RU2615704C2 - Substrates containing foamed useful substances for increased advantages of substrates - Google Patents

Abstract

FIELD: textile and paper.

SUBSTANCE: invention relates to absorbent nonwoven products and concerns a substrate, containing foamed useful substances. Nonwoven substrate comprises a fibre cloth, which determines the surface, and a layer of the useful substance. Useful substance is an additional composition. Useful substance is foamed and is connected with said surface of the fibre cloth by means of the creping process so, that the additional composition on said substrate forms the surface, which is more similar to a film, than the substrate. Nonwoven substrate is printed and demonstrates more improved printing in comparison with an untreated substrate.

EFFECT: invention provides a nonwoven substrate for absorbent products, which demonstrates improvements, selected according to a tactile sensation, printing, bulk, elasticity/extensibility, reduction of hysteresis, ability to reduce, reduction of ripple marks and their combinations in comparison with an untreated substrate.

40 cl, 10 dwg, 5 tbl, 3 ex

Description

CROSS REFERENCE TO A RELATED APPLICATION

This application is a partial continuation of the application for US patent No. 13/330440, filed December 19, 2011, which was a partial continuation of the application for US patent No. 12/979852, filed December 28, 2010

FIELD OF THE INVENTION

The present invention relates to a creped non-woven substrate containing foamed polymer and additional softeners and showing improved tactile sensation, improved printing, reduced hysteresis, increased bulkiness, increased elasticity / extensibility, increased contractility, reduced wrinkling and other useful advantages of using the product in comparison with raw backing.

BACKGROUND OF THE INVENTION

Absorbent non-woven products, such as paper towels, paper-based products, diapers and other similar products, are designed to have the required levels of bulkiness, softness and strength. For example, in some paper products, softness is enhanced by an additive composition, such as a softener, applied at certain places on the outer surface (s) of the web of the paper-based product. Such an additive composition may be a binder applied in certain places to a substrate such as a nonwoven material, alone or in combination with creping operations. Creping may be part of the nonwoven fabrication process in which a paper-based product is adhered to the hot surface of a rotary dryer by means of an additive composition. The dried paper-based article and the additive composition are cut from the dryer drum by means of a doctor blade. Creping adds puffiness to paper substrates, which in turn increases the softness determined by touch to the touch. It also affects other properties, such as strength, flexibility, crepe folds, etc. Typically, the additive compositions can be sprayed onto a Yankee-cylinder dryer drum. However, the spraying process has low levels of effectiveness of the active masses (40–70%) due to the loss of the additive composition caused by the boundary layer of air near the surface of the desiccant and the relatively high temperature of the desiccant. If necessary, the application device is typically located at a distance of approximately 4 inches (101.6 mm) from the desiccant surface. Due to the high rotation speed of the desiccant, the boundary layer of air near the desiccant surface stretches along it, creating a pressure barrier that prevents spray particles from reaching the desiccant surface.

In addition, modifying any additives so that they contain additional solid particles and short fibers that increase the overall softness of the substrate is very limited. Many additional particles capable of improving the final touch of the substrate require mixing into the dispersion sprayed onto the desiccant. Since many of these particles are larger than spray nozzles, clogging of nozzles is a difficulty preventing proper application of additional dispersion to the surface of the desiccant. Thus, there is a need for a method for applying the additive composition on its own or in combination with particles providing softness to the surface of the desiccant and, ultimately, to the substrate, in order to provide a substrate having increased softness.

SUMMARY OF THE INVENTION

The present invention provides a nonwoven substrate comprising a fibrous web defining a surface; and a layer of a useful substance, wherein said useful substance is selected from an additive composition, a reinforcing component, and combinations thereof; wherein said beneficial agent is foamed and bonded to the surface of the fibrous web by a creping process, and said non-woven substrate exhibits improvements selected from improved tactile sensation, improved printing, reduced hysteresis, increased bulkiness, increased elasticity / extensibility, increased reduction ability , reducing folding and their combinations in comparison with the untreated substrate.

BRIEF DESCRIPTION OF GRAPHIC MATERIALS

In order to illustrate the invention, a graphic is shown in the graphic materials which is illustrative; however, it should be understood that the present invention is not limited to the exact layouts and tools shown.

FIG. 1 is a schematic view of the steps of a process used to create one embodiment of a foam in accordance with the present invention.

FIG. 2 shows an SEM image of a raw ink spunbond.

FIG. 3 shows an SEM image of one embodiment of the present invention, where the spanbond was used as a substrate that was processed in accordance with the present invention and printed with ink.

FIG. 4 shows a graphical representation of elastic deformation as a function of applied deformation for embodiments of waterjet materials that have been processed in accordance with the present invention, along with comparative data for an untreated substrate.

FIG. 5 shows a graphical representation of elastic deformation as a function of applied strain for an embodiment of spunbond materials that have been processed in accordance with the present invention, along with comparative data for an untreated substrate.

FIG. 6 is a series of SEM photographs showing a structural change in the material of a paper-based product after it has been processed by one embodiment of the present invention.

FIG. 7 shows the elastic deformation in the processing direction (MD) depending on the applied deformation for one embodiment of a paper substrate that has been processed in accordance with the present invention, along with comparative data for an untreated paper substrate.

FIG. 8 shows elastic deformation in the transverse direction (CD) of the treatment as a function of the applied strain for one embodiment of a paper substrate that has been treated in accordance with the present invention, along with comparative data for an untreated paper substrate.

FIG. 9 shows SEM images of an untreated control film.

(a) shows an SEM image of one side of an untreated control film.

(b) shows an SEM image of the opposite side of the untreated control film.

(c) shows an SEM image of a cross-sectional view of an untreated control film.

(d) shows an SEM image of a cross-sectional view of an untreated 5-fold control film of FIG. 9 (s).

FIG. 10 shows an SEM image of the film deposited foam layer of one embodiment of a beneficial agent according to the present invention, the embodiment comprises a dispersion HYPOD ^®.

(a) shows an SEM image of one side of a layer of a film of settled foam.

(b) shows an SEM image of the opposite side of the film layer of the settled foam.

(c) shows an SEM image of a view in cross section of a layer of a film of settled foam.

(d) shows an SEM image of a cross-sectional view of a settling foam film layer with an almost 2-fold increase in FIG. 10 (c).

(e) shows an SEM image of a cross-sectional view of a settling foam film layer with an almost 7-fold increase in FIG. 10 (c).

(f) shows an SEM image of a cross-sectional view of a 25-fold enlarged foam film layer of FIG. 10 (c).

DETAILED DESCRIPTION OF THE INVENTION

Since the description of the invention ends with the claims, in particular indicating and clearly stating the present invention, it is intended that the present invention be better understood from the following description.

All percentages, proportions and ratios are calculated based on the total weight of the compositions of the present invention, unless otherwise indicated. All such weights, as they relate to the listed ingredients, are based on the level of active substances and therefore do not include solvents or by-products that may be included in commercially available materials, unless otherwise indicated. The term "weight percent" may be referred to as "weight. % ”In this document. Except where specific examples of actual measured values are provided, the numerical values indicated in this document should be quantified with the word “approximately”.

As used herein, the term “comprising” means that other steps and other ingredients that do not affect the end result can be added. This term covers the terms “consisting of” and “essentially consisting of”. Compositions and methods / processes according to the present invention may comprise, consist of and essentially consist of the essential elements and features of the invention described herein, as well as any additional or optional ingredients, components, steps or features described herein.

As used herein, the term “additive composition” refers to chemical additives (sometimes referred to as a chemical, chemical composition, chemical composition, and added element) applied to a substrate in certain places. Application at specific locations in accordance with the method of the present invention may occur during a drying process or a conversion process. Additional compositions in accordance with the present invention can be applied to any substrate (for example, on paper-based products or non-woven materials) and may include, without limitation, polymer dispersions, polymer solutions, or mixtures thereof.

The “air-laid web” used herein is made in an air molding process where bundles of small fibers, typically ranging in length from about 3 millimeters to about 52 millimeters (mm), are separated and entrained by the feed air and then deposited onto the molding grill, usually with a vacuum. Randomly deposited fibers are then bonded to each other using, for example, hot air or sprayed adhesive. The manufacture of air-laid non-woven composites is well defined in the literature and documented in the art. Examples include, but are not limited to, the DanWeb process described in US Pat. No. 4,640,810 to Laursen et al. And assigned to Scan Web of North America Inc .; Kroer process described in US patent No. 4494278 issued by Kroyer and others; and US Pat. No. 5,527,171 to Soerensen and assigned to Niro Separation upon presentation; and a method according to US Patent No. 4,375,448 to Appel et al. and assigned to Kimberly-Clark Corporation, or other similar methods.

“Useful substances” are compositions or components providing for the entire processed substrate such advantages as softness, smoothness, humidity, perfumes, and the like. Useful substances according to the present invention without limitation include “additive compositions” and “enhancing components”.

“Carded web” or “BCW” refers to a non-woven web formed by carding processes known to those skilled in the art, as well as described, for example, in US Pat. No. 4,488,928, incorporated herein by reference to the extent which it is compatible with the present invention. In the carding process, you can use a mixture of staple fibers, binder fibers and, possibly, other binding components, such as adhesive. These components are formed into a puffy ball, which is combed or otherwise processed to create a substantially uniform base weight. This fabric is heated or otherwise treated to activate any adhesive component, which results in a combined, elastic high-quality non-woven material.

As used herein, the term “coform-derived material” is a meltblown polymeric material to which fibers or other components can be added. In the most important sense, the material obtained by the technology of koform can be made with at least one extrusion die for meltblown located near the trough through which other materials are added to the meltblown materials during web formation. These “other materials” may be natural fibers, superabsorbent particles, natural polymer fibers (eg, from viscose) and / or synthetic polymer fibers (eg, polypropylene or polyester). The fibers may have a staple length. Obtained by the technology of conformal material may contain cellulosic material in an amount of from about 10 wt.% To about 80 wt.%, Such as, for example, from about 30 wt.% To about 70 wt.%. For example, in one embodiment, the koform-derived material can be made as containing wood pulp fibers in an amount of from about 40 wt.% To about 60 wt.%.

The “creping” as defined herein occurs when the web adhered to the surface of the desiccant is cut off with a scraper such as a doctor blade.

“Reinforcing components” according to the present invention are beneficial substances that are additional components that can be added to the additive composition in order to give other tactile or additional benefits that cannot be achieved by the additive composition by itself. Reinforcing components include, but are not limited to, microparticles, expandable microspheres, fibers, additional polymer dispersions, perfumes, antibacterial agents, moisturizers, medicines, sedatives, and the like.

The term “foam” as defined herein is a liquid foam. According to the present invention, if the foamable composition of the present invention is heated on the surface of the desiccant, it will not form a solid foam structure. Instead, such a foamable composition, when applied to a heated surface, turns into a substantially continuous film with air bubbles inside the film.

The term "water-jet bonded web" in accordance with the present invention refers to a web that has been subjected to columnar jets of fluid that cause tangling of fibers. Water-jet fastening of the canvas, as a rule, increases the strength of the canvas. In one of the features of the wood pulp fiber can be fastened by jets of water into a material of continuous filaments, such as "spunbond fabric". The web obtained by water-bonding, resulting in a nonwoven composite, may contain wood pulp fibers in an amount of from about 50 wt.% To about 80 wt.%, For example, in an amount of about 70 wt.%. The above-described water jets bonded composite webs are commercially available from Kimberly-Clark Corporation under the name HYDROKNIT ^®. Water-jet bonding is described, for example, in US patent No. 5389202 issued by Everhart.

The term “non-woven” as defined herein is one of the classes of fabrics made generally by bonding fibers to each other. Non-woven fabric is made using mechanical, chemical, thermal, adhesive or solvent means, or any combination thereof. The manufacture of non-woven materials is different from weaving, knitting or tufting. Non-woven fabrics can be made from synthetic thermoplastic polymers or from natural polymers such as cellulose. One example of a nonwoven fabric is cellulosic fabric.

As used herein, the term “meltblown process” is a non-woven fabric formation process in which molten polymer resins are extruded and drawn with heated air at high speed to form thin threads. The fibers are cooled and collected as a web on a moving grate. This process is similar to the spunbond process, but the fibers obtained by the meltblown process are much finer and are usually measured in microns.

As used herein, the term “processing aids” refers to compositions capable of assisting in the process of forming a treated substrate according to the present invention. For example, blowing agents may be suitable processing aids according to the present invention. In addition, creping additives may contribute to additional adhesion or release properties when creping a substrate from a tumble dryer.

As used herein, the term “folding” describes the behavior of an elastic laminate that manifests itself as tubular folds as a result of attaching an elastic material (film or thread) that has been stretched previously to a substrate of non-stretch material (such as non-woven material). Folding may depend on how the laminate is attached to or bonded to a non-stretch substrate. When the layered material is loose or released, the substrate appears to have furrowed or tubular folds similar to those of an accordion. This effect is well known in personal care products, where cuffs and belts are often assembled in order to provide an improved fit to the wearer. Foldings are also described in further detail according to US Pat. No. 6,475,600 issued to Morman et al. November 5, 2002.

As used herein, the term “spunbond” is a process for forming a non-woven fabric, in which the filaments were extruded, stretched and laid on a moving grid to form a fabric. The term “spunbond” is often replaced by the term “spunbond”, but the industry has traditionally recognized the terms “spunbond” or “obtained using spanbond technology” to refer to a specific process of forming a web. This is necessary to distinguish between this process of web formation and two other forms of spun blade web formation, which are the meltblown and flash spinning processes.

As used herein, the term “spunbond / meltblown composite” is a layered composite defined by a multilayer fabric, which is usually made of various alternating layers of spunbond webs (“S”) and meltblown webs (“M”): SMS, SMMS, SSMMS and other

As used herein, the term “paper based product” generally refers to various paper products, such as cosmetic tissue, toilet paper, paper towels, table napkins, sanitary napkins, and the like. A paper product according to the present invention can usually be obtained from a cellulosic web containing one or more layers. For example, in one embodiment, the implementation of the cellulosic, or "paper" product may contain a single-layer paper web formed from a mixture of fibers. In another embodiment, the paper product may comprise a multilayer paper (i.e., layered) web. In addition, the paper product may also be a single or multi-layer product (for example, containing more than one paper web), in which one or more layers may contain a paper web formed in accordance with the present invention.

The present invention is an alternative to the modern method of spraying on a desiccant surface (for example, a Yankee-cylinder drum or a hot calender) an aqueous dispersion or a solution of creping chemicals. Unlike a liquid chemical composition, a foamed chemical composition has sufficient structural integrity to reach the desiccant surface, acting against gravity due to its significantly higher viscosity. By creating a foamed chemical composition in accordance with the present invention, a chemical application device can be placed much closer to the desiccant surface. In addition, when using the foamed chemical composition according to the present invention, it becomes possible to realize additional advantages that otherwise would be difficult to apply.

Another advantage of the present invention is that the desiccant consumes less energy. Closer placement of the device for applying the chemical composition to the surface of the desiccant increases the efficiency of the active masses (i.e., reduces losses during application) and energy efficiency. Efficiency is enhanced because the air introduced into the foam of the present invention acts as a diluent. As a result, less heat is required during the drying process to remove water from the foamed chemical composition for creping (i.e., from beneficial substances). This is an improvement in the atomization process in which water is used to dilute the beneficial agent.

In addition, after the creping step, a layer of the beneficial agent remains on the surface of the non-woven substrate, in order to provide greater swelling and softness. This increase in puffiness is caused by air trapped inside the coated layer. The increased softness is caused by beneficial substances that can be foamed on the surface of the desiccant and subsequently transferred or glued to the surface of the substrate through a creping process. Due to the fact that foamed nutrients become a film during the drying step, not all air trapped in the foam is lost during the drying step due to the higher viscosity associated with higher levels of solids in the foamed additive composition.

The “film” of a useful substance would be more appropriately and accurately described as a “film layer of settled foam”. For a better understanding of this difference, FIG. 9 shows a view of a conventional film (such as a film cast from a solution, an extruded film or a film obtained by blowing). As shown in FIG. 9a, this film is relatively smooth with few voids on one side and completely smooth on the other side, as shown in FIG. 9b. When considering the cross-sectional views of FIG. 9c and 9d, the voids of the film are seen as relatively parallel to the horizontal axis of the film. For comparison, FIG. 10 shows a view of a deposited foam film layer according to the present invention. As shown in FIG. 10a and FIG. 10b, both sides of the deposited foam film layer exhibit a unique cellular structure, allowing it to have differences in both mechanical and tactile properties compared to traditional films. FIG. 10c — FIG. 10f show enlarged cross-sectional views of one embodiment of a settling foam film layer according to the present invention. As shown, the foamed useful layer has voids from the air trapped by the foam, which leads to the advantages provided by the present invention. In addition, it is easy to observe the cellular structure in the Z direction, while the voids of the layer are more perpendicular to the horizontal axis of the layer. Thus, the present invention not only provides a film in the traditional sense of the word, but provides an advantageous layer of a film of settled foam by foaming and creping, which provides the improvements and improvements described herein.

In accordance with the present disclosure, various substrates other than a paper based product can be processed. Examples include, but are not limited to, hydraulically laid sheets, air-laid sheets, spunbond sheets, meltblown sheets, webs made from coform material, carded sheets (BCW), continuous film, spunlace, film / laminate sheets and water-bonded sheets. A useful substance, as a rule, is applied on one side of any substrate, but if desired, it can be applied on both sides.

Useful material

1. Supplementary composition

In a desired application, the additive composition may be present at a level of from about 50 mg / m ² to about 10,000 mg / m ² , or from about 50 mg / m ² to about 1000 mg / m ² , or from about 100 mg / m ² to approximately 1000 mg / m ² . The difference between these suggested intervals depends on whether or not the additive composition is applied to the substrate either in the production line (such as a paper machine) or non-production line (such as a non-woven fabric conversion line) by a machine. The additive compositions of the present invention may be in the form of a polymer dispersion or polymer solution, as set forth below.

A. Polymer Dispersions

Foaming compositions of water-insoluble polymers may be in the form of dispersions. Water-insoluble polymeric materials that are solids, such as powders, granules, etc., can be converted into a foamable dispersion by mixing them with water and a surfactant (s) under certain processing conditions, such as high pressure extrusion at elevated temperature. To convert to foam, the polymer dispersion can then be mixed with air and a foaming agent.

Examples of dispersions in accordance with the present invention include, without limitation dispersion of polyolefins, such as HYPOD 8510 ^®, commercially available from Dow Chemical, Freeport, Texas, USA; polyisoprene dispersion, such as KRATON ^®, or copolymers of styrene-ethylene / butylene-styrene (SEBS), available commercially from Kraton Polymers US LLC, Houston, Texas, USA; dispersion of the block copolymer of polybutadiene and styrene, such as Butanol ^®, commercially available from BASF Corporation, Florham Park, New Jersey, USA; dispersion latexes, such as E-PLUS ^®, commercially available from Wacker, Munich, Germany; a dispersion of a copolymer of polyvinylpyrrolidone and styrene; and a dispersion of a copolymer of polyvinyl alcohol and ethylene, both of which are available from Aldrich, Milwaukee, Wisconsin, USA.

B. Polymer Solutions

Foaming compositions of water-soluble polymers may also be in the form of solutions. Water-soluble polymeric materials that are solids, such as powder, granules and the like, can be dissolved in the solution. To convert it into a foam, the polymer solution can then be mixed with air and a foaming agent.

Examples of polymer solutions in accordance with the present invention include water-soluble polymers, both synthetic and natural. Synthetic water-soluble polymers include, without limitation, polyalcohols, polyamines, polyimines, polyamides, polycarboxylic acids, polyoxides, polyglycols, polyethers, polyesters, copolymers and mixtures of the above polymers.

Naturally based water-soluble polymers include modified cellulose, such as cellulose ethers and esters, modified starch, chitosan and its salts, carrageenin, agar, gellan gum, guar gum, other modified polysaccharides and proteins, and combinations thereof. In one particular embodiment, water-soluble polymers also include: poly (acrylic acid) and its salts, poly (acrylate esters) and poly (acrylic acid) copolymers. Other suitable water soluble polymers include polysaccharides with a chain length sufficient to form films, such as, but not limited to, pullulan and pectin. For example, water-soluble polymers may contain additional monoethylenically unsaturated monomers that do not carry a side suspended acid group, but are capable of copolymerization with monomers carrying acid groups. Such compounds include, for example, monoacrylic esters and monomethacrylic esters of polyethylene glycol or polypropylene glycol, the molar masses (Mn) of the polyalkylene glycols being, for example, up to about 2000.

In another particular embodiment, the water soluble polymers may be hydroxypropyl cellulose (HPC) sold by Ashland, Inc. under the brand name KLUCEL ^® . Water-soluble polymers may be present in the additive composition in any effective amount, which will vary depending on the selected chemical component, as well as on the final properties, which are desirable. For example, in the illustrative case of KLUCEL ^® , biodegradable water-soluble polymers may be present in the additive composition in an amount of from about 1% to about 75%, or at least about 1%, at least about 5%, or at least about 10%, or up to about 30%, or up to about 50%, or up to about 75% based on the total weight of the additive composition. Other examples of suitable water soluble polymers include methyl cellulose (MC) sold by Ashland, Inc. under the brand name BENECEL ^® ; hydroxyethyl cellulose sold by Ashland, Inc. under the brand name NATROSOL ^® ; and hydroxypropyl starch sold by Chemstar (Minneapolis, Minnesota, USA) under the brand name GLUCOSOL 800 ^® . Any of these chemical compositions, when dissolved in water, is deposited on the hot, non-porous surface of the desiccant for the final transfer of the chemical composition to the surface of the web. Water-soluble polymers in these chemical compositions include, but are not limited to, polyvinyl alcohol, polyethylene glycol, polyethylene oxide, hydroxypropyl starch, hydroxypropyl cellulose, and combinations thereof.

Conventional creping compositions in the manufacture of paper-based products may include solutions of water-soluble polymers, such as an aqueous mixture containing polyvinyl alcohol and a polyamideepihalohydrin resin. Although these traditional creping chemicals contain solutions of water-soluble polymers, they are not able to provide the advantages of the present invention, including increased softness without compromising the strength of a sheet of paper-based product.

The additive composition according to the present invention may be commercially available, such as the dispersion HYPOD ^® 8510 from Dow Chemical Corporation, and is composed of water, polietilenoktenovogo copolymer and ethylene-acrylic acid copolymer. Polietilenoktenovy copolymer commercially available from Dow Chemical Corporation under the name AFFINITY ^® (type 2980I), and ethylene-acrylic acid copolymer commercially available from Dow Chemical Corporation under the designation PRIMACOR ^® (type 59081). PRIMACOR ^® acts as a surfactant to emulsify and stabilize AFFINITY ^® dispersion particles. The acrylic acid comonomer of PRIMACOR ^{® is} neutralized with potassium hydroxide to a degree of neutralization of about 80%. Therefore, in comparison, PRIMACOR ^® is more hydrophilic than AFFINITY ^® . In the dispersion, PRIMACOR ^® acts as a surfactant or as a dispersant. Unlike PRIMACOR ^® , AFFINITY ^®, when suspended in a dispersion, takes the form of microdroplets with a diameter of several microns. PRIMACOR ^® molecules surround AFFINITY ^® droplets, forming a micellar structure that stabilizes droplets. HYPOD 8510 ^® contains approximately 60% AFFINITY ^® and 40% PRIMACOR ^® .

When the dispersion becomes molten liquid on the hot surface of the desiccant, AFFINITY ^® forms the dispersion phase and PRIMACOR ^® forms the dispersed phase, which forms islands in the AFFINITY ^® "ocean". This phase change is called phase reversal. However, the occurrence of such phase reversal depends on such external conditions as temperature, time, molecular weight of solids and concentration. Ultimately, phase reversal occurs only when two polymers (or two phases) have a relaxation time sufficient to complete phase reversal. In the present invention, the coated film retains HYPOD 8510 ^® dispersion morphology, indicating that there is incomplete phase inversion. The advantages of the residual dispersion morphology without limitation include a more hydrophilic coating layer due to the openness of the PRIMACOR ^® phase; and stronger increased softness of the coated product due to air bubbles trapped inside the coated HYPOD 8510 ^® layer, which provides additional bulkiness.

A diluted dispersion can have an extremely low viscosity (about 1 cP - almost like water). A dispersion with a low viscosity when applied to a hot dryer drum will undergo a process of water evaporation and complete reversal of the AFFINITY ^® phase. The resulting continuous molten film then contains PRIMACOR ^® dispersion islands embedded in it. The film formed after complete evaporation of water is solid without any trapped air bubbles in it. After transferring the molten film to the web by the creping process, the thin film covering the surface of the paper-based processed product is intermittent, but still interconnected, see discussed below in FIG. 6s

The process according to the present invention can use a highly viscous dispersion with a high solids content (from about 10% to about 30%) and may contain a large number of air bubbles (air volume at least ten times the volume of the dispersion). It is desirable that a commercially available dispersion of HYPOD 8510 ^® (approximately 42% solids, including both AFFINITY ^® and PRIMACOR ^® ) have a viscosity of about 500 cP, while water has a viscosity of about 1 cP. A dispersion containing approximately 20% HYPOD 8510 ^® may have a viscosity of about 200 cP, i.e. a relatively high viscosity, while a dispersion containing less than approximately 1% HYPOD 8510 ^® may have a viscosity closer to that of water (1 cp). After capturing a high air ratio, the viscosity of the HYPOD 8510 ^® foam dispersion increases exponentially compared to the dispersion before foaming.

As shown in FIG. 1, when a foamed dispersion is applied to the non-porous surface 23 of the desiccant, a limited amount of water will quickly evaporate from it. There is reason to believe that the slow evaporation of the dispersion due to its high solids content in combination with its high viscosity will prevent the completion of the phase reversal of the dispersion AFFINITY ^® -PRIMACOR ^® (in this case, AFFINITY ^® becomes dispersive and PRIMACOR ^® becomes dispersed) and the trapped air outlet. This results in a unique microstructured molten film on the hot surface of the desiccant.

As shown in FIG. 6, SEM photographs confirm the above hypothesis. When comparing prior art paper based products with surface treated with surface treated paper products according to the present invention, two immediate advantages can be observed. First, the method according to the present invention leads to a paper-based product that is more puffy and has a softer touch to the touch due to the entrainment of air bubbles 21 (see FIG. 6b). Secondly, the paper product according to the present invention has a more wettable surface due to incomplete phase reversal, which, in turn, leads to the emergence of a hydrophilic component on the surface.

Visually compare FIG. 6a, 6b, 6c of FIG. 6a ’, 6b’, 6c ’. Shown in FIG. 6b, a coated layer containing dispersion balls 19 and trapped air bubbles 21 is softer than that shown in FIG. 6b ’fused film as determined by the manual ranking test disclosed herein.

II. Reinforcing components

The present invention not only provides a substrate with increased softness caused by the useful substances and process described herein, but also has an improved touch to the touch. Reinforcing components are added to the dispersions of the present invention to provide a cotton / fluffy feel to the substrate instead of the silk / slippery feel that can often be felt when using the dispersions per se. This can be understood as the fact that the improved touch test provided by the present invention may also include properties such as velvety, chamois, hairiness, smoothness, fluffiness and other similar descriptors used to describe soft tactile properties. Although a silk / slippery feel may be desirable for some substrates, the present invention provides other possibilities for providing a variety of textures and aesthetic properties. The reinforcing components of the present invention include, without limitation, microparticles, such as silica gel microparticles, thermally expandable microspheres, such as EXPANCEL ^® , fibers, such as cotton liner tows, dispersions of polymers such as poly (vinylpyrrolidone-styrene), and combinations thereof. When using tow cotton linters or other types of fibers, they can be fibers from about 0.1 mm to about 5 mm in length.

In addition to the reinforcing components providing a contrasting touch to the touch, the reinforcing components can also provide additional benefits that could not be appreciated when using the dispersion alone. The enhancing components according to the present invention may also include flavorings, antibacterial agents, moisturizers, soothing, coloring agents, hydroxyethyl cellulose, medicines and their combinations. Such components will provide a common substrate having an improved dispersion feel combined with advantages that would not otherwise have been possible without the present technology. The present invention can use any or a combination of reinforcing components included in the additive composition according to the present invention. For example, reinforcing components can be added to the dispersion according to the present invention in an amount of from about 0.5% to about 30%, or from about 1% to about 20%, or from about 2% to about 10% by weight of the dispersion composition.

Reinforcing components can be added to the foamed chemical composition either before or after foaming the chemical composition. If desired, the level of reinforcing components is from about 0.5% to about 30%, or from about 1% to about 20%, or from about 2% to about 10%, by total dry weight of the additive composition.

When reinforcing components are used in combination with the additive compositions of the present invention, they allow increased softness without compromising strength. For example, if a cosmetic wipe is used as the substrate according to the present invention, the total logarithm increases from about 0.5 to about 18, and the GMT level from about 800 to about 1200 compared to substrates that have not been treated in the same way as in the present invention. As used herein, the term “GMT” refers to a combination of the processing direction and the transverse processing direction when determining the tensile strength. Expandable microspheres remain on the surface of both film and paper-based products, contributing to improved touch testing when consumers touch them under conditions of use.

III. Technological Additives

Technological additives according to the present invention include chemicals that can assist in the process of forming the treated substrate according to the present invention. Technological additives may slightly manifest themselves or may disperse in the final, processed substrate. Although they are included solely to support the manufacturing process of the processed substrates, they can also confer minor advantages to the base which are desired according to the present invention. For the purposes of this application, “processing aids” are additives used in the process of foaming or applying beneficial substances to a substrate and not used in the manufacturing process of the precursor substrate.

A. Frothers

Most commercial blowing agents are suitable for creating the foam of the present invention. Suitable blowing agents include, but are not limited to, both low molecular weight and polymeric materials in liquid form. Foaming agents can be anionic, cationic and nonionic. Depending on the function, these blowing agents can be divided into four groups:

1. Air capture tool - used to enhance the ability of a liquid (dispersion, solution, mixture, etc.) to capture air, which can be measured by determining the "degree of inflation". An illustrative list of blowing agents, without limitation, includes potassium laurate, sodium lauryl sulfate, ammonium lauryl sulfate, ammonium stearate, potassium oleate, disodium octadecyl sulfosuccinimate, hydroxypropyl cellulose, etc.

2. Stabilizer - used to increase the stability of air bubbles in the foam, depending on time and temperature; examples without limitation include sodium lauryl sulfate, ammonium stearate, hydroxypropyl cellulose, etc.

3. Wetting agent - used to enhance the wettability of the dried surface of the coated film. Examples include, but are not limited to, sodium lauryl sulfate, sodium laurate, disodium octadecyl sulfosuccinimate, etc.

4. Gelling agent - used to stabilize air bubbles in the foam by ensuring that the additional composition takes a gel shape, which serves to strengthen the cell walls. Examples include, but are not limited to, hydroxypropyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose, and other modified cellulose ethers.

Some blowing agents can perform more than one of the above functions. Therefore, it is not necessary to use all four blowing agents in the expandable additive composition. The choice of blowing agents depends on the chemical composition of the additive composition. For example, if the additive composition contains an anionic component such as HYPOD 8510 ^® , suitable blowing agents will have to be selected from either anionic or nonionic groups. If a cationic foaming agent is used to increase the foaming ability of the anionic additive composition, the cationic components in the foaming agent will form ionic bonds with the anionic components in the additive composition and cause the cationic foaming agent and the anionic additive composition to become insoluble in water due to the formation of bonds. On the other hand, if the additive composition contains cationic components, then anionic blowing agents are not suitable for use.

B. Additives for creping

Creping additives are chemical compositions that are added to the beneficial substances of the present invention to optimize the adhesion and release properties of the paper backing from the paper based product from the desiccant surface. They broadly fall under the following classifications:

1. Adhesive additive - used to increase the adhesion of a sheet of paper-based products to the surface of the desiccant. Examples include, but are not limited to, polyvinyl alcohol, polyacrylate, hydroxypropyl starch, carboxymethyl cellulose, cymol, polyvinylamine, copolymers or mixtures thereof.

2. Release additive - used to reduce the adhesion (improve release) of a sheet of paper-based product to (c) the surface of the desiccant. Examples without limitation include polyethylene glycol, polypropylene glycol, polyethylene oxide, polypropylene oxide, polyolefin, fluorinated polyolefin, copolymers and mixtures containing the above.

3. Curing additive - used to speed up or slow down the curing of a creping system, such as a plasticizer or hardener.

4. Lutensol A 65 N Iconol 24 7 ^® , hereinafter referred to as “Lutensol ^® " (from BASF ^® Chemical Company) can also be used to support creping within the scope of the present invention.

Foam generation process

Typically, in the preparation of foamed chemicals, a system is used that pumps both liquid and air into the mixer. A mixer kneads air into a liquid, producing a foam substantially containing many small air bubbles. Foam leaves the mixer and flows into the applicator.

One of the parameters for determining the quality of the foamed chemical composition is the degree of blowing, defined as the ratio of the volume of small air bubbles captured by the dispersion chemical to the volume of the dispersion before mixing. For example, if the degree of inflation is 10: 1 at a dispersion flow rate of 1 l / min, you can capture 10 l / min of air into its liquid and develop a total foam flow rate of 11 liters per minute.

To achieve a high degree of inflation, both mechanical mixing and the foaming ability of the additive composition are decisive factors. If a chemical is capable of holding or capturing a volume of air only up to a degree of blowing 5, no matter how powerful the foaming unit is, it will not be able to produce a stable foam having a degree of blowing 10. Any air beyond the degree of blowing 5 will be released from the foam system, as soon as mechanical stress is eliminated. In other words, any trapped air in an amount higher than the dispersion's ability to hold air will become unstable. Most of these unstable air bubbles will come out of the foam (elimination of bubbles) immediately after stopping mechanical mixing.

In FIG. 1 schematically shows a system 10 capable of generating a foamed chemical composition in accordance with the present invention. First foamable chemicals (e.g., HYPOD 8510 ^®, KRATON ^®, etc.) is placed in tank 12 for chemicals. The chemical tank 12 is connected to the pump 14. It may be desirable to modify the piping system 13 between the chemical tank 12 and the pump 14 so that foaming chemicals can be transferred to the pumps of two different sizes. Preferably, the chemical tank 12 is located at an elevated level above the pump 14 in order to keep the pump energized.

To start the foaming process at low speeds relative to the pump 14, you can use an optional small auxiliary pump (not shown). A larger main pump 14 is capable of producing flow rates up to 25 L / min for fluid flow rates at high application rates and / or for large quantities of additive composition. A smaller auxiliary pump (not shown) is capable of flow rates of up to about 500 cm ³ / min for low application rates and / or small amounts of additive composition.

A flow meter 16 is located between the pump (s) 14 and the foam mixer 18. The fluid flow rates are calculated based on the desired additive composition, the amount of solids in the chemical, the line capacity and the width of the application device. The flow rate may range from about 5: 1 to about 50: 1. When using a small auxiliary pump, its flow rate is in the range from about 10 cm ³ / min to about 500 cm ³ / min. When using the large pump 14, its flow rate is in the range from about 0.5 l / min to about 25 l / min. When using a small auxiliary pump, an air flow meter of 20 l / min is selected. When starting the larger main pump 14, an air flow meter of 200 l / min should be used.

In one aspect, a foam mixer 18 is used to knead air into a liquid mixture of expandable chemicals to create small air bubbles in the foam 18. Air is measured into system 10 using specific liquid flow rates and blowing rates, as discussed above. Desirably, a foam mixer 18 having a size of 25.4 cm (10 inches) is used to generate the foam. One possible foam mixer 18 is a CFS-10 inch Foam Generator from Gaston Systems, Inc., Stanley, North Carolina, USA.

Desirably, the rotation speed of the foam mixer 18 is limited to approximately 600 rpm. The speed of the mixer in rpm in this process depends on the ability of the additive composition to foam (i.e., on its ability to capture air with the formation of stable bubbles). If the additive composition foams easily, a lower rpm speed is usually required. If the additive composition does not foam easily, a higher rpm speed is usually required. A higher mixer speed helps to accelerate the balancing of the foam or the optimal degree of inflation. The normal speed in rpm for the mixer is 20% —60% of the maximum speed in rpm. The type and / or amount of blowing agent, in addition to the additive composition, also affects the speed requirements of the mixer.

The foam is checked for uniformity, stability and structure of the flow of bubbles. If the uniformity, stability and structure of the bubble flow does not meet the required standards, you can make adjustments in the flow rate, mixing speed, degree of inflation and / or chemical compositions of the solutions / dispersions before directing the foam into the device 24.

In one aspect of the invention, HYPOD 8510 ^® or other chemical compositions to be foamed and used for creping are mixed and added to the chemical tank 12. Diluted HYPOD 8510 ^® solutions (with a total solids content of <10%) and other difficult-to-foam chemicals usually require the addition of something that increases viscosity and foamability. For example, to produce a stable foam for evenly applying a desiccant surface onto a heated and impermeable surface of a rotating drum, hydroxypropyl cellulose or other foaming agents or surfactants can be used. Reinforcing components, such as silica gel particles or cotton liner tows, can be added to the additive composition in various ways, including without limitation: add to the additive composition before the additive composition is pumped into a foaming machine; introduce into the foam additive composition after the additive composition leaves the foaming machine, but before the foam additive composition is applied to the surface of the desiccant; or applied to the dryer before contacting the substrate with the additive composition. When the reinforcing components are introduced into the additive composition, it is necessary to constantly mix the mixture before adding it to the foaming machine in order to prevent the solid reinforcing component from settling to the bottom of the container. When the reinforcing components are introduced into the foamed additive composition, a suitable device is required to ensure uniform mixing of the reinforcing components and the foamed additive composition.

Substrates

Suitable substrate materials include, but are not limited to, a cosmetic wipe; a paper-based product not creped with dry air drying (UCTAD); paper towel; nonwoven HYDROKNIT ^® from Kimberly Clark Corporation, Nina, Wisconsin, USA; hydraulically laid cloths; air laid canvases; spunbond cloths; canvases meltblown; canvases made of material obtained by technology of conformal form; carded webs (BCW); continuous film; spanlace; film / laminated sheets; blades fastened by jets of water; and all types of paper, paper products, and other nonwoven products.

In the non-limiting examples discussed herein, a foamed chemical composition can be applied to a non-woven material such as a paper based product. The term “nonwovens” as used herein is intended to include a cosmetic towel, toilet paper, paper towels, spunbond, diaper, feminine sanitary napkins and their covers, napkins (such as hand and face wipes), and the like. A paper-based product can be made in various ways, with it including, without limitation, traditional thin paper from pressed felt; high-volume compacted screen-printed thin paper; and high-volume uncompressed thin-paper. Tissue products made therefrom may have a single layer or multi-layer structure, such as in US Pat. No. 2008/0135195. Another embodiment for forming a paper product according to the present invention uses a papermaking technique known as a technology that does not use dry-air creping ("UCTAD"). Examples of such a technique are disclosed in US Pat. No. 5,048,589 to Cook et al .; U.S. Patent No. 5,399,412 to Sudall et al .; US patent No. 5510001 issued by Hermans and others; U.S. Patent No. 5,591,309 to Rugowski et al .; and US patent No. 6017417 issued by Wendt and others.

Surface coating process

Unlike a process in which a diluted dispersion or solution is sprayed onto a desiccant surface, such as a Yankee-cylinder surface 23 (or other surface of a drying drum (not shown)), the foam composition can be applied onto the desiccant surface 23 using a process according to the present invention high in solids. In the present invention, air is used to dilute a beneficial substance containing any level of solids, while the viscosity is within the range that can be pumped by the foaming machine. For example, containing up to about 65% solids, up to about 50% solids, up to about 35% solids, or up to about 20% solids.

The high solids coating process of the present invention can demonstrate the benefits of a product or process, including without limitation, a softer surface due to the unique microstructure of the settled foam film layer, lower chemical losses due to the close and direct application of the foamed chemical composition, and no need in the use of soft or deionized water due to the high ratio of chemical composition to water (for example, a chemical such as HYPOD 8510 ^® , becomes unstable when exposed to a large amount of hard water, i.e., at a solids level of 1% or less); and lower drying energy required to dry the foamed chemical composition as well as the base sheet. Additional advantages caused by the addition of reinforcing components include, without limitation, uniformity of the entire film coating of a nonwoven substrate useful substance; improved adhesion of the entire coating with a useful substance to a non-woven substrate; increased mechanical strength of the entire coating with a film of a useful substance; and increased stability of the foam of the beneficial substance on the way from the foam generator block to the surface of the desiccant.

Foamed nutrients can be applied to the substrate in two ways: in-line application and in-line application. In in-line processes, the foam generator and application device will be involved in the manufacture of paper-based products, and foamed chemicals will be applied to any substrate during its manufacture. In-line application allows foamed chemical composition to be applied to those substrates that were made in the process without creping. For example, non-crepe dry air drying (“UCTAD”) toilet paper and melt-spun non-woven materials are suitable for use in a continuous flow application method.

As shown in FIG. 1, in one aspect of the invention, foamed chemicals are applied to the surface 23 of the desiccant through the application device 24. For uniform distribution of foam over the surface 23 of the desiccant, the device 24 for applying foam is placed close to the surface of the desiccant (0.64 cm or ¼ inch). This arrangement makes possible an improved direct contact of the foamed chemical composition with the desiccant surface 23, especially during high speed operations.

For applying the chemical composition to the surface 23 of the rotary dryer drum, it is most desirable to use a single parabolic application device 24. However, if, due to the variability of the desiccant or base sheet, varying levels of chemical application are required across the width of the desiccant surface, application devices (not shown) with several zones of miniature parabolic application devices can be used.

In general, the reinforcing component causes the appearance of a coating of an additive composition (i.e., the oceanic layer) of an innovative and improved touch test. For example, as an additive composition which is foamed / applied on the substrate surface without the reinforcing component can be used HYPOD 8510 ^®. In contact with its surface, it provides a significant increase in softness in comparison with the same paper-based product with a traditional chemical composition for creping. However, at the same time, it also feels a bit waxy or slippery. Some types of consumers may like this slippery feeling, but others may not have the desire for that feeling. Adding a reinforcing component can alter the sensation without compromising with increased softness. A touch test obtained through this approach includes, without limitation, cottoniness, velvety, fluffy and / or hairiness. Another advantage of adding a reinforcing component (s) is that the coating layer of the HYPOD 8510 ^® additive composition has increased strength, which is important when useful substances are applied to pre-prepared substrates, such as thermoplastic non-woven materials. Increased strength allows the coated film of beneficial substances to have a uniform and complete coating on the substrate.

In addition, it can be shown that the reinforcing components and the application method could be used to improve such a touch to the touch as softness, or to improve surface properties such as absorbency, friction, swelling, etc. In addition, other surface beneficial substances, such as perfumes, antibacterial agents, moisturizers, soothing agents, could be applied better than the HYPOD 8510 ^® composition alone could provide. Substrates containing both HYPOD 8510 ^® and polyvinylpyrrolidone-styrene were perceived as almost 1.5 logarithmic units, the risk ratios are softer (which is significant) than when using HYPOD 8510 ^® without any reinforcing components.

Applicants have found that IHR results for a substrate treated with HYPOD 8510 ^® foam with 6% silica gel particles as reinforcing components provide a substrate that produces the softest perceived results with a difference of more than 5 logarithmic units relative to an untreated substrate with a traditional chemical composition for creping. The next was the control of the substrate treated with HYPOD 8510 ^® foam without any reinforcing components, with a difference of more than 4 logarithmic units. All other foam-treated substrates were perceived as at least 3 logarithmic units softer than the control, non-foam-treated substrate.

Another advantage of adding reinforcing components is the huge increase in thickness that can be achieved, while at the same time maintaining or obtaining a greater tensile strength than for a substrate with a surface not treated with foam. All of these substrates were calendared under the same roll pressure as the pressure for the cosmetic wipes conversion process. The percentages listed next to the data points are the amounts of reinforcing components added to the composition based on the dry weight of the HYPOD 8510 ^® before foaming. It has been shown that foamed and creped substrates showed an additional increase in bulk compared to creped substrates not treated with foam, with the highest level increasing by almost 35%. Most substrates with reinforcing components increased swelling compared to a foam treated substrate containing only HYPOD 8510 ^® . All processing conditions, such as types of inserts, tilt angles and pressure loading, were the same.

Creping process

Creping is a part of the substrate manufacturing process, in which the substrate is cut off from the surface of a rotating dryer (for example, a Yankee cylinder) by means of a scraper mechanism. Creping can be done as described in U.S. Patent Application No. 13/330440 to Qin et al., Filed December 19, 2011.

Other useful factors

Useful substances according to the present invention can be used to provide many benefits that can be used to cover the substrate and provide the above benefits. In addition, there are other advantages provided by the present invention, which can be clearly identified and described as follows.

Print enhancement

A unique advantage provided by the present invention described herein is that it allows improved printing capabilities on a non-woven substrate. The additive composition can be applied so that it essentially forms a surface on the substrate, more like a film, and thus, the print is more compatible, and in some cases more lively. For example, spunbond is recognized for its tissue-like tactile properties, or sensation, however, it is not a substrate that has an advantage over film laminates when it comes to printing, since ink tends to spread or absorb into the material, reducing the ink coating visible on the substrate. Of course, a film laminar material is optimal for printing graphics, however, it is not optimal as a substrate that will be near the skin. Prior to the present invention, the solution for printing onto a nonwoven substrate was to apply a layer of a printed film to the substrate by adhesive. And although this was justified, it complicated the production process and increased costs. Therefore, the present invention provides a unique compromise in which tissue-like tactile properties, or sensation, of the substrate are not eliminated, but in addition, a surface is provided that allows increased printing capabilities with respect to the substrate. The present invention provides a relatively smooth surface, eliminating the pixel appearance of modern exterior coating materials. In addition, paint adhesion is improved. The substrates according to the present invention will have an improved paint coating of at least about 25%, at least about 50%, or at least about 75% compared to the untreated substrate. The present invention provides for an increased surface area, so that most of the substrate can be coated with printing ink, thereby improving the appearance or legibility of printing on the substrate in comparison with the untreated substrate. Modern surface printing for laminates with an external coating requires the use of special inks to avoid potential difficulties with ink curing. The present invention can be adapted to any commercially available ink used for printing on substrates. In addition, within the scope of the present invention, any conventional techniques suitable for printing can be used. Such techniques may include, without limitation, coating using an engraved cylinder, offset printing, screen printing, flexography, inkjet printing, laser printing, digital printing, and the like. Dispersions according to the present invention provide polar functional groups which are expected to improve ink adhesion and thus improve printing directly on non-woven substrates.

FIG. 2 shows an untreated spunbond that has been ink printed. (White spots are ink printed on spunbond fibers). For comparison: FIG. 3 shows a spunbond substrate that has been treated with a useful substance according to the present invention and printed with ink. It can be seen that the treated sample (Fig. 3) contains a film-like coating on the surface, which gives it a large area for coating the surface with ink, which leads to improved visual aesthetic properties in terms of legibility and print brightness. In an untreated spunbond, FIG. 2, only about 20% of the surface is coated with paint compared to 50% of the spanbond paint, FIG. 3, which was processed according to the present invention. These data were obtained by quantifying SEM images using image analysis software. The ink is able to adhere more densely and smoothly to the treated substrate and therefore improves the overall appearance of the print.

Increased puffiness and elasticity

In addition to improving the overall tactile feel of the non-woven backing, the present invention also allows to increase both bulk and bulk compared to the untreated backing. Without being limited by theory, in the substrates of the present invention, the swelling may be proportional to the bulk of the fibers. If the bulk weight increases, the folding of the fibers can stretch the thickness of the fibers in the Z direction and thus increase the bulkiness of the fibers. The fibers will rise, thereby increasing the bulkiness of the fibers. The beneficial substances of the present invention can, alone or in combination with certain creping mechanisms within the scope of the present invention, contribute to said increase in bulk and increase in weight. For example, without limitation, in comparison with an untreated spunbond substrate with a base weight of 12 g / m ² and a swelling of 13 cm ³ / g, the present invention can make it possible to demonstrate with a spanbond a bulk of 16 g / m ² and a swelling of 27 cm ³ / g (increase respectively 33% and 108%). Similarly, the creping mechanism and process can demonstrate even greater advantage and make it possible to demonstrate with a spanbond the main weight of 25 g / m ² and bulkiness of 25 cm ³ / g (or an increase of 108% and 92%, respectively). For example, the present invention allows nonwovens with a variable cellulose content to have an increase in base weight of more than at least about 20% to about 250% compared to an untreated substrate. For example, a nonwoven cellulose substrate has been shown to have a base weight of approximately 56 g / m ² and a hysteresis of 84%. However, the non-woven cellulose support of the present invention may exhibit a base weight of approximately 95 g / m ² (increase in base weight of approximately 70%) and hysteresis of approximately 74%. In addition to such useful substances as foamed dispersion HYPOD 8510 ^®, used in the present invention, in the continuation of the increase in bulk substrates according to the present invention may further contribute to the non-ionic surfactant such as Lutensol ^®. Lutensol ^® consists of the adduct of seven moles of linear ethylene oxide lauryl myristyl alcohol, which is also readily biodegradable. In addition, using a non-ionic surfactant such as Lutensol ^® , the present invention allows the use of foamed beneficial substance, such as HYPOD 8510 ^® dispersion, with a low level of addition, which is still uniformly sprayed over the entire surface of the substrate. However, the present invention allows to increase bulk with or without the addition of the addition to about 50% of nonionic surfactant such as Lutensol ^®. For example, in some embodiments of the present invention, approximately 500 mg / m ^{2 of a} foamed beneficial agent, for example, a HYPOD 8510 ^® dispersion, can be combined with approximately 250 mg / m ^{2 of a} nonionic surfactant such as Lutensol ^® (i.e., the ratio of nonionic surfactant to the beneficial substance is approximately 1: 2).

The “hysteresis” value used for this sample can be determined by initially stretching the sample to the required elongation, and then allowing the sample to contract in a controlled manner at the same speed. The magnitude of the hysteresis is the reduction or loss of energy during such a cyclic load. Percentage hysteresis (Hysteresis%) is calculated by integrating the area under the load curve (A _L ) and unloading (A _UL ), determining their difference and dividing it by the area under the load curve. Hysteresis% = (A _L –A _UL ) * 100 / (A _L ). These measurements are carried out using a “strip elongation test," which essentially meets the specifications of ASTM D5035-95. More specifically, this test uses two clamps, each of which contains two cheeks, with each cheek having an outer coating in contact with the sample. The clamps hold the material in the same plane, usually vertically, at a distance of 3 inches, and move the cross member with a given stretching speed. The sample size is from 3 inches to 6 inches, and the height of the outer coating of the cheeks is 1 inch high and 3 inches wide, and a constant speed is 10 inches / min. The sample is captured by an MTS electromechanical test frame (mechanical test system) with data acquisition capability. The test is carried out at ambient conditions both in the transverse and in the longitudinal direction of processing (CD and MD). The results are reported as average for at least five samples.

Without limiting the data shown, FIG. 4 illustrates one example of the present invention — foam treated and creped, using a water-jet knitted material as a substrate, having an elastic deformation of from about 22% to about 25% with an applied deformation of about 100% until there is any tear. For comparison, the control water-jet knitted material has an elastic deformation of approximately 15% and breaks when applied strain of approximately 25%. Similarly, without limiting the data shown in FIG. 5, the present invention — foam treated and creped using a spunbond as a substrate — has an elastic deformation of from about 27% to about 55% when stretched by about 100% compared to a control sample that stretches only to elastic deformation of about 18% at tensile before breaking approximately 50%. Without limiting the data shown, FIG. 7 shows the elastic tension (shape recovery) in the direction (MD) of the treatment, depending on the applied strain. The present invention shows an increase in tension because of the presence of the foamed dispersion HYPOD ^® 8510 in combination with Lutensol ^®, foamed on the paper substrate. The present invention unexpectedly shows an elastic tensile of about 30% with an applied strain of about 80%, while a base paper-based pulp article shows an elastic tensile of no more than only about 8% with an applied strain of about 18%. Without limiting the data shown, FIG. 8 shows a comparison of lateral strain (CD) versus applied strain for a paper based product of the present invention compared to an untreated paper backing. As shown, the present invention, using the HYPOD 8510 ^® dispersion in combination with Lutensol ^® on a paper backing as the foamed nutrient, has the highest elastic stretch up to failure compared to the base pulp paper product.

Thus, although untreated nonwoven substrates may exhibit elongation or elongation at break, they usually do this at earlier stages of elongation. In general, conventional untreated substrates can exhibit elongation at break from about 8% to about 45%. However, the present invention allows substrates treated as described herein to exhibit an elongation at break greater than about 45% elongation at break. For example, the present invention may exhibit an elongation at break of from about 45%, or from about 47% to about 55%, to about 80%, to about 280%, to about 337%, or to about 350%. Especially for some substrates where elongation at break is usually low, the present invention can provide elongation at break of about 25%, about 30%, about 35%, about 38%, about 45%, or about 47%. Such elasticity can particularly serve as an example in paper substrates according to the present invention.

The nonwoven substrates of the present invention will exhibit a hysteresis reduction of at least about 5%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60 %, at least about 70%, or at least about 100% in comparison with a similar untreated substrate. An increase in swelling by at least about 20%, at least about 25%, at least about 50%, at least about 70%, at least about 80%, at least about 90%, at least at least about 100%, at least about 110%, at least about 125%, at least about 200%, at least about 225%, or at least about 250% in comparison with the untreated substrate as defined in the described This document bulk test.

Again, the present invention will increase the bulk and / or elasticity in the substrate with or without Lutensol ^® and can exhibit bulk and / or elasticity foamed dispersion HYPOD ^® 8510 itself. Without limitation, an untreated substrate of water-knit material can exhibit hysteresis of approximately 87% and elongation at break of approximately 25%. The water-knit backing of the present invention, however, may exhibit hysteresis of approximately 67% and elongation at break of approximately 337%. Similarly, an untreated spunbond substrate may exhibit 100% hysteresis and a tensile elongation of approximately 45%, while a spunbond substrate according to the present invention may exhibit a hysteresis of approximately 40% and a tensile elongation of approximately 280%. Thus, the present invention provides enhanced versatility by allowing substrates that usually do not provide elasticity to not only have the ability to stretch, but also to easily restore shape and go beyond the usual and expected essence of a similar substrate that has not been processed by the present invention.

A material with greater elastic deformation has greater elasticity or energy of elastic deformations. The substrates according to the present invention can exhibit an increased tensile strength of the applied deformation by at least about 25%, at least about 50%, at least about 75%, or at least about 100% compared to the untreated substrate. Although various substrates will vary, it is clear that the present invention enables improved stretching compared to substrates that have not been suitably treated. For example, untreated waterjet knitted material can withstand approximately 15% elongation by applied deformation of approximately 25%. With an applied strain of approximately 50%, the same untreated water-jet knitted material is not able to withstand tensile without breaking. The water-knit material of the present invention can withstand approximately 12% elongation at an applied strain of approximately 25%, approximately 18% elongation at an applied strain of approximately 50%, approximately 21% elongation at an applied strain of approximately 75%, and approximately 23% elongation at applied strain of approximately 100%. Similarly, untreated spunbond can withstand approximately 10% elongation with an applied strain of approximately 25% and approximately 16% elongation with an applied strain of approximately 50%. With an applied strain of approximately 75%, however, the same untreated spunbond is not able to withstand stretching without breaking. However, the spunbond according to the present invention can withstand approximately 17% elongation with an applied strain of approximately 25%, approximately 36% elongation with an applied strain of approximately 50%, approximately 46% elongation with an applied strain of approximately 75%, and approximately 54% elongation with an applied strain of approximately 100%.

Increased tensile with elastic contraction ability

Currently existing elastic film laminates, such as those described in US Pat. No. 8,287,677, issued to Lake et al. On October 16, 2012, incorporated into personal care products, use exterior coatings that are not elastic or extensible. As a result, the elastic film (and this is also the case of the execution of elastic filaments) must be stretched before lamination of the outer coatings, and then weakened. As a result of stretching / loosening the film, elastic laminate materials tend to be more puffy than traditional textile materials. In addition to the increase in puffiness, the appearance of the elastic laminate is dictated by the location of the binder used for lamination. The visual impression is most similar to the successively folded peaks and troughs. Foldings, as they are known in the art, are usually visible along the cuffs and belts of disposable personal care products, such as, without limitation, feminine hygiene products, incontinence products and diapers. Customer feedback shows that materials that are thin, able to fold and have tissue-like visual and tactile aesthetic properties are highly desirable. So, a smoother elastic zone that looks more like underwear due to the reduction or absence of wrinkles is more desirable. In addition, the elastic film laminates lie on top of the inelastic outer coating, driving the perception of tissue-like aesthetic properties (visual and tactile). Currently, approaches to modifying the aesthetic properties of laminate exterior coatings rely on post-lamination processing (for example, rolled products in shaped gauges) or on the use of materials with a high basis weight (in particular, carded webs that are not cost effective). Thus, the outer coating material, stretchable, having a relatively low base weight and providing for swelling, gives a more tissue-like appearance and tactile properties, and also provides an excellent opportunity to contain film laminated materials that mimic traditional textile products, i.e. looking more like woven underwear. The present invention provides such a solution by providing a creped non-woven substrate having improved tensile properties and increased bulk to produce an article, in particular an elastic film laminate, for an article with reduced or absent folds. Non-woven substrates in combination with an elastic film not pre-stretched, in order to create an elastic laminate according to the present invention can demonstrate the elimination of folding (reduction of folding by 100%) or at least a reduction of folding from at least about 5%, by at least about 10%, from at least about 25%, or from at least about 50% in comparison with the untreated substrate. Creped outer coatings can also be used in work clothes and in medical clothing (especially from the side of the garment facing the body) to improve the perception of softness and a more fabric-like texture for improved visual and tactile sensations. Creping can also provide opportunities for improved dehumidification depending on the non-woven substrate used as the outer coating.

Thus, in addition to the aforementioned improvements in the form of increased softness and increased swelling, the present invention makes it possible to crepe non-woven substrates such as spunbond, carded canvas, spunlace, etc., leading to the development of structures with improvements such as higher swelling and improved tactile and visual aesthetic properties. Since the present invention provides a film layer of settled mineral foam on non-woven substrates, it allows the non-woven material to maintain a creped structure, which should be advantageous during the lamination process. Structural evaluation of non-woven materials, such as spunbond, using the present invention, shows that the coating with a layer of useful substance essentially remains on one side, in particular on the outer surface, of the non-woven material. The beneficial substance according to the present invention is concentrated mainly on the tops of the creped material, which may coincide with the binding points with the nonwoven material. The creped nonwoven fabric exhibits longitudinal extensibility (with a certain level of shape recovery) and more tissue-like visual aesthetic properties, since the external manifestation of the binding points (if any) on the nonwoven fabric is minimized and, thus, reduces folding. When applying a layer to elastic films / threads (without the need for preliminary stretching of the elastic material), the result is a laminated sheet that can be included in the product, for example a disposable personal care product that looks and feels like underwear, but provides protection and controlled hygiene the quality of a disposable product. Although not limited to such products, in the case of disposable products for use in incontinence, adults may require a product less like a diaper that folds at the waist and legs when worn to provide a more discreet wearing and sensation.

The possibility of creping the outer coating of a tensile and contractible non-woven material was advantageously used for the manufacture of pre-stretched (with no or fewer folds) elastic layered materials. For manufacturing these laminates creped nonwovens according to the present invention (e.g., spunbonded material is coated with a layer of a beneficial agent comprising HYPOD ^® 8510) with an adhesive laminated on one or both sides of the elastic film. As a result, the beneficial substance can be applied in the form of a layer on the side of the creped substrate, which is attached to the film, to obtain tactile and visual signs of layered materials, which are a tissue-like material with greater bulkiness. Since the film layer is not stretched or shortened, the bulk of the film can be adjusted to meet the requirements of physical properties rather than the requirements of the process. The present invention provides creped nonwoven substrates made from a variety of raw materials. Of particular interest are non-woven materials made from polypropylene, polyamides, polyesters, polyethylene, propylene / ethylene copolymers and other blends of polyolefins. In addition, the creping level can be adjusted to provide variable degrees of elongation MD, making possible elastic layered materials with different tensile / shape recovery values.

The use of creped substrates according to the present invention also makes it possible to improve the visual and tactile aesthetic properties of resilient film laminate materials, such as those used in external coating materials in personal care products, such as without limitation feminine hygiene products, incontinence products and diapers. The adhesive lamination of creped outer coatings provides a more puffy, tissue-like appearance and tactile properties without the need for materials with a high base weight.

The present invention demonstrates improvements not found in substrates that have not been treated with the agents contemplated by the present invention. As described, the improvements according to the present invention in comparison with untreated substrates can be selected from improved tactile sensations, such as softness and the like, improved printing, reduced hysteresis, increased bulkiness, increased elasticity / extensibility, increased ability to reduce, reduce wrinkles and their combinations.

Other additives

Non-woven substrates according to the present invention may contain additional compositions added to provide additional benefits over such aforementioned as softness, improved printing, elasticity and bulkiness. Compositions can be added to substrates treated with a useful substance to support the overall performance of the substrate. More specifically, in products such as personal care products, additive compositions can contribute to the performance or user experience of the product as a whole.

Rheological modifiers of body fluids

An advantage of providing a rheological modifier of body fluids is the support of the nonwoven substrates of the present invention when handling fluids including blood components, such as without limitation feminine hygiene products and wound dressings. Rheological modifiers of body fluids include, without limitation, mucolytic agents, mucin modifiers, red blood cell modifiers, and the like, as well as combinations thereof. The rheological modifiers of body fluids according to the present invention include a variety of compositions or substances capable of interacting with body fluids to support the interaction of body fluids with a substrate. For example, mucolytic agents are known to break down critical disulfide intramolecular and / or intermolecular bonds in the mucus glycoprotein or mucin component of the menstrual fluid, thereby significantly reducing the viscoelasticity of the mucus. Such agents have been described in US Pat. No. 7,687,681 to DiLuccio et al., March 30, 2010, and are suitable for this document. Mucolytic agents can also modify mucin by cleaving the protein skeleton, modifying the three-dimensional structure and reducing the entanglement in the structure of mucin. These agents include non-ionic surfactants such as Lutenzol ^® , enzymes such as papain, and carbohydrates such as dextran, which are further described in US Pat. No. 8,044,255, issued to Potts et al. On October 25, 2011, respectively. US No. 6060636 issued by Yahiaoui et al. May 9, 2000, and US Patent No. 7928282 issued by Dibb et al. April 19, 2011. Mucolytic agents of the present invention include, without limitation, L-cysteine, thioglycolates, dithiotriacol, and combinations thereof. The rheological modifiers of body fluids can be used in the present invention in amounts of from about 0.1% or from about 0.2% to about 5% or up to about 20% by weight of the composition of beneficial substances.

In some substrates, the nonwoven material may exhibit pore blockage caused by red blood cells, which results in a decrease in the ability of the substrate to receive and absorb liquids. There are also red blood cell modifiers that can reduce viscosity and also reduce clogging of pores. They include, without limitation Glucopon 220 ^®, PLURONIC ^®, as well as those disclosed in U.S. Patent № 6,350,711, issued to Potts et al. February 26 2002 In addition, when the substrate is used to capture body fluids, including without limitation the red blood cells, clogging of pores may result in increased leakage. Thus, adding such a composition to a nonwoven substrate according to the present invention can improve the end user experience, thereby creating an advantageous substrate product.

Release agents

In order to prevent the attachment of viscoelastic fluids to the skin, such as menstrual fluid and excrement, release agents may be added. Release agents may comprise at least one viscoelastic material, at least one release agent, or combinations thereof, and may be added to the nonwoven substrate of the present invention. Release agents are described in US Pat. No. 7642396 to Schroeder et al., January 5, 2010. More specifically, release agents act to prevent adhesion of menstrual fluid and / or fecal material to the skin, respectively, in the labial and perianal areas during and after menstruation or defecation. Suitable viscoelastic properties materials include, but are not limited to, bound enzymes, alkyl polyglycosides containing 8-10 carbon atoms in the alkyl chain, bovine lipid extract surfactant, dextrans, dextran derivatives, and combinations thereof. Suitable release compounds according to the present invention include, but are not limited to, alginic acid, beta-benzylidenebutyric acid, plant materials, casein, farnesol, flavones, fucans, galactolipids, kininogen, hyaluronates, inulin, iridoid glycosides, nanoparticles, perolecano-oligonucleotides, tyrolecoamide, tyrolecoamide, tyrolecoamide, thiolecodioxide, tyrolecoamide, thiolecodioxide, tyrolecoamide polymethyl methacrylate, silicone, sulfated exopolysaccharides, tetrachloride decoxide and combinations thereof. Release agents may be added to the nonwoven substrates of the present invention in an amount of from about 0.01% to about 25% by weight of a viscoelastic material or release agent. Other quantity options include from about 0.05% to about 10%, or from about 0.1% to about 8%, or from about 0.1% to about 5% by weight of viscoelastic material or release material .

Deodorizing materials

In accordance with the present invention, any variety of deodorizing materials capable of imparting a deodorizing property to a nonwoven substrate can be used. This use of deodorization is especially useful in absorbent personal care products. For example, deodorizing materials may be a deodorizing mixture consisting of an anhydrous mixture of basic, pH neutral and acidic odor absorbing particles described in US Pat. No. 5,342,333 to Tanzer et al., August 30, 1994, or US Pat. No. 5,364,380 issued by Tanzer et al. November 15, 1994. Suitable deodorant materials according to the present invention may also contain deodorant systems that reduce odor by acting on foul-smelling substances in the substrate (such as an absorbent article) or weakening odor by acting on the nose user receptors, as described in U.S. Patent Application No. 2008249490 to Carlucci et al., filed October 9, 2008. Other deodorizing materials of the present invention may also contain deodorizing systems providing extended deodorization by focusing on materials with high and low volatility, such as the materials described in US Patent Application Serial No. 2008071238 to Sierri et al., filed March 26, 2008. Deodorizing materials are also described in US Patent No. 8066956, issued to Do et al. on November 29, 2011, and in US Pat. US No. 6926862 issued by Fontenot et al. August 9, 2005. The deodorizing materials of the present invention include, but are not limited to, ammonia neutralizers, functional flavors, chelating agents, particles of inorganic oxides such as silica, alumina, zirconia, magnesium oxide, titanium dioxide , iron oxide, zinc oxide, copper oxide, baking soda (sodium bicarbonate), activated charcoal, activated carbon, diatomaceous earths, zeolites, clays (e.g. smectite clays), and combinations thereof. Deodorizing materials may be present in amounts of from about 2 g / m ² to about 80 g / m ² , from about 8 g / m ² to about 40 g / m ^2, or from about 12 g / m ² to about 30 g / m ² depending on the main weight of the non-woven substrate.

EXAMPLES

The following examples further describe and demonstrate embodiments within the scope of the present invention. The examples are provided solely for the purpose of illustration and should not be construed as limitations of the present invention, since many of their changes are possible without deviating from the essence and scope of the present invention.

EXAMPLE 1

Commercial HYPOD ^® dispersion was diluted with water to a solids level HYPOD ^® 30%, and then foamed by Gaston block. Stable foam was applied to the hot drum surface of a 60-inch calendaring desiccant. The cured dispersion HYPOD ^® creped from the dryer surface. Spunbond base sheets were creped using the foaming process described herein according to the present invention. Bases sheets coated HYPOD ^®, then imprinted blue paint, the paint 100 parts was mixed with 4.5 parts by weight of crosslinker. Samples were hand-printed using an anilox roll of 10.8 billion cubic meters. microns (billion cubic microns).

Foaming process conditions:

Solids in dispersion,%: 10-30% HYPOD8510®

Dryer Temperature: 260-300 ° F

Dispersion flow rate: 100-500 cm3 / min

Mixer speed: 20-60%

Degree of inflation: 5-30

To quantify the surface coverage of the paint on both an untreated spanbond and a spanbond treated with a useful substance according to the present invention, image analysis was performed on SEM images. As shown in table 1, the processed samples show a greater% of the surface coverage of the paint than untreated spunbond.

Table 1

Substrate Coating% Spunbond Control A (8 g / m ² ) 14.00 Spanbond Control B (12 g / m ² ) 17.00 Foam Spanbond (8 g / m ² ) 61.00

EXAMPLE 2

The HYPOD 8510 ^® commercial polyolefin dispersion was diluted with water to HYPOD 8510 variable solids levels either without or with 50% Lutensol ^® A 65 N ICONOL ^® 24 7 based on solids in HYPOD 8510 ^® . This chemical composition was then foamed with a Gaston Systems foaming unit and stable foam was applied to the hot surface of a 60-inch desiccant. The base sheet was then pressed against the desiccant surface covered with settled foam, creped from the desiccant surface and wound on a drum reel.

The base sheets, namely a cellulose-based towel, HYDROKNIT ^® water-knit material, spunbond, were used to create stretch materials using a process controlled by the geometry of the creping scraper and / or the extrusion coefficient.

Foaming process conditions:

Solids in dispersion,%: 5-30% HYPOD 8510 ^®

Desiccant Temperature: 230-300 degrees Fahrenheit

The dispersion flow rate: 50-500 cm ³ / min

Mixer speed: 20-60%

Degree of inflation: 5-30

Mechanical Test - Hysteresis%:

The test was performed using an MTS dynamometer, Insight Model EL1. A 3-inch wide test specimen was stretched at a rate of 10 inch / min to a strain of 20%, and then reduced at the same speed to a strain of 0%. The area under the load and unload curve was measured as% hysteresis as shown in Tables 2 and 3. In addition, Table 3 shows the elongation at break for each of the tested substrates.

table 2

% Hysteresis for creped cellulose towel

The main weight (g / m ² ) Hysteresis,% Average Standard deviation The control 56 84 ± 0.6 Foam treated cellulose 95 74 ± 0.7

Table 3

% Hysteresis for creped spunbond, waterjet knitted material and cellulose cosmetic wipes

Hysteresis,% Elongation at break,% Control water-jet knitted material 87 25 Water-jet knitted foam treated material A 70 153 Water-jet knitted foam material B 66 337 Control spanbond one hundred 45 Foam Spanbond A 42 124 Foam Spanbond B 40 280 Control Cosmetic Wipes 95 29th Foam-treated napkin 65 47

Mechanical test - Energy of elastic deformations:

The test was performed using an MTS dynamometer, Insight Model EL1. A 3-inch wide test specimen was stretched at a rate of 10 in / min through several cyclic loading and unloading curves to increasing deformations (25, 50, 75 and 100%). The amount of permanent deformation was measured after each cycle in accordance with the applied deformation (inch / inch) for each cycle, as shown in table 4.

Table 4

Elastic deformation at a given applied deformation

Applied Warp (inch / inch) 0.25 0.50 0.75 1.00 Control water-jet knitted material 0.15 0.00 0.00 0.00 Water-jet knitted foam treated material A 0.12 0.18 0.21 0.23 Water-jet knitted foam material B 0.10 0.17 0.22 0.25 Control spanbond 0.10 0.16 0.00 0.00 Foam Spunbond A 0.16 0.28 0.30 0.28 Foam Spanbond B 0.17 0.36 0.46 0.54 Control Cosmetic Wipes 0.06 0.00 0.00 0.00 Foam-treated napkin 0.12 0.16 0,03 0.00

EXAMPLE 3

Swelling was measured by quantifying the base weight (g / m ² ) and swelling (cm ³ / g) by measuring the weight and thickness of the material. The results are shown in table 5.

Table 5

The code The main weight (g / m ² ) Swelling (cm ³ / g) Control spanbond 12 13 Foam Spanbond A 16 27 Foam Spanbond B 25 25

Test methods

(1) Manual tactile ranking test (IHR test):

The Manual Ranking Test (IHR) is a basic manual assessment of the sensation of fibrous webs, in which features such as softness are evaluated. This test is useful in obtaining a quick indication as to whether a process change is detectable by a person and / or whether it affects the perception of softness compared to control. The difference in IHR softness data between the treated web and the control web reflects the degree of softness improvement.

An expert group of testers was prepared to conduct a more accurate assessment than the average unprepared consumer could provide. The ranked data generated by the expert group for the code for each sample was analyzed using a proportional risk regression model. Based on the calculations, this model assumes that a member of the expert group goes through the ranking procedure from the highest value of the attribute being evaluated to the lowest value of this attribute. Softness test results are presented as logarithm values. The logarithm is the natural logarithm of the risk relationship, evaluated for each code, based on the regression model of proportional risks. Large values of the logarithms indicate that the sign of interest is perceived with greater intensity.

Since IHR results are expressed in logarithms, the difference in increased softness is actually much more significant than these data indicate. For example, when the difference in IHR data is 1, this actually means a 10-fold (10 ¹ = 10) increase in overall softness, or its improvement relative to control by 1000%. In another example, if the difference is 0.2, then it represents 1.58 times (10 ^0.2 = 1.58) or an improvement of 58%.

IHR data can also be presented in rank format. These data can usually be used to make relative comparisons in tests, since the ranking of the product depends on the products among which it is ranked. Comparisons between tests can be made when at least one product is tested in both tests.

(2) The test of puffiness

Sheet puffiness was calculated as the quotient of the sheet thickness for the conditioned fibrous sheet, expressed in microns, divided by the conditioned bulk, expressed in grams per square meter. The resulting puffiness of the leaf is expressed in cubic centimeters per gram (cm ³ / g). More specifically, the sheet thickness is the representative single sheet thickness measured in accordance with the TAPPI test methods: T402 "Standard Conditioning and Testing Atmosphere For Paper, Board, Pulp Handsheets and Related Products" and T411 om-89 "Thickness (caliper) of Paper, Paperboard, and Combined Board ”with Note 3 for stacked sheets. The micrometer used to test the T411 om-89 was the Emveco 200-A Tissue Caliper Tester, available from Emveco, Inc., Newburgh, Oregon, USA. The micrometer has a load of 2 kilopascals; the area of the clamping device is 2500 square millimeters; diameter of the clamping device 56.42 mm; time delay of 3 seconds; and a lowering speed of 0.8 millimeters per second.

(3) Viscosity Test

Viscosity was measured using a Brookfield Viscometer viscometer, model RVDV-II +, available from Brookfield Engineering Laboratories, Middleborough, Mass., USA. Measurements were taken at room temperature (23 ° C) at a speed of 100 rpm, or with rod 4, or with rod 6, depending on the expected viscosity. Viscosity measurements are reported in units such as centipoise.

(4) Testing the amount of additive composition HYPOD 8510 ^®

In one aspect of the invention, the added HYPOD element was determined using acid decomposition. The samples were wet-wetted with a sufficient amount of concentrated sulfuric and nitric acids to break down the carbon-containing material, and potassium ions were extracted from the cellulose matrix. Potassium concentration was then measured using atomic absorption analysis. The added HYPOD 8510 ^® elements were determined by assigning the HYPOD 8510 ^® potassium concentration in the sample to volume measurements of the HYPOD 8510 ^® from the control solution of the HYPOD 8510 ^® dispersion (LOTVB1955WC30, 3.53%).

 (5) A method for determining the content of an additive composition in a paper based product.

Samples were decomposed following the 3010A EPA method. This method consists in splitting a known amount of material with nitric acid in a block digester and bringing it to a known volume at the end of decomposition.

The analysis was performed on a flame atomic absorption spectrophotometer using the 7610 EPA method, dated July 1986, which is a direct atomization method using an air-acetylene flame. The tool used was VARIAN AA240FS, available from Aligent Technologies, Santa Clara, California, USA.

The analysis was performed as follows: The instrument was calibrated using a blind sample and five standards. To confirm calibration standards, calibration was followed by analysis of the secondary reference standard. In this particular case, the convergence was 97% (with an acceptable convergence of 90-110%). Then, a blind decomposition sample and a decomposition standard were analyzed. In this particular case, the blind sample was less than 0.1 mg / L, and the standard convergence was 93% (with an acceptable convergence of 85-115%). Then the samples were analyzed and, after every tenth sample, the standard analysis was started (allowable convergence of 90-110%). At the end of the whole analysis, blind assay and standard assay was run.

 (6) Base weight

The main weight of the paper sheet samples was determined using the modified TAPPI T410 procedure. The samples preliminarily folded several times were conditioned at 23 ° C ± 1 ° C and a relative humidity of 50 ± 2% for at least 4 hours. After conditioning, a stack of 16-3 "× 3" preliminarily folded several times samples was cut using a die cutter and a connected cutter. This represents a sample area of a sheet of paper-based paper product of 144 square inches or 0.0929 m ² . Examples of suitable punching presses are a TMI DGD punching press manufactured by Testing Machines, Inc. with a location in Iceland, New York, USA, or a Swing Beam testing machine manufactured by USM Corporation with a location in Wilmington, Massachusetts. Torch size tolerances are ± 0.008 inches in both directions. A stack of samples was then weighed to the nearest 0.001 grams on a calibrated analytical balance. The basic weight in grams per square meter (g / m ² ) was calculated by the following equation:

Base weight (conditioned) = stack weight in grams / (0.0929 m ² )

(7) Geometric average of tensile strength (GMT)

The geometric mean tensile strength (GMT) is the square root of the product of the tensile strength in the longitudinal (MD) direction of dry processing, multiplied by the tensile strength in the transverse direction (CD) of dry processing, and is expressed in grams by 3 inches sample width. The tensile strength MD is the peak load on a 3-inch wide specimen when the specimen is stretched to break in the longitudinal direction of processing. Similarly, the CD tensile strength is the peak load on a 3-inch-wide specimen when the specimen is stretched to break in the transverse direction of processing. Tensile curves were obtained under laboratory conditions of 23.0 ° C ± 1.0 ° C at a relative humidity of 50.0 ± 2.0% after the samples of paper-based products were balanced under test conditions for a period of at least four hours .

The tensile strength test specimens were cut into strips of 3 inches (76 mm) wide and at least 5 inches (127 mm) long in the orientation both in the longitudinal direction (MD) of the treatment and in the transverse direction (CD) of the treatment using JDC Precision Sample Cutter (Thwing-Albert Instrument Company, Philadelphia, PA, USA, Model No. SC130). Tensile tests were measured on an MTS Systems Synergie 100 machine, run with TestWorks ^® 4 software, version 4.08 (MTS Systems Corp., Eden Prairie, Minnesota, USA).

The load sensor was selected with a maximum of either 50 Newtons or 100 Newtons depending on the strength of the test sample so that most peak loads fall in the range of 10–90% of the full scale of the load sensor. The measuring base between the cheeks was 4.00 ± 0.04 inches (102 ± 1 mm). The cheeks were driven using a pneumatic drive and were coated with rubber. The minimum grip width is 3 inches (76 mm) and the approximate cheek height is 0.5 inches (13 m). The traverse speed is 10.0 ± 0.4 inch / min (254 ± 10 mm / min), and the tensile sensitivity is set at 65%.

The sample was placed in the grip of the device with centering vertically and horizontally. Then the test was started and completed when the sample was broken. Peak load was recorded either as the “tensile strength MD” or the “tensile strength CD” of an instance depending on the direction in which the sample was tested. Ten (10) instances of each sample were tested in each direction with an arithmetic mean of the article as the tensile strength of either MD or CD. The geometric mean tensile strength was calculated from the following equation:

GMT = (MD Break × CD Break) ^1/2

The geometric dimensions and values disclosed in this document should not be understood as strictly limited to the stated exact numerical values. Instead, unless otherwise indicated, each such geometric dimension is intended to mean both a quoted value and a functionally equivalent interval surrounding that value. For example, a geometric dimension disclosed as “40 mm” is intended to mean “approximately 40 mm”.

All documents cited in the section "Detailed Description of the Invention", in the corresponding part, are incorporated herein by reference; citation of any document should not be construed as recognition that it relates to the prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document is contrary to any meaning or definition of a term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall prevail.

Although particular embodiments of the present invention have been illustrated and described, it should be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the present invention. Therefore, it is intended that the appended claims cover all such changes and modifications that are within the scope of the present invention.

Claims (47)

1. A nonwoven substrate for use in absorbent products, comprising: a fibrous web defining a surface; and a layer of a useful substance, wherein said useful substance is an additive composition; wherein said beneficial agent is foamed and bonded to said surface of the fibrous web by a creping process such that the additive composition on said substrate forms a surface that is more like a film than said substrate; and wherein said non-woven substrate is printed and exhibits improved printing compared to an untreated substrate. 2. The non-woven substrate according to claim 1, characterized in that it demonstrates a decrease in hysteresis by at least about 5%, an increase in swelling by at least about 40%, and combinations thereof in comparison with an untreated substrate. 3. The non-woven substrate according to claim 1, characterized in that the fibrous web is selected from the group consisting of a paper-based product obtained by air-drying a paper-based product, a paper towel obtained by water-jet bonding of the fabric, spunbond, meltblown obtained by the technology of conform material, carded canvas, air-laid material, laminated materials, paper and composite combinations of the above. 4. The nonwoven substrate according to claim 1, characterized in that said additive composition is a polymer dispersion selected from dispersions of polyolefins, dispersions of SEBS copolymers, dispersions of polyisoprene, dispersions of block copolymers of polybutadiene and styrene, dispersions of latexes, dispersions of copolymers of polyvinylpyrrolidone and styrene, copolymers of polyvinyl alcohol and ethylene, and combinations thereof. 5. The nonwoven substrate according to claim 1, characterized in that said useful substance further comprises a reinforcing component selected from microparticles, expandable microspheres, fibers, additional dispersions of polymers, perfumes, antibacterial agents, moisturizers, medicines and soothing. 6. The nonwoven substrate of claim 4, further comprising a reinforcing component added to the polymer dispersion in an amount of from about 0.5% to about 30% by weight of the dispersion. 7. The nonwoven substrate according to claim 1, characterized in that the additive composition is a water-insoluble polyolefin copolymer selected from ethylene acrylic acid, a copolymer of polyethylene and octene, and combinations thereof. 8. The nonwoven substrate according to claim 1, characterized in that the additive composition is selected from a synthetic water-soluble polymer, a natural water-soluble polymer, and mixtures thereof. 9. The nonwoven substrate according to claim 8, characterized in that the additive composition is a synthetic water-soluble polymer selected from polyalcohols, polyamines, polyimines, polyamides, polycarboxylic acids, polyoxides, polyglycols, polyethers, polyesters, their copolymers and mixtures. 10. The nonwoven substrate according to claim 8, characterized in that the additive composition is a natural water-soluble polymer selected from modified cellulose, modified starch, modified protein, chitosan, salts of chitosan, carrageenin, agar, gellan gum, guar gum, and combinations thereof. 11. The non-woven substrate according to claim 1, characterized in that it exhibits an improved ink coating of at least about 25% while improving the appearance of printing on said substrate. 12. The non-woven substrate according to claim 1, characterized in that it exhibits an increase in swelling from about 20% to about 250% when determined by the swelling test. 13. The non-woven substrate according to claim 4, characterized in that in a ratio of approximately 1: 2, a non-ionic surfactant is combined with the additive composition. 14. The nonwoven substrate according to claim 1, characterized in that it exhibits an elastic deformation capable of withstanding tensile stress by an applied deformation of from about 25% to about 100% before rupture. 15. The nonwoven substrate according to claim 1, characterized in that it exhibits an elongation at break of more than about 45%. 16. The nonwoven substrate according to claim 1, characterized in that it is combined with a pre-stretched elastic film to create an elastic layered material with a reduction in wrinkles from about 5% to about 100%. 17. The nonwoven substrate of claim 1, further comprising from about 0.1% to about 20% of a rheological modifier of body fluids. 18. The nonwoven substrate according to claim 17, characterized in that the rheological modifier of body fluids is selected from mucolytic agents, wherein said mucolytic agents are selected from L-cysteine, thioglycolates, dithiotriacol, and combinations thereof; mucin modifiers; red blood cell modifiers; and their combinations. 19. The non-woven substrate according to claim 1, additionally containing a release agent selected from from about 0.01% to about 25% of at least one material that affects the viscoelastic properties, wherein said material that affects the viscoelastic properties is selected from enzymes, alkylpolyglycosides containing 8-10 carbon atoms in the alkyl chain, bovine lipid extract surfactant, dextrans, derivatives of dextrans and combinations thereof; at least one anti-adhesive compound, wherein said anti-adhesive compound is selected from alginic acid, beta-benzylidenebutyric acid, substances of plant origin, casein, farnesol, flavones, fucans, galactolipid, kininogen, hyaluronate, inulin, iridoid glycosophane, nanoparticles, nanoparticles oligodeoxynucleotides, poloxamer 407, polymethyl methacrylate, silicone, sulfated exopolysaccharides, tetrachloride decoxide and combinations thereof; and their combinations. 20. The nonwoven substrate of claim 1, further comprising from about 2 g / m ² to about 80 g / m ^{2 of} deodorizing material. 21. Non-woven substrate for use in absorbent products, containing: fibrous web defining a surface; and a layer of a useful substance, wherein said useful substance is an additive composition; wherein said beneficial agent is foamed and bonded to said surface of the fibrous web through a creping process; and wherein said non-woven substrate is combined with a previously unstretched elastic film to create an elastic laminate. 22. The non-woven substrate according to p. 21, characterized in that it shows a decrease in hysteresis by at least about 5%, an increase in swelling by at least about 40%, and combinations thereof in comparison with an untreated substrate. 23. The non-woven substrate according to p. 21, characterized in that the fibrous web is selected from the group consisting of a paper-based product obtained by air-drying a paper-based product, a paper towel obtained by water-jet bonding of the fabric, spunbond, meltblown obtained by the technology of conform material, carded canvas, air-laid material, laminated materials, paper and composite combinations of the above. 24. The non-woven substrate according to claim 21, characterized in that said additive composition is a polymer dispersion selected from dispersions of polyolefins, dispersions of SEBS copolymers, dispersions of polyisoprene, dispersions of block copolymers of polybutadiene and styrene, dispersions of latexes, dispersions of copolymers of polyvinylpyrrolidone and styrene, copolymers of polyvinyl alcohol and ethylene, and combinations thereof. 25. The nonwoven substrate according to claim 21, characterized in that said useful substance further comprises a reinforcing component selected from microparticles, expandable microspheres, fibers, additional dispersions of polymers, fragrances, antibacterial agents, moisturizers, medications and soothing. 26. The nonwoven substrate of claim 24, further comprising a reinforcing component added to the polymer dispersion in an amount of from about 0.5% to about 30% by weight of the dispersion. 27. The non-woven substrate according to claim 21, wherein the additive composition is a water-insoluble polyolefin copolymer selected from ethylene acrylic acid, a polyethylene-octene copolymer, and combinations thereof. 28. The non-woven substrate according to p. 21, characterized in that the additive composition is selected from a synthetic water-soluble polymer, a natural water-soluble polymer and mixtures thereof. 29. The nonwoven substrate of claim 28, wherein the additive composition is a synthetic water-soluble polymer selected from polyalcohols, polyamines, polyimines, polyamides, polycarboxylic acids, polyoxides, polyglycols, polyethers, polyesters, their copolymers and mixtures. 30. The nonwoven substrate according to claim 28, wherein the additive composition is a natural water-soluble polymer selected from modified cellulose, modified starch, modified protein, chitosan, chitosan salts, carrageenin, agar, gellan gum, guar gum, and combinations thereof. 31. The non-woven substrate according to claim 21, characterized in that it exhibits an improved ink coating of at least about 25% while improving the appearance of printing on said substrate. 32. The non-woven substrate according to p. 21, characterized in that it exhibits an increase in swelling from about 20% to about 250% when determined by testing the swelling. 33. The non-woven substrate according to p. 24, characterized in that in a ratio of approximately 1: 2 with the additive composition combined non-ionic surfactant. 34. The non-woven substrate according to p. 21, characterized in that it exhibits an elastic deformation capable of withstanding tensile stress applied by from about 25% to about 100% before rupture. 35. The non-woven substrate according to p. 21, characterized in that it exhibits an elongation at break of more than approximately 45%. 36. The non-woven substrate according to p. 21, characterized in that the said elastic laminate is characterized by a reduction in wrinkles from about 5% to about 100%. 37. The nonwoven substrate of claim 21, further comprising from about 0.1% to about 20% of a rheological modifier of body fluids. 38. The nonwoven substrate according to claim 37, wherein the rheological modifier of body fluids is selected from mucolytic agents, wherein said mucolytic agents are selected from L-cysteine, thioglycolates, dithiotriacol, and combinations thereof; mucin modifiers; red blood cell modifiers; and their combinations. 39. The nonwoven substrate of claim 21, further comprising a release agent selected from from about 0.01% to about 25% of at least one viscoelastic material, said viscoelastic material being selected from enzymes, alkylpolyglycosides containing 8-10 carbon atoms in the alkyl chain, bovine lipid extract surfactant, dextrans, derivatives of dextrans and combinations thereof; at least one anti-adhesive compound, wherein said anti-adhesive compound is selected from alginic acid, beta-benzylidenebutyric acid, substances of plant origin, casein, farnesol, flavones, fucans, galactolipid, kininogen, hyaluronate, inulin, iridoid glycosophane, nanoparticles, nanoparticles oligodeoxynucleotides, poloxamer 407, polymethyl methacrylate, silicone, sulfated exopolysaccharides, tetrachloride decoxide and combinations thereof; and their combinations. 40. The nonwoven substrate of claim 21, further comprising from about 2 g / m ² to about 80 g / m ^{2 of} deodorizing material.

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