HOT MELT ADHESIVE WASTE BARRIER

Abstract: Leakage resistant waste barriers for use on absorbent articles are prepared by coating a portion of a nonwoven sheet with a water insoluble or water impermeable hot melt adhesive composition.

Description: The present invention relates to a disposable absorbent article comprising an absorbent material, one surface of which is at least partially in contact with a water-insoluble or water-impermeable hot melt adhesive as a leakage resistant waste barrier. Such a disposable absorbent article is disclosed in the EP-A-0 025 315. However, this known disposable absorbent article comprises a pressure sensitive adhesive in form of, for example, a hot melt adhesive serving two purposes, namely to enable the pad to be removeably bonded to a garment on the one hand and to prevent the passage of body liquids from the pad to the garment to which it is attached on the other hand. In this context, the pressure sensitive adhesive is protected in transit and storage by an additional cover layer, which has to be removed before the pad is supplied to the garment. Thus the pressure sensitive adhesive does not serve for the constructional connection of different layers of the pad. On the contrary, different layers of the pad are secured to one another by a further adhesive in addition to the presure sensitive adhesive. This means that the production of this known disposable absorbent article needs many steps in manufacturing and therefore involves great expense as being also time-wasting. Besides, this known pad does not comprise an additional liquid permeable nonwoven sheeting, which is secured to the absorbent material by the pressure sensitive adhesive. This means that the known disposable absorbent article does not have any characteristics which enable a rapid transport of the liquid away from the contacting skin and into the absorbent material. Finally, the the known disposable absorbent article does not serve for preventing leakage of liquid which migrates toward the perimeter of the absorbent material thus wetting the vicinity surrounding the par at all. On the contrary, the layer of liquid impermeable adhesive need not necessarily extend to the edges of the absorbent material, because a small margin of uncovered absorbent material is acceptable. This means that the liquid which penetrates the thickness of the absorbent material will not be prevented by the pressure sensitive adhesive from wetting the vicinities surrounding the pad. Therefore, the object of the present invention is to provide a disposable absorbent article, the production of which is especially economical, which has characteristics to enable a rapid transport of the liquid away from the contacting skin into the absorbent material and to reduce or eliminate the amount of leakage from the perimeter of the disposable article concerned and which comprises other requirements concerning the quality and behaviour, especially the softness. According to the present invention, this object is achieved by the water-insoluble or water-impermeable hot melt adhesive securing the absorbent material to a liquid permeable nonwoven sheeting, whereby the water-insoluble or water-impermeable hot melt adhesive is positioned on an appropriate portion of the nonwoven sheeting. The precise positioning of the waste barrier provided by coating a portion of the nonwoven sheeting with a water-insoluble or water-impermeable hot melt adhesive will vary depending upon the particular disposable construction being manufactured. Thus, in the case of disposable diapers, the waste barrier may be positioned at the end seal of the diaper with a portion of the barrier overlaying the lateral end portions of the absorbent core so as to prevent leakage to the waist and chest area of the baby or incontinent adult. A similar end seal/waste barrier construction can be employed for a sanitary napkin to prevent lateral leakage of the menstrual fluid. Depending upon the side of the nonwoven coated, the hot melt adhesive will perform different functions in addition to serving as a waste barrier. Thus, if coated on the side of the nonwoven which will not come into direct contact with the absorbent core, the hot melt if formulated to be pressure sensitive could be utilized as a positioning adhesive as required in "beltless" pad constructions. Finally, in the case of bed pads, it is also contemplated that the hot melt adhesive coating be used to form a waste barrier around the total perimeter of the pad. It will be recognized that for all the above contemplated uses, the hot melt adhesive serves a dual function of securing as well as of preventing leakage from the core, thus requiring no reduction in manufacturing line speeds. Further, since the hot melt is not a saturant but rather a coating, it does not require further curing or drying and can be applied only to the interior surface of the nonwoven which does not come in contact with the skin so as to provide no reduction in softness or feel of the article. Preferred embodiments of the present invention are described in the subclaims. One general embodiment of the invention is illustrated by the attached figure I. This drawing is merely illustrative of certain embodiments of the invention but is not considered as limiting or essential to an understanding thereof. Fig I represents a similar construction utilizing the adhesive barrier of the present invention, as shown by the hatched portion of the nonwoven topsheet. Hot melt adhesives are 100% solid materials and do not contain nor require any solvents. They are solid materials at room temperature but, on application of heat, melt to a liquid or fluid state in which form they are applied to a substrate. On cooling, the adhesive regains its solid form and gains its cohesive strength. In this regard, hot melt adhesives differ from other types of adhesives which achieve the solid state through evaporation or removal of solvents or by polymerization . Virtually any water insoluble or water impermeable hot melt adhesive composition will serve the waste barrier function contemplated herein. For convenience, it is generally preferred to employ one of the hot melt adhesives already being utilized by the manufacturer in the construction of the particular absorbent article. Representative of suitable adhesives are those hot melt adhesive compositions based on ethylene/vinyl acetate copolymers, isotactic or atactic polypropylene, styrene-butadiene, styrene-isoprene, or styrene-ethylene-butylene A-B-A or A-B-A-B block copolymers such as those sold under the Kraton, Solprene and Stereon tradenames; or mixtures thereof. In addition to the base polymer, these hot melt adhesive compositions generally contain tackifiers, oils and/or waxes as well as conventional additives including stabilizers, anti-oxidants, pigments and the like. Typical of such formulations are those described in U.S. Patents 4,460,728 issued July 17, 1984 to R. C. Schmidt, Jr. et al.; 3,492,372 issued Jan. 27, 1970 to T. P. Flanagan; 4,411,954 issued Oct. 25, 1985 to P. J. Butch III et al.; 4,419,494 issued Dec. 6, 1983 to P. P. Puletti et al.; 4,136,699 issued Jan. 30, 1979 to J. A. Collins et al.; 4,259,220 issued March 31, 1981 to W. L. Bunnelle et al. The hot melt adhesive may be applied to the nonwoven sheeting using any conventional methods such as slot coating, transfer coating, spray coating or nozzle wheel applicator. The hot melt adhesive is generally coated so as to form a continuous film at least 1.0 mils (25 µm) in thickness, generally at leas 1.2 mils (30 µm) in thickness and preferably at least 3 mils (75 µm) in thickness, and in such a manner as to insure that virtually no pin holes exist in the overall coated film. The entire coating may be applied in one application or two or more adhesive applications may be used to achieve the desired thickness. Alternatively, that portion of the nonwoven to be utilized as the waste barrier may be first coated with a thin application Of a low molecular weight thermoplastic such as a low molecular weight polyethylene or ethylene vinyl acetate copolymer and subsequently coated with a layer of the hot melt adhesive. In accordance with the latter embodiment, the lower molecular weight (and less expensive) coating will provide some waste barrier properties but the final coating with the hot melt adhesive will be required to provide additional barrier properties as well as sealant properties to the construction. In the case of disposable diapers or sanitary napkins utilizing the waste barrier at the peripheral ends thereof, the adhesive is conveniently metered laterally onto the continous nonwoven topsheet at timed intervals so as to position the coated portions to fall between the spaced absorbent core sections as they are transported on'the conveyorized manufacturing equipment. The amount of adhesive is metered so as to form a coating twice as long as needed. By so doing, when the continuously produced products are cut in half traversely to form and seal the diaper or napkin, one half of the coating provides the adhesive for the barrier and seal of the trailing edge of the lead diaper while the other half provides the barrier and seal for the leading edge of the following diaper or napkin. In this embodiment as shown in Fig. I, the hatching represents the coated hot melt adhesive. In this figure it is seen that the nonwoven topsheet and fluid impermeable backsheet are coterminus, while the absorbent core, preferably surrounded by tissue for integrity, is slightly smaller in overall dimension. The hot melt coating thus forms the end seal portion joining the top and back sheets so as to encase the absorbent core while additionally covering a portion of the absorbent core thereby forming the desired barrier. As a general guide to the extent of the overlapping required to form an adequate waste barrier, it is suggested that the width of the overlap of the core be approximately the same width as the end seal itself. The particular materials used in the manufacture of the absorbent article are not critical and will vary depending upon the particular construction as well as the manufacturer. In general, the nonwoven topsheet or cover sheet will consist of any fluid permeable, compliant material containing hydrophilic or hydrophobic components. Nonwoven webs comprising natural or synthetic fibers or mixtures thereof are generally used although some constructions may employ thread-reinforced nonwoven webs or cellulose wadding. There are a number of manufacturing techniques which may be utilized to prepared such topsheets. For example, the web may be dry or wet laid utilizing carding, air-laying or spunbonding techniques to produce the web which is then joined mechanically, chemically or thermally. Preferable topsheets for use in the articles contemplated herein have a basis weight range of 21-36 grams per square meter from (18-30 grams per square yard), a minimum wet tensile strength of at least 400 grams per cm. in the machine direction and at least about 55 grams per cm. in the crossmachine direction. Examples of suitable topsheets are described in U.S. Pat. No. 3,180,335 issued April 27, 1965 to R. C. Duncan et al., reissued Jan. 31, 1967 as Re. 26,151 which utilizes a hydrophobic nonwoven rayon web bonded with a thermoplastic binder. Other suitable topsheets are shown in U.S. Pat. No. 3,860,003 issued Jan. 14, 1975 to K.B. Buell which describes a spunbonded nonwoven polyester fabric, in particular a fibrous topsheet comprising by weight about 65 percent staple length polyester 20 fibers having a denier of about 1.5, such as Kodel Type 411 polyester fiber marketed by Tennessee Eastman Corporation, about 15 percent staple length (i.e., at least 1.588 cm. - 0.625 in.) crimped rayon fibers having a denier of approximately 1.5; and about 20 percent acrylic copolymer binder such as Celanese CPE 8335 marketed by Celanese Corporation. Other nomroven topsheets may comprise thermally bonded webs of thermoplastic fibers such as polypropylene or may be a blend of a higher melting matrix fiber such as rayon, cotton or polyester with a lower melting fiber. Typical of this latter class of nonwovens are those described in U.S. Pat. No. 4,315,965 issued Feb. 16, 1982 to C. R. Mason et al., reissued as Re 31,825 on Feb. 5, 1985. The absorbent core is typically a highly porous, loosely compacted batting such as formed from a layer of cellulosic fluff from wood pulp, multiple layers of cellulose wadding, absorbent cotton or rayon fibers, or any similar material with suitable absorbent properties. It is optional, although preferred, to cover or encase the absorbent core in a tissue so as to provide more integrity to the core during manufacturing operations and afterwards to reduce the tendency of the absorbent core to lump or ball when wetted. The tissue layer may comprise densified compacted cellulosic fibers of relatively high wettability and relatively high fluid retentivity such as described in U.S. Pat. No. 3,017,304 issued Jan. 16, 1962 to A. A. Burgeni. The fluid impermeable backsheet may be of polyethylene or other thin, pliable, plastic film such as polypropylene or ethylene and polypropylene copolymers with acrylate or vinyl acetate. The backing sheet may be treated so as to be vapor permeable as described in U.S. Pat. No. 4,341,216 issued July 27, 1982 to M. C. Obenour. A typical diaper containing the waste barrier herein may be constructed in accordance with conventional manufacturing techniques, e.g., utilizing end-seal or multi-line type constructions and may be rectangular or hour-glass in shape. The longitudinal edges may be partially or completely elasticized. They may further have adhesive tabs applied to one end for fastening purposes or pins may be used. Similarly, the invention may be adapted to use on any of the wide variety of sanitary napkin constructions and shapes and may be used in the production of maxi-pad, mini-pad or panti-liner type absorbent articles. In order to illustrate the efficacy of the hot melt waste barriers herein, a conventionally employed disposable construction hot melt adhesive based on 25% Stereon 840 (a styrene-butadiene rubbery copolymer available from Firestone), 60% Zonatac 105 (an aromatic terpene tackifier), and 15% white mineral oil was coated onto a nonwoven fabric and then placed between two plastic sleeves which were clamped together. Water was poured into the top sleeve and the apparatus observed for any liquid leakage from the bottom sleeve. The tests were terminated when leakage was observed or after twenty-four hours if no leakage appeared. After 24 hours, no leakage was observed from sample coated at adhesive levels of 3 mils (75 µm) in thickness, thereby showing the high efficiacy of the adhesive coated nonwoven as a waste barrier. Another series of sample were tested coated the nonwoven two times, each with an 0.6 mil (15 µm) thicknesses of the adhesive to form a coating 1.2 mils (30 µm) in total. No leakage was observed. Additional tests were run by coating the nonwoven first with a 1 mil (25µm) thickness of Ultrathene UE 80271, a low molecular weight ethylene/vinyl acetate copolymer, and then with a second coating using the hot melt adhesive described above. When second coatings were made at thicknesses of 0.5, 1.0 and 1.5 mils (12.5, 25 and 37.5 µm), none of the coated samples exhibited leakage during the entire test period. Further, other Stereon type hot melt adhesives as well as those adhesive compositions based on ethylene/vinyl acetate copolymers, Kraton-type A-B-A block copolymers and atactic or isotactic polypropylene have been observed to exhibit similar waste barrier properties as required herein.

Claims: Disposable absorbent article comprising an absorbent material, one surface of which is at least partially in contact with a water-insoluble or water-impermeable hot melt adhesive as a leakage resistant waste barrier, characterized in that the water-insoluble or water-impermeable hot melt adhesive secures the absorbent material to a liquid permeable nonwoven sheeting, whereby the water-insoluble or water-impermeable hot melt adhesive is positioned on an appropriate portion of the nonwoven sheeting. Disposable absorbent article according to Claim 1, characterized in that the water-insoluble or water-impermeable hot melt adhesive secures a liquid impermeable backsheet portion to the permeable nonwoven sheeting, whereby the liquid impermeable backsheet portion and the permeable nonwoven sheeting encase the absorbent material. Disposable absorbent article according to Claim 2, characterized in that the article is provided with leakage resistant waste barriers formed by coating the lateral end portions of the nonwoven topsheet with the water-insoluble or water-impermeable hot melt adhesive, the barrier extending over a portion of the lateral end of the absorbent material. Disposable absorbent article according to any of Claims 1 to 3, characterized in that the absorbent material is covered or encased in tissue so as to provide more integrity to the absorbent material. Disposable absorbent article according to Claim 3, characterized in that the article is a disposable diaper. Disposable absorbent article according to Claim 3, characterized in that the article is a sanitary napkin.

Inventors: DECOWSKI, STANLEY J., JR., PULETTI, PAUL P.
Applicants: NATIONAL STARCH AND CHEMICAL INVESTMENT HOLDING CORPORATION
Application year: 1986
Main classification: A61F13
IPC codes: A61F13, A61G7, A61L15