US 12,226,181 B2
Absorbent composite comprising a hydroentangled nonwoven
Lei Wang, Mooresville, NC (US); Nyle Bishop, Mooresville, NC (US); Ralph A. Moody, III, Mooresville, NC (US); Jerry Snider, Mooresville, NC (US); and Pierre Grondin, Mooresville, NC (US)
Assigned to AVINTIV SPECIALTY MATERIALS INC., Charlotte, NC (US)
Filed by AVINTIV Specialty Materials Inc., Charlotte, NC (US)
Filed on Jan. 19, 2016, as Appl. No. 15/000,750.
Claims priority of provisional application 62/104,120, filed on Jan. 16, 2015.
Prior Publication US 2016/0206393 A1, Jul. 21, 2016
Int. Cl. A61B 46/00 (2016.01); A61F 13/01 (2024.01); A61F 13/15 (2006.01); A61F 13/53 (2006.01); A61F 13/84 (2006.01); B32B 3/30 (2006.01); B32B 5/02 (2006.01); B32B 5/06 (2006.01); B32B 5/08 (2006.01); B32B 5/26 (2006.01); B32B 27/12 (2006.01); B32B 27/30 (2006.01); B32B 27/32 (2006.01); B32B 27/40 (2006.01); D04H 1/492 (2012.01); D04H 1/498 (2012.01); D04H 3/16 (2006.01); D04H 5/03 (2012.01)
CPC A61B 46/40 (2016.02) [A61F 13/01029 (2024.01); A61F 13/15203 (2013.01); A61F 13/15804 (2013.01); A61F 13/53 (2013.01); A61F 13/8405 (2013.01); B32B 3/30 (2013.01); B32B 5/022 (2013.01); B32B 5/06 (2013.01); B32B 5/08 (2013.01); B32B 5/26 (2013.01); B32B 27/12 (2013.01); B32B 27/306 (2013.01); B32B 27/308 (2013.01); B32B 27/32 (2013.01); B32B 27/40 (2013.01); D04H 1/492 (2013.01); D04H 1/498 (2013.01); D04H 3/16 (2013.01); D04H 5/03 (2013.01); A61F 2013/15463 (2013.01); B32B 2260/021 (2013.01); B32B 2260/046 (2013.01); B32B 2262/0253 (2013.01); B32B 2262/0261 (2013.01); B32B 2262/0276 (2013.01); B32B 2262/062 (2013.01); B32B 2262/12 (2013.01); B32B 2274/00 (2013.01); B32B 2307/4023 (2013.01); B32B 2307/7145 (2013.01); B32B 2307/726 (2013.01); B32B 2307/7265 (2013.01); B32B 2307/728 (2013.01); B32B 2307/75 (2013.01); B32B 2535/00 (2013.01); B32B 2556/00 (2013.01)] 13 Claims
 
1. A two-layered composite, comprising:
(a) a first layer that is an absorbent nonwoven consisting of a plurality of synthetic fibers rendered hydrophilic by the presence of (i) a topical hydrophilic surfactant thereon, (ii) a hydrophilic melt additive, or both (i) and (ii), wherein the absorbent nonwoven is a hydroentangled spunbond web that has been subjected to a first hydroentanglement process and a second hydroentanglement process, the hydroentangled spunbond web having an outermost surface defined by a three-dimensional pattern formed by the plurality of synthetic fibers, wherein the three-dimensional pattern formed by the plurality of synthetic fibers defines a first outermost surface of the two-layered composite; and
(b) a second layer that is a liquid-impermeable film,
wherein the liquid-impermeable film is an extrusion coated film located directly onto and impregnating at least a plurality of voids between individual spubonbond fibers of the hydroentangled spunbond web to provide an extrusion coated film at least partially embedded into the hydroentangled spunbond web; and wherein the composite a normalized absorbency (g/g) from 10 to 20 and has a lint level of at most about 2000 particles/cubic foot as determined according to test method IS09073-10:2003 and wherein the composite has a Spill Absorption Time of less than 20 seconds and a Spread Index from 1 to 35 cm, and wherein the synthetic fibers are selected from the group consisting of a polyolefin, a polyester, a polyamide, and any combinations thereof.
 
10. A three-layered composite, comprising:
(a) a first layer that is an absorbent nonwoven consisting of a plurality of synthetic fibers rendered hydrophilic by the presence of (i) a topical hydrophilic surfactant thereon, (ii) a hydrophilic melt additive, or both (i) and (ii), and wherein the absorbent nonwoven is a hydroentangled spunbond web that has been subjected to a first hydroentanglement process and a second hydroentanglement process;
(b) a second layer that is a liquid-impermeable film, wherein the liquid-impermeable film comprises a breathable film that is impermeable to liquid water and permeable to water vapor; wherein the breathable film is at least partially embedded into the hydroentangled spunbond web; and
(c) a third layer that is a second nonwoven that is a non-absorbent nonwoven, wherein the liquid-impermeable film is extrusion coated directly between the absorbent nonwoven and the non-absorbent nonwoven,
wherein the composite has a Spill Absorption Time of less than 20 seconds and a Spread Index from 1 to 35 cm.
 
13. A two-layered composite, consisting of:
(a) a first layer that is an absorbent nonwoven consisting of a plurality of synthetic fibers rendered hydrophilic by the presence of a topical hydrophilic additive, and an antimicrobial additive, wherein the absorbent nonwoven is a hydroentangled spunbond web that has been subjected to a first hydroentanglement process and a second hydroentanglement process, the hydroentangled spunbond web having an outermost surface defined by a three-dimensional pattern formed by the plurality of synthetic fibers, wherein the three-dimensional pattern formed by the plurality of synthetic fibers defines a first outermost surface of the two-layered composite; and
(b) a second layer that is a liquid-impermeable film, wherein the liquid-impermeable film is extrusion coated directly onto and is at least partially embedded into the absorbent nonwoven;
wherein the plurality of synthetic fibers are selected from the group consisting of a polyolefin, a polyester, a polyamide, and any combinations thereof.