxysilane, vinyltris(beta-methoxyethoxy)silane, gamma-methacryloxypropyltrimethoxysilane, beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, gammaglycidoxypropyltrimethoxysilane, vinyl-triacetoxysilane, gamma-mercaptopropyltrimethoxysilane, gamma-aminopropyltriethoxysilane, N-beta-(aminoethyl)-gamma-aminopropyl-trimethoxysilane, and the like, or any combination thereof. Said adhesives may be applied through melt processes or through solution, emulsion, dispersion, or other suitable coating processes.
Suitable additives for optional use in conjunction with the present invention may include, but not be limited to, active particles, active compounds, ion exchange resins, superabsorbent polymers, zeolites, nanoparticles, ceramic particles, abrasive particulates, absorbent particulates, softening agents, plasticizers, pigments, dyes, aromas, controlled release vesicles, binders, adhesives, tackifiers, surface modification agents, lubricating agents, emulsifiers, vitamins, peroxides, biocides, antifungals, antimicrobials, deodorizers, antistatic agents, flame retardants, antifoaming agents, degradation agents, conductivity modifying agents, stabilizing agents, or any combination thereof. Said additives are detailed further herein.
Active particles for use in conjunction with the present invention may be useful in actively reducing components from a fluid stream by absorption or reaction. Suitable active particles for use in conjunction with the present invention may include, but not be limited to, nano-scaled carbon particles, carbon nanotubes having at least one wall, carbon nanohorns, bamboo-like carbon nanostructures, fullerenes, fullerene aggregates, graphene, few layer graphene, oxidized graphene, iron oxide nanoparticles, nanoparticles, metal nanoparticles, gold nanoparticles, silver nanoparticles, metal oxide nanoparticles, alumina nanoparticles, magnetic nanoparticles, paramagnetic nanoparticles, superparamagnetic nanoparticles, gadolinium oxide nanoparticles, hematite nanoparticles, magnetite nanoparticles, gado-nanotubes, endofullerenes, Gd@C60, core-shell nanoparticles, onionated nanoparticles, nanoshells, onionated iron oxide nanoparticles, activated carbon, ion exchange resins, desiccants, silicates, molecular sieves, silica gels, activated alumina, zeolites, perlite, sepiolite, Fuller's Earth, magnesium silicate, metal oxides, iron oxides, activated carbon, and any combination thereof.
Suitable active particles for use in conjunction with the present invention may have at least one dimension of about less than one nanometer, such as graphene, to as large as a particle having a diameter of about 5000 nanometers. Active particles for use in conjunction with the present invention may range from a lower size limit in at least one dimension of about: 0.1 nanometers, 0.5 nanometers, 1 nanometer, 10 nanometers, 100 nanometers, 500 nanometers, 1 micron, 5 microns, 10 microns, 50 microns, 100 microns, 150 microns, 200 microns, and 250 microns. The active particles may range from an upper size limit in at least one dimension of about: 5000 microns, 2000 microns, 1000 microns, 900 microns, 700 microns, 500 microns, 400 microns, 300 microns, 250 microns, 200 microns, 150 microns, 100 microns, 50 microns, 10 microns, and 500 nanometers. Any combination of lower limits and upper limits above may be suitable for use in conjunction with the present invention, wherein the selected maximum size is greater than the selected minimum size. In some embodiments, the active particles for use in conjunction with the present invention may be a mixture of particle sizes ranging from the above lower and upper limits. In some embodiments of the present invention, the size of the active particles may be polymodal.
Active compounds for use in conjunction with the present invention may be useful in actively reducing components from a fluid stream by absorption or reaction. Suitable active compounds for use in conjunction with the present invention may include, but not be limited to, malic acid, potassium carbonate, citric acid, tartaric acid, lactic acid, ascorbic acid, polyethyleneimine, cyclodextrin, sodium hydroxide, sulphamic acid, sodium sulphamate, polyvinyl acetate, carboxylated acrylate, or any combination thereof.
Suitable ion exchange resins for use in conjunction with the present invention may include, but not be limited to, polymers with a backbone, such as styrene-divinyl benezene (DVB) copolymer, acrylates, methacrylates, phenol formaldehyde condensates, and epichlorohydrin amine condensates; a plurality of electrically charged functional groups attached to the polymer backbone; or any combination thereof.
As used herein, the term “superabsorbent materials” refers to materials, e.g., polymers, capable of absorbing at least three times their weight of a fluid. Suitable superabsorbent materials for use in conjunction with the present invention may include, but not be limited to, sodium polyacrylate, starch graved copolymers of polyacrylonitriles, polyvinyl alcohol copolymers, cross-linked poly(ethylene oxides), polyacrylamide copolymers, ethylene maleic anhydride copolymers, cross-linked carboxymethylcelluloses, and the like, or any combination thereof. By way of nonlimiting example, superabsorbent materials incorporated into a nonwoven may be useful in chemical spill rags and kits.
Zeolites for use in conjunction with the present invention may include crystalline aluminosilicates having pores, e.g., channels, or cavities of uniform, molecular-sized dimensions. Zeolites may include natural and synthetic materials. Suitable zeolites may include, but not be limited to, zeolite BETA (Na7(Al7Si57O128) tetragonal), zeolite ZSM-5 (Nan(AlnSi96-nO192) 16H2O, with n<27), zeolite A, zeolite X, zeolite Y, zeolite K-G, zeolite ZK-5, zeolite ZK-4, mesoporous silicates, SBA-15, MCM-41, MCM48 modified by 3-aminopropylsilyl groups, alumino-phosphates, mesoporous aluminosilicates, other related porous materials (e.g., such as mixed oxide gels), or any combination thereof.
Suitable nanoparticles for use in conjunction with the present invention may include, but not be limited to, nano-scaled carbon particles like carbon nanotubes of any number of walls, carbon nanohorns, bamboo-like carbon nanostructures, fullerenes and fullerene aggregates, and graphene including few layer graphene and oxidized graphene; metal nanoparticles like gold and silver; metal oxide nanoparticles like alumina, silica, and titania; magnetic, paramagnetic, and superparamagentic nanoparticles like gadolinium oxide, various crystal structures of iron oxide like hematite and magnetite, about 12 nm Fe3O4, gado-nanotubes, and endofullerenes like Gd@C60; and core-shell and onionated nanoparticles like gold and silver nanoshells, onionated iron oxide, and others nanoparticles or microparticles with an outer shell of any of said materials; and any combination of the foregoing. It should be noted that nanoparticles may include nanorods, nanospheres, nanorices, nanowires, nanostars (like nanotripods and nanotetrapods), hollow nanostructures, hybrid nanostructures that are two or more nanoparticles connected as one, and non-nano particles with nano-coatings or nano-thick walls. It should be further noted that nanoparticles for use in conjunction with the present invention may include the functionalized derivatives of nanoparticles including, but not limited to, nanoparticles that have been functionalized covalently and/or non-covalently, e.g., pi-stacking, physisorption, ionic association, van der Waals association, and the like. Suitable functional groups may include, but not be limited to, moieties comprising amines (1°, 2°, or 3°), amides, carboxylic acids, aldehydes, ketones, ethers, esters, peroxides, silyls, organosilanes, hydrocarbons, aromatic hydrocarbons, and any combination thereof; polymers; chelating agents like ethylenediamine tetraacetate, diethylenetriaminepentaacetic acid, triglycollamic acid, and a structure comprising a pyrrole ring; and any combination thereof.
Suitable ceramic particles for use in conjunction with the present invention may include, but not be limited to, oxides (e.g., silica, titania, alumina, beryllia, ceria, and zirconia), nonoxides (e.g., carbides, borides, nitrides, and silicides), composites thereof, or any combination thereof. Ceramic particles may be crystalline, non-crystalline, or semi-crystalline.
Suitable softening agents and/or plasticizers for use in conjunction with the present invention may include, but not be limited to, water, glycerol triacetate (triacetin), triethyl citrate, dimethoxy-ethyl phthalate, dimethyl phthalate, diethyl phthalate, methyl phthalyl ethyl glycolate, o-phenyl phenyl-(bis) phenyl phosphate, 1,4-butanediol diacetate, diacetate, dipropionate ester of triethylene glycol, dibutyrate ester of triethylene glycol, dimethoxyethyl phthalate, triethyl citrate, triacetyl glycerin, and the like, any derivative thereof, and any combination thereof. One skilled in the art with the benefit of this disclosure should understand the concentration of plasticizers to use as an additive to the filaments.
As used herein, pigments refer to compounds and/or particles that impart color and are incorporated throughout the filaments. Suitable pigments for use in conjunction with the present invention may include, but not be limited to, titanium dioxide, silicon dioxide, carbon black, tartrazine, E102, phthalocyanine blue, phthalocyanine green, quinacridones, perylene tetracarboxylic acid di-imides, dioxazines, perinones disazo pigments, anthraquinone pigments, carbon black, metal powders, iron oxide, ultramarine, calcium carbonate, kaolin clay, aluminum hydroxide, barium sulfate, zinc oxide, aluminum oxide, caramel, fruit or vegetable or spice colorants (e.g., beet powder, beta-carotene, turmeric, paprika), or any combination thereof.
As used herein, dyes refer to compounds and/or particles that impart color and are a surface treatment of the filaments. Suitable dyes for use in conjunction with the present invention may include, but not be limited to, CARTASOL® dyes (cationic dyes, available from Clariant Services) in liquid and/or granular form (e.g., CARTASOL® Brilliant Yellow K-6G liquid, CARTASOL® Yellow K-4GL liquid, CARTASOL® Yellow K-GL liquid, CARTASOL® Orange K-3GL liquid, CARTASOL® Scarlet K-2GL liquid, CARTASOL® Red K-3BN liquid, CARTASOL® Blue K-5R liquid, CARTASOL® Blue K-RL liquid, CARTASOL® Turquoise K-RL liquid/granules, CARTASOL® Brown K-BL liquid), FASTUSOL® dyes (an auxochrome, available from BASF) (e.g., Yellow 3GL, Fastusol C Blue 74L).
Suitable aromas for use in conjunction with the present invention may include, but not be limited to, methyl formate, methyl acetate, methyl butyrate, ethyl acetate, ethyl butyrate, isoamyl acetate, pentyl butyrate, pentyl pentanoate, octyl acetate, myrcene, geraniol, nerol, citral, citronellal, citronellol, linalool, nerolidol, limonene, camphor, terpineol, alpha-ionone, thujone, benzaldehyde, eugenol, cinnamaldehyde, ethyl maltol, vanilla, anisole, anethole, estragole, thymol, furaneol, methanol, or any combination thereof.
Suitable binders for use in conjunction with the present invention may include, but not be limited to, polyolefins, polyesters, polyamides (or nylons), polyacrylics, polystyrenes, polyvinyls, polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), any copolymer thereof, any derivative thereof, and any combination thereof. Non-fibrous plasticized cellulose derivatives may also be suitable for use as binder particles in the present invention. Examples of suitable polyolefins may include, but not be limited to, polyethylene, polypropylene, polybutylene, polymethylpentene, and the like, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable polyethylenes may include, but not be limited to, ultrahigh molecular weight polyethylene, very high molecular weight polyethylene, high molecular weight polyethylene, low-density polyethylene, linear low-density polyethylene, high-density polyethylene, and the like, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable polyesters may include, but not be limited to, polyethylene terephthalate, polybutylene terephthalate, polycyclohexylene dimethylene terephthalate, polytrimethylene terephthalate, and the like, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable polyacrylics may include, but not be limited to, polymethyl methacrylate, and the like, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable polystyrenes may include, but not be limited to, polystyrene, acrylonitrile-butadiene-styrene, styrene-acrylonitrile, styrene-butadiene, styrene-maleic anhydride, and the like, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable polyvinyls may include, but not be limited to, ethylene vinyl acetate, ethylene vinyl alcohol, polyvinyl chloride, and the like, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable cellulosics may include, but not be limited to, cellulose acetate, cellulose acetate butyrate, plasticized cellulosics, cellulose propionate, ethyl cellulose, and the like, any copolymer thereof, any derivative thereof, and any combination thereof. In some embodiments, binder particles may comprise any copolymer, any derivative, or any combination of the above listed binders. Further, binder particles may be impregnated with and/or coated with any combination of additives disclosed herein.
Suitable tackifiers for use in conjunction with the present invention may include, but not be limited to, methylcellulose, ethylcellulose, hydroxyethylcellulose, carboxy methylcellulose, carboxy ethylcellulose, water-soluble cellulose acetate, amides, diamines, polyesters, polycarbonates, silyl-modified polyamide compounds, polycarbamates, urethanes, natural resins, shellacs, acrylic acid polymers, 2-ethylhexylacrylate, acrylic acid ester polymers, acrylic acid derivative polymers, acrylic acid homopolymers, anacrylic acid ester homopolymers, poly(methyl acrylate), poly(butyl acrylate), poly(2-ethylhexyl acrylate), acrylic acid ester co-polymers, methacrylic acid derivative polymers, methacrylic acid homopolymers, methacrylic acid ester homopolymers, poly(methyl methacrylate), poly(butyl methacrylate), poly(2-ethylhexyl methacrylate), acrylamido-methyl-propane sulfonate polymers, acrylamido-methyl-propane sulfonate derivative polymers, acrylamido-methyl-propane sulfonate co-polymers, acrylic acid/acrylamido-methyl-propane sulfonate co-polymers, benzyl coco di-(hydroxyethyl) quaternary amines, p-T-amyl-phenols condensed with formaldehyde, dialkyl amino alkyl(meth)acrylates, acrylamides, N-(dialkyl amino alkyl) acrylamide, methacrylamides, hydroxy alkyl(meth)acrylates, methacrylic acids, acrylic acids, hydroxyethyl acrylates, and the like, any derivative thereof, or any combination thereof.
Suitable lubricating agents for use in conjunction with the present invention may include, but not be limited to, ethoxylated fatty acids (e.g., the reaction product of ethylene oxide with pelargonic acid to form poly(ethylene glycol) (“PEG”) monopelargonate; the reaction product of ethylene oxide with coconut fatty acids to form PEG monolaurate), and the like, or any combination thereof. The lubricant agents may also be selected from nonwater-soluble materials such as synthetic hydrocarbon oils, alkyl esters (e.g., tridecyl stearate which is the reaction product of tridecyl alcohol and stearic acid), polyol esters (e.g., trimethylol propane tripelargonate and pentaerythritol tetrapelargonate), and the like, or any combination thereof.
Suitable emulsifiers for use in conjunction with the present invention may include, but not be limited to, sorbitan monolaurate, e.g., SPAN® 20 (available from Uniqema, Wilmington, Del.), or poly(ethylene oxide) sorbitan monolaurate, e.g., TWEEN® 20 (available from Uniqema, Wilmington, Del.).
Suitable vitamins for use in conjunction with the present invention may include, but not be limited to, vitamin B compounds (including B1 compounds, B2 compounds, B3 compounds such as niacinamide, niacinnicotinic acid, tocopheryl nicotinate, C1-C18 nicotinic acid esters, and nicotinyl alcohol; B5 compounds, such as panthenol or “pro-B5”, pantothenic acid, pantothenyl; B6 compounds, such as pyroxidine, pyridoxal, pyridoxamine; carnitine, thiamine, riboflavin); vitamin A compounds, and all natural and/or synthetic analogs of Vitamin A, including retinoids, retinol, retinyl acetate, retinyl palmitate, retinoic acid, retinaldehyde, retinyl propionate, carotenoids (pro-vitamin A), and other compounds which possess the biological activity of Vitamin A; vitamin D compounds; vitamin K compounds; vitamin E compounds, or tocopherol, including tocopherol sorbate, tocopherol acetate, other esters of tocopherol and tocopheryl compounds; vitamin C compounds, including ascorbate, ascorbyl esters of fatty acids, and ascorbic acid derivatives, for example, ascorbyl phosphates such as magnesium ascorbyl phosphate and sodium ascorbyl phosphate, ascorbyl glucoside, and ascorbyl sorbate; and vitamin F compounds, such as saturated and/or unsaturated fatty acids; or any combination thereof.
Suitable antimicrobials for use in conjunction with the present invention may include, but not be limited to, anti-microbial metal ions, chlorhexidine, chlorhexidine salt, triclosan, polymoxin, tetracycline, amino glycoside (e.g., gentamicin), rifampicin, bacitracin, erythromycin, neomycin, chloramphenicol, miconazole, quinolone, penicillin, nonoxynol 9, fusidic acid, cephalosporin, mupirocin, metronidazolea secropin, protegrin, bacteriolcin, defensin, nitrofurazone, mafenide, acyclovir, vanocmycin, clindamycin, lincomycin, sulfonamide, norfloxacin, pefloxacin, nalidizic acid, oxalic acid, enoxacin acid, ciprofloxacin, polyhexamethylene biguanide (PHMB), PHMB derivatives (e.g., biodegradable biguanides like polyethylene hexamethylene biguanide (PEHMB)), clilorhexidine gluconate, chlorohexidine hydrochloride, ethylenediaminetetraacetic acid (EDTA), EDTA derivatives (e.g., disodium EDTA or tetrasodium EDTA), and the like, and any combination thereof.
Antistatic agents (antistats) for use in conjunction with the present invention may comprise any suitable anionic, cationic, amphoteric or nonionic antistatic agent. Anionic antistatic agents may generally include, but not be limited to, alkali sulfates, alkali phosphates, phosphate esters of alcohols, phosphate esters of ethoxylated alcohols, or any combination thereof. Examples may include, but not be limited to, alkali neutralized phosphate ester (e.g., TRYFAC® 5559 or TRYFRAC® 5576, available from Henkel Corporation, Mauldin, S.C.). Cationic antistatic agents may generally include, but not be limited to, quaternary ammonium salts and imidazolines which possess a positive charge. Examples of nonionics include the poly(oxyalkylene) derivatives, e.g., ethoxylated fatty acids like EMEREST® 2650 (an ethoxylated fatty acid, available from Henkel Corporation, Mauldin, S.C.), ethoxylated fatty alcohols like TRYCOL® 5964 (an ethoxylated lauryl alcohol, available from Henkel Corporation, Mauldin, S.C.), ethoxylated fatty amines like TRYMEEN® 6606 (an ethoxylated tallow amine, available from Henkel Corporation, Mauldin, S.C.), alkanolamides like EMID® 6545 (an oleic diethanolamine, available from Henkel Corporation, Mauldin, S.C.), or any combination thereof. Anionic and cationic materials tend to be more effective antistats.
To facilitate a better understanding of the present invention, the following examples of preferred embodiments are given. In no way should the following examples be read to limit, or to define, the scope of the invention.
To combine two tow bands, a system was used that included a tow band processing line having three tow spreaders, a master air jet for receiving the tow bands from the tow band processing line, hand-held guidery between the first and second tow spreaders of the tow band processing line, and hand-held guidery between the tow band processing line and master air jet. Two tow bands were spread on the tow band processing lines then introduced in a stacked configuration into the master air jet. One tow band was colored while the other tow band was white. The produced ADL produced has intermingling at the interface of the two tow bands and has sidedness with one side being substantially the colored tow band and the other side being substantially the white tow band. This example demonstrates the cross-sectional make-up of the ADL is substantially the same as the composition and positional relationship of the processed tow bands as introduced into the master air jet.
A polyester tow band having 280,000 total denier, 2.25 dpf, 44 crimps/10 cm, and a 4 inch width, shown in
While an ADL may more preferably be a smaller caliper, this example demonstrates the efficacy of a system according to at least one embodiment of the present invention in producing bulked ADL-like materials from continuous tow bands.
A section of 3,000,000 tow band was extracted yielding about a 200,000 total denier tow band. A lyocell tow band having a 24-inch substantially circular cross-section (as compared to the rectangular cross-section of Example 2) with a total denier of about 350,000, 3 dpf filaments, and 30 crimps/10 cm, shown after spreading in
While an ADL may more preferably be a smaller caliper, this example demonstrates the efficacy of a system according to at least one embodiment of the present invention in producing bulked ADL-like materials from continuous tow bands.
Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope and spirit of the present invention. The invention illustratively disclosed herein suitably may be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
This application is a continuation-in-part and claims priority pursuant to 35 U.S.C. §120 to U.S. patent application Ser. No. 13/297,787, filed Nov. 16, 2011, entitled “Nonwoven Materials from Continuous Tow Bands and Apparatuses and Methods Thereof,” which is incorporated by reference herein for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13297787 | Nov 2011 | US |
| Child | 13492198 | US |
