Coated non-woven material, its making process and its use in a d

Details Coated non-woven material, its making process and its use in a d Coated non-woven material, its making process and its use in a d

1996-10-03

1999-06-01

Weiss, John G.

Surgery

Means and methods for collecting body fluids or waste material

Absorbent pad for external or internal application and...

604366, 604370, 4283197, A61F 1315, A61F 1320

Patent

active

059084120

DESCRIPTION:

BRIEF SUMMARY
BACKGROUND OF THE INVENTION

The present invention concerns a coated non-woven material comprising a base layer made of a fibrous non-woven web and at least one layer made of a thermoplastic film which has been applied under heat onto one face of the base layer. The coated non-woven material can be used, in particular, in disposable absorbent hygiene articles such as diapers for babies or incontinent persons as well as training pants and sanitary napkins comprising a liquid impervious backsheet, a liquid permeable topsheet and an absorbent pad disposed between the backsheet and the topsheet and bonded at least to the internal face of the backsheet, for making, in particular, the backsheet which usually is made of a thin polyethylene film, to impart to this backsheet with a fabric-like or textile appearance and tactile impression, more agreeable for the user.
The invention also concerns a process for making such a coated non-woven material.
It is known in the art to coat fibrous non-woven materials with a thermoplastic film. Such a material is disclosed in patent GB 1 403 603. However, this patent does not give any indication about adhesivity between the two layers, or the textile appearance of the resulting product.
EP 0 187 725 discloses a coated fabric comprising a base layer made of a fibrous non-woven material in which densified and non-densified portions are preformed and a thermoplastic film hot bonded onto one face of said base layer so that the penetration depth of the film within the base layer is limited to less than the total thickness of the basic layer.
According to this patent, such a penetration depth of the thermoplastic film within the base layer is necessary to obtain an improved adhesion of the thermoplastic film to the fibrous non-woven material of the base layer.
However, penetration of the thermoplastic film (which may range from 10 to 250 micrometers) within the fibrous non-woven material, which is enhanced by temperature and pressure during the manufacturing process, becomes a major drawback since a significant amount of the melted thermoplastic film may penetrate into non-densified areas of the fibrous non-woven material, resulting in a decrease in the fabric-like tactile, impression and softness of the uncoated face of the fibrous material.


SUMMARY OF THE INVENTION

A coated non-woven material having improved softness and fabric-layer tactile impression has been discovered, which comprises a base layer made of a fibrous non-woven web and at least one layer of a thermoplastic film, and which is characterized in that the thermoplastic film applied onto the base layer made of a fibrous non-woven web has a peel strength, as determined according to NFT 76-112 standard (peeling angle:180.degree.; pulling speed:200 mm/mn) which is equal to or less than 98.times.10.sup.-3 kN/m and ranges preferably from 6.times.10.sup.-3 to 70.times.10.sup.-3 kN/m.
According to the present invention, the thermoplastic film contacting the base layer made of a fibrous non-woven web has preferably a thickness at most equal to 10 .mu.m (micrometers) and, preferably, ranges from 5 .mu.m to 8 .mu.m.
According to a preferred embodiment, the thermoplastic film comprises at least one ethylene polymer associated with at least one anti-blocking agent.
The ethylene polymer may be selected from the group comprising copolymers of ethylene with at least one .alpha.-olefin having 3 to 8 carbon atoms, copolymers of ethylene/alkyl(meth)acrylate in which the alkyl group may be a linear or branched group having 1 to 6 carbon atoms, copolymers of ethylene and at least one vinyl ester of a saturated carboxylic acid having 2 to 6 carbon atoms.
By way of example, among the ethylene polymers are included low density polyethylene, very low density polyethylene, copolymers of ethylene/methyl(meth)acrylate, copolymers of ethylene/ethyl(meth)acrylate, copolymers of ethylene/butyl(meth)acrylate, copolymers of ethylene/vinyl acetate and mixtures of two or more of the foregoing.
Among these ethylene polymers, the invention concerns pr

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