Absorbent composite comprising a hydroentangled nonwoven

Patent metadata

Field	Value
Publication number	US-12226181-B2
Application number	US-201615000750-A
Country	US
Kind code	B2
Filing date	Jan 19, 2016
Priority date	Jan 16, 2015
Publication date	Feb 18, 2025
Grant date	Feb 18, 2025

Abstract

Absorbent composites suitable for a wide variety of uses (e.g., sorbent drapes, sorbent patches around a fenestration area, tray liners for surgical tools, incontinence pads and liners, other liners, etc.) are provided. The composite includes an absorbent nonwoven. The absorbent nonwoven may comprise a hydroentangled spunbond web. The composite also may comprise a liquid-impermeable film. One or more absorbent nonwovens of a composite may additionally comprise a three-dimensional pattern, for example, a three-dimensional pattern that has been imaged using hydroentanglement. Optionally, any one or more layers of the composites may comprise an antimicrobial additive.

First claim

That which is claimed:

1. A two-layered composite, comprising:
(a) a first layer that is an absorbent nonwoven consisting of a plurality of synthetic fibers rendered hydrophilic by the presence of (i) a topical hydrophilic surfactant thereon, (ii) a hydrophilic melt additive, or both (i) and (ii), wherein the absorbent nonwoven is a hydroentangled spunbond web that has been subjected to a first hydroentanglement process and a second hydroentanglement process, the hydroentangled spunbond web having an outermost surface defined by a three-dimensional pattern formed by the plurality of synthetic fibers, wherein the three-dimensional pattern formed by the plurality of synthetic fibers defines a first outermost surface of the two-layered composite; and
(b) a second layer that is a liquid-impermeable film,

wherein the liquid-impermeable film is an extrusion coated film located directly onto and impregnating at least a plurality of voids between individual spubonbond fibers of the hydroentangled spunbond web to provide an extrusion coated film at least partially embedded into the hydroentangled spunbond web; and wherein the composite a normalized absorbency (g/g) from 10 to 20 and has a lint level of at most about 2000 particles/cubic foot as determined according to test method IS09073-10:2003 and wherein the composite has a Spill Absorption Time of less than 20 seconds and a Spread Index from 1 to 35 cm, and wherein the synthetic fibers are selected from the group consisting of a polyolefin, a polyester, a polyamide, and any combinations thereof.

2. The composite according to claim 1 , wherein the liquid-impermeable film is extrusion coated on the absorbent nonwoven.

3. The composite according to claim 1 , wherein the absorbent nonwoven comprises bicomponent fibers having a sheath and a core; wherein the sheath comprises a first polyolefin and the core comprises a second polyolefin or a polyester.

4. The composite according to claim 1 , wherein the composite has a normalized absorbency from about 5 to about 20.

5. The composite according to claim 1 , wherein the composite has a 1 mL Absorption Time of less than 10 seconds.

6. The composite according to claim 1 , wherein the composite has a Spread Index from about 1 to about 35.

7. The composite according to claim 1 , wherein the first hydroentanglement process is performed on a flat belt.

8. The composite according to claim 7 , wherein the second hydroentanglement process is performed on an image transfer sleeve.

9. The composite according to claim 7 , wherein the second hydroentanglement process comprises a fluid pressure from 1400 to 3500 psi.

10. A three-layered composite, comprising:
(a) a first layer that is an absorbent nonwoven consisting of a plurality of synthetic fibers rendered hydrophilic by the presence of (i) a topical hydrophilic surfactant thereon, (ii) a hydrophilic melt additive, or both (i) and (ii), and wherein the absorbent nonwoven is a hydroentangled spunbond web that has been subjected to a first hydroentanglement process and a second hydroentanglement process;
(b) a second layer that is a liquid-impermeable film, wherein the liquid-impermeable film comprises a breathable film that is impermeable to liquid water and permeable to water vapor; wherein the breathable film is at least partially embedded into the hydroentangled spunbond web; and
(c) a third layer that is a second nonwoven that is a non-absorbent nonwoven, wherein the liquid-impermeable film is extrusion coated directly between the absorbent nonwoven and the non-absorbent nonwoven,
wherein the composite has a Spill Absorption Time of less than 20 seconds and a Spread Index from 1 to 35 cm.

11. The composite of claim 10 , wherein the plurality of synthetic fibers are selected from the group consisting of a polyolefin, a polyester, a polyamide, and any combinations thereof.

12. A composite of claim 11 , wherein the liquid-impermeable film is extrusion coated on the absorbent nonwoven.

13. A two-layered composite, consisting of:
(a) a first layer that is an absorbent nonwoven consisting of a plurality of synthetic fibers rendered hydrophilic by the presence of a topical hydrophilic additive, and an antimicrobial additive, wherein the absorbent nonwoven is a hydroentangled spunbond web that has been subjected to a first hydroentanglement process and a second hydroentanglement process, the hydroentangled spunbond web having an outermost surface defined by a three-dimensional pattern formed by the plurality of synthetic fibers, wherein the three-dimensional pattern formed by the plurality of synthetic fibers defines a first outermost surface of the two-layered composite; and
(b) a second layer that is a liquid-impermeable film, wherein the liquid-impermeable film is extrusion coated directly onto and is at least partially embedded into the absorbent nonwoven;
wherein the plurality of synthetic fibers are selected from the group consisting of a polyolefin, a polyester, a polyamide, and any combinations thereof.

Assignees

• Avintiv Specialty Materials Inc

Inventors

• Wang Lei
• Bishop Nyle
• Moody Iii Ralph A
• Snider Jerry
• Grondin Pierre

Classifications

• A61F2013/15463

  Absorbency · CPC title

• A61F13/8405

  Additives, e.g. for odour, disinfectant or pH control · CPC title

• A61F13/53

  characterised by the absorbing medium (A61F13/20 takes precedence) · CPC title

• A61F13/15804

  Plant, e.g. involving several steps · CPC title

• A61F13/15203

  Properties of the article, e.g. stiffness or absorbency (chemical aspects A61L15/00) · CPC title