JP2014181436A - Nonwoven substrate having fibril - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a nonwoven substrate which has improved characteristics of cleaning, scrubbing, holding of dirt and/or application; a method for manufacturing the same; and a method of using the same.SOLUTION: The nonwoven substrate comprises a layer of fibers. In the layers, each of the plurality of fibers includes a plurality of fibrils extending outwardly from a surface of the fibers. The plurality of fibrils comprise a lipid ester.

Description

  The present invention relates generally to nonwoven fabric substrates and methods for making the same, as well as the use of nonwoven fabric substrates in products such as absorbent articles and wipes, packaging of products and packaging materials.

  Nonwoven substrates can be useful in a wide variety of applications. Various nonwoven substrates include spunbond-meltblown-spunbpnd (“SMS”) substrates consisting of an outer layer of spunbond thermoplastic (eg, polyolefin) and an inner layer of meltblown thermoplastic. It may consist of Some non-woven substrates, in addition to or instead of meltblown thermoplastics, create fine fibers (ie, for example, “SMNS” or “SNS” substrates, less than 1 micrometer (“N -Fiber ") fiber)). Such nonwoven substrates are durable spunbond layers and porous, but liquids such as bodily fluids may strike through quickly or prevent bacteria from entering the nonwoven substrate. It may consist of a resulting internal meltblown layer and / or fine fiber layer.

  Absorbent articles such as diapers, training pants, adult incontinence products, and feminine hygiene products utilize nonwoven substrates for many purposes. In many applications, the barrier properties of the nonwoven substrate play an important role in the performance of the nonwoven substrate, for example, as a barrier to liquid penetration. Absorbent articles are in close proximity to or on the outer surface of liquid permeable materials or topsheets, absorbent articles, various barrier layers or cuffs intended to be placed in contact with the wearer's skin. A plurality of elements such as a liquid-impermeable material or a backsheet intended to be disposed on and an absorbent core disposed between at least a part of the liquid-permeable material and the liquid-impermeable material. Also good.

  Films such as elastomeric films are often used to produce various components of absorbent articles and other commodities. For example, the films are used in liquid permeable layers, liquid impermeable layers, barrier cuffs, barrier layers, side panels, or other components of absorbent articles or other products. The film provides high resistance to liquid flow and thus provides ideal barrier performance. This also applies to formed, apertured films where the film area around the opening provides excellent protection against liquid flow and rewet. Films, however, are very expensive and less comfortable to the wearer than non-woven substrates. Thus, manufacturers of merchandise that incorporate films typically attempt to reduce the amount of film in their products. What is needed is that it can match certain advantageous properties of the film, such as low surface tension liquid strike-through time, while providing comfort to the user and a cost advantage to the manufacturer, or It is a nonwoven fabric base material that can be in a state close to that. What is also needed is to have the same liquid strike-through time as a conventional nonwoven substrate to save material costs for the manufacturer again, but with a lower basis weight compared to a conventional nonwoven substrate It is the nonwoven fabric base material which has.

  Commodities such as wipes (including cleaning substrates) use nonwoven substrates for a variety of applications, such as cleaning, scrubbing, and / or applying compounds. Many disadvantages exist with their nonwoven substrates. Thus, the nonwoven substrates should be improved so that they have more beneficial properties and allow for better cleaning, scrubbing, soil retention, and / or application properties. It is.

  In some cases, polymer films are used as packaging materials for goods. Film provides high resistance to liquid and air flow and is therefore an ideal packaging material for commercial products. Films, however, are very expensive and are not aesthetically pleasing compared to nonwoven substrates. Thus, manufacturers of products that use film as a packaging material typically attempt to reduce the amount of film required for their packaging material and / or obtain an aesthetically pleasing film. . What is needed is that it can function like a film, or is substantially film-like and aesthetically pleasing, but is much cheaper to manufacture than conventional polymer films. It is a non-woven substrate that can be made.

  The above and other features, as well as the advantages of the disclosure of the present invention and the manner of achieving them, will become more apparent and the disclosure itself, in conjunction with the appended drawings, is non-limiting A better understanding can be had by reference to the following description of specific embodiments.

Schematic of a forming machine used to produce a nonwoven substrate, according to a non-limiting embodiment Sectional view of a three-layer nonwoven fabric substrate according to a non-limiting embodiment 2 is a perspective view of the nonwoven substrate of FIG. 2 of various portions of the nonwoven layer cut away to show the composition of each nonwoven layer, according to a non-limiting embodiment. Sectional view of a four-layer nonwoven substrate according to a non-limiting embodiment 4 is a perspective view of the nonwoven substrate of FIG. 4 of various portions of the nonwoven layer cut to show the composition of each nonwoven layer, according to a non-limiting embodiment. Scanning electron microscope ("SEM") photograph of a nonwoven substrate having fibrils in its spunbond layer, according to various non-limiting embodiments. Scanning electron microscope ("SEM") photograph of a nonwoven substrate having fibrils in its spunbond layer, according to various non-limiting embodiments. Scanning electron microscope ("SEM") photograph of a nonwoven substrate having fibrils in its spunbond layer, according to various non-limiting embodiments. Additional SEM pictures of a nonwoven substrate with fibrils in its spunbond layer, according to various non-limiting embodiments Additional SEM pictures of a nonwoven substrate with fibrils in its spunbond layer, according to various non-limiting embodiments Additional SEM pictures of a nonwoven substrate with fibrils in its spunbond layer, according to various non-limiting embodiments SEM photo of a cross-sectional view of a portion of a nonwoven substrate having fibrils in its spunbond layer, according to various non-limiting embodiments. SEM photo of a cross-sectional view of a portion of a nonwoven substrate having fibrils in its spunbond layer, according to various non-limiting embodiments. SEM photo of a cross-sectional view of a portion of a nonwoven substrate having fibrils in its spunbond layer, according to various non-limiting embodiments. SEM photo of a portion of a binding site with a binding region, according to a non-limiting embodiment, where a plurality of fibrils extend from the binding region. SEM photograph of a cross-sectional view of a portion of a bonding site having a bonding region of a nonwoven substrate according to various non-limiting embodiments, wherein a plurality of fibrils extend from the bonding region. SEM photograph of a cross-sectional view of a portion of a bonding site having a bonding region of a nonwoven substrate according to various non-limiting embodiments, wherein a plurality of fibrils extend from the bonding region. SEM photograph of a cross-sectional view of a portion of a bonding site having a bonding region of a nonwoven substrate according to various non-limiting embodiments, wherein a plurality of fibrils extend from the bonding region. Effects of the melt additive, glycerin tristearate, on the specific surface area of the nonwoven substrate of the present disclosure compared to the specific surface area of a conventional nonwoven substrate that does not include glycerin tristearate, according to a non-limiting embodiment Graph showing an example An example of the ratio (seconds / gsm) of the low surface tension liquid strike-through time (seconds) to the basis weight (gsm) to the amount of glycerin tristearate (gsm) in the nonwoven substrate according to a non-limiting embodiment Graph showing Graph showing an example of specific surface area (m ² / g) versus time (hours) for post nonwoven substrate or nonwoven layer formation for a nonwoven substrate of the present disclosure, according to a non-limiting embodiment. Bar chart showing an example of low surface tension liquid strike-through time (seconds) for various nonwoven substrates of the present disclosure compared to a conventional SMS 13 gsm nonwoven substrate, according to a non-limiting embodiment Graph showing an example of low surface tension liquid strike-through time (seconds) based on the ratio of glycerin tristearate to the weight of the composition used to form the fiber, according to a non-limiting embodiment A graph showing an example of low surface tension liquid strike-through time (seconds) based on the ratio of glycerin tristearate to the weight of the composition used to form the fiber, according to a non-limiting embodiment (bottom) (The line represents a 19 gsm spunbond nonwoven substrate, the middle line represents a 16 gsm spunbond nonwoven substrate, and the top line represents a 13 gsm spunbond nonwoven substrate.) Graph showing an example of low surface tension liquid strike-through time (seconds) versus fiber diameter (μm), according to a non-limiting embodiment Graph showing an example of low surface tension liquid strike-through time (seconds) based on the amount of glycerin tristearate (gsm) in various nonwoven substrates, according to non-limiting embodiments. A perspective view of a commodity package according to a non-limiting embodiment (wherein a portion of the package may consist of the nonwoven substrate of the present disclosure). SEM photo of a cross-sectional view of a nonwoven substrate of the present disclosure in which ester lipids in spunbond fibers are dissolved using a weight reduction method, according to a non-limiting embodiment. SEM photo of a cross-sectional view of the spunbond fiber of FIG. 28, according to a non-limiting embodiment. Illustration of a graph of specific surface area (Y axis) versus mass average fiber diameter (X axis) according to a non-limiting embodiment Diagram of the orifice used in the low surface tension liquid strike-through time test described herein

  Various non-limiting embodiments of the present disclosure will now be described to provide an overall understanding of the structure, function, manufacture, and use of the nonwoven substrates disclosed herein and the principles of their manufacturing methods. Is done. One or more examples of these non-limiting embodiments are illustrated in the accompanying drawings. Those skilled in the art will appreciate that the non-woven substrate and method of manufacture thereof specifically described herein and shown in the accompanying drawings are examples of non-limiting embodiments and various non-limiting embodiments of the present invention. It will be understood that the scope of the embodiments is defined only by the claims. Features shown or described with respect to one non-limiting embodiment may be combined with features of other non-limiting embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure.

In this specification, the following words have the following meanings.
The term “absorbent article” refers to the wearer's body or a natural opening in the body to absorb and contain various exudates (eg, urine, BM, menstrual blood) discharged from the body. By means of disposable devices such as diapers or incontinence products for infants, children or adults, training pants, sanitary napkins, tampons, etc., placed against or in close proximity to. Some absorbent articles consist of a topsheet, i.e., a liquid permeable layer, a backsheet, i.e., a liquid impermeable layer, and an absorbent core that is located at least partially intermediate the topsheet and backsheet. The article may also consist of a capture system (which may consist of one or more layers) and other typical components. Exemplary absorbent articles of the present disclosure are further described in the following description and drawings in the form of tape diapers and sanitary napkins. This description should not be construed as limiting the claims in any way based on the illustrative absorbent article shown and described. Thus, the present disclosure applies to any suitable form of absorbent article (eg, training pants, adult incontinence products, sanitary napkins). In order to avoid the occurrence of doubt, the absorbent article does not include wipes. Wiping articles are defined below and are also within the scope of the present disclosure.

The term “atmospheric conditions” is defined as more typical post-nonwoven substrate and / or absorbent article manufacturing conditions, non-woven substrate and / or absorbent article storage conditions, and more specifically Specifically, the relative humidity is 20 ° C. ± 7 ° C. and 50% ± 30%.
The term “product” includes any product such as, for example, absorbent articles, wipes (wet or dry), cleaning or dusting substrates, filters, filter media, toothbrushes, or batteries.
The term “basis weight” is defined by the basis weight test described below. Basis weight is described in grams / m ² (gsm).
The term “binding region” means a region of an individual binding site.

The term “lateral direction” generally means a direction perpendicular to the machine direction.
The term “diameter”, when referring to fibers, is defined by the fiber diameter and denier tests described below. The fiber diameter is described in microns.
The term “elastic strand” or “elastic member” refers to a ribbon or strand (ie, either its cross-sectional width and height or diameter) that may be part of an inner or outer cuff collecting component. The larger length compared).
The term “fiber” may be continuous or discontinuous produced by spinning, melt-blowing, melt fibrillation or film fibrillation processes, or electrospun manufacturing processes, or other suitable manufacturing processes. Regardless, it means any type of man-made fiber, filament (monofilament), or fibril.

The term “film” refers to a polymeric material having a skin-like structure, and it does not consist of individually identifiable fibers. Thus, “film” does not include non-woven materials. For purposes herein, materials such as skin may be perforated, open, or microporous, and they are nevertheless considered “film”. It is.
The term “fibril” means a protrusion, an extended protrusion, or a bump that extends outward from the surface of the fiber or generally radially outward from its outer surface. In some cases, the protrusions, extended protrusions, or bumps may extend radially outward relative to the longitudinal axis of the fiber. The outer side in the radial direction means a range of 1 to 89 ° with respect to the vertical axis. In yet other cases, the protrusions, extended protrusions, or bumps may extend radially outward from the surface of the fiber, at least in the direction of the fiber longitudinal center 1/3. The protrusions, extended protrusions, or bumps consist solely of, or consist essentially of, a melt additive such as an ester lipid (eg, 51% -100% or 51% -99%). The protrusions, extended protrusions, or bumps grow from the fibers post-nonwoven substrate formation only after a certain period of time (eg, 6-100 hours) under atmospheric conditions. Fibrils can be viewed using a SEM at a magnification of at least 1,000 times.
The term “hydrophobic” was edited by Robert F. Gould and copyrighted in 1964, published by the American Chemical Society, “Contact Angle, Wettability, and Adhesion”. , Wettability, and Adhesion) "refers to a material or composition having a contact angle greater than or equal to 90 °. In certain embodiments, the hydrophobic surface exhibits a contact angle greater than 120 °, greater than 140 °, or even greater than 150 °. Hydrophobic liquid compositions are generally immiscible with water. The term “hydrophobic melt additive” refers to a hydrophobic composition that has been added as an additive to a hot melt composition (ie, blended into a thermoplastic melt), which then comprises fibers and / Or forming a substrate (eg, by spunbonding, meltblowing, melt fibrillation, or extrusion).
The term “hydrophobic surface coating” means a composition applied to a surface to make the surface hydrophobic or more hydrophobic. By “hydrophobic surface coating composition” is meant a composition that is to be applied to the surface of a substrate, such as a nonwoven substrate, to provide a hydrophobic surface coating.

As used herein, the terms “joined” or “bonded” or “attached” are defined by the fact that an element is directly attached to another element, thereby causing the element to directly adhere to the other element. And elements that are attached to the intermediate member (s), which are similarly attached to the other elements, thereby causing the elements to be indirectly secured to the other elements.
The term “low surface tension liquid” means a liquid having a surface tension of 32 mN / m ± 1.0 mN / m.
The phrase “low surface tension liquid strike-through time” is defined in the low surface tension liquid strike-through time test described below. The low surface tension liquid strike-through time is described in seconds.
The term “machine direction” (MD) refers to the direction of material flow through the process.

The term “calendar bonding” or “thermal bonding” means that the polymer fibers are melted or fused together in the bond to form a compressed, flat region that may be a continuous film-like material. As such, it means the bond formed between the fibers of the nonwoven by pressure and temperature. The term “calendar bond” does not include bonds formed using adhesives or bonds formed using only pressure, as defined by the following mechanical bond. The terms “thermally bond” or “calendar bond” refer to the process used to form the thermal bond.
The term “mechanical bond” means a bond formed between two materials by pressure, ultrasonic bonding and / or other mechanical bonding processes without intentionally applying heat. The term mechanical bond does not include a bond formed using an adhesive.
The term “layer” means a sheet or ply of nonwoven or other material.
The term “substrate” means a sheet-like structure of one or more layers such as a nonwoven substrate.

The term “titer” means the density in the longitudinal direction, measured in mass per unit length of fiber.
The term “denier” means a unit of fiber fineness equal to the weight (grams) per 9000 meters of fiber.
The term “mass mean diameter” means the mass weighted arithmetic mean diameter of the fiber calculated from the fiber diameter as measured by the fiber diameter and denier test method described below. The mass average diameter of the fiber is calculated by the fiber diameter calculation method described below. The mass average diameter of the fiber is described in microns.
The term “number average diameter” or “average diameter” means the arithmetic average diameter of the fiber calculated from the fiber diameter, and is measured by the fiber diameter and denier test methods described below. The number average diameter of the fiber is calculated by the fiber diameter calculation method described below. The number average diameter of the fibers is described in microns.

  Nonwoven substrates having properties that are identical to or approach some film properties are desired. One film property that may be advantageous for nonwoven materials is that of a film that is liquid impermeable or substantially liquid impermeable. Films are typically less breathable, less comfortable, and generally less noisy during operation, unless the film is made to resemble a nonwoven by expensive manufacturing methods. Many. Thus, non-woven materials that are film-like or film-like and have liquid permeation capabilities are desired for significant cost savings and greater comfort for the user wearing them. In an embodiment, the present disclosure provides a nonwoven substrate with increased liquid barrier properties. In other embodiments, the present disclosure provides a nonwoven substrate having one or more layers of fibers, the nonwoven substrate having a specific surface area that is higher than the specific surface area of conventional nonwoven substrates. Have In embodiments, the nonwoven substrate of the present disclosure may consist of one or more layers of fibers, wherein from the surface of at least some of the fibers in one or more layers of fibers. The plurality of fibrils may extend outward or radially outward. Fibrils can reduce liquid (ie, liquid or gas) permeability, particularly that of liquids, generally in fiber layers and nonwoven substrates. The nonwoven fabric substrate may have fibers in which all layers are fibrils, or fewer layers than all layers may have fibers with fibrils. Stated another way, some layers may have fibers without fibrils, while other layers may have fibers with fibrils. Some layers may have fibers with fibrils and fibers without fibrils. The specific surface area of the nonwoven substrate and fibers with fibrils are described in more detail below after a more general description of the example absorbent article for the nonwoven substrate application of the present disclosure. Wipes, packages, and packaging materials that use the nonwoven substrates described herein are also within the scope of the present disclosure. These are described in further detail below.

  Nonwoven substrates may consist of sheets of individual nonwoven layers, fibers, filaments, or a combination of fibers and filaments, bonded together using a mechanical, thermal, or chemical bonding process. Nonwoven substrates are relatively flat, porous sheets made directly from individual fibers, including staple fibers (short fibers), directly from molten plastic, from plastic films, and / or some combination of the foregoing. It may be formed. Some nonwoven substrates may be reinforced or reinforced, for example, with a backing sheet. The nonwoven substrate may be a engineered fabric having a limited life, a disposable fabric, or a very durable, reusable fabric. In various embodiments, the nonwoven substrate provides specific functions such as absorbency, liquid repellency, elasticity, stretchability, opacity, softness, and / or strength. These properties are often combined to create a nonwoven substrate suitable for a particular application while achieving a good balance between product life and cost. A detailed list of non-woven fabric manufacturing processes can be found, for example, in S.A. J. et al. "The Handbook of Nonwovens" published by S. J. Russell, Woodhead Publishing Limited and CRC Press LLC (ISBN: 978-0-) 8493-2596-0).

Direct polymer melt materials and typical thermoplastic continuous and discontinuous fiber spinning techniques for wet nonwoven materials are commonly referred to as melt spinning (spun melt) or spunmelt techniques. Spunmelt technology consists of both a meltblowing process and a spunbond process. The spunbond process consists of being extruded under pressure through a number of orifices (openings) in a plate known as a spinneret. The resulting continuous fibers are quenched and drawn by any of a number of methods such as, for example, slot draw systems, attenuator guns, or draw rolls (Godet). The In the spun laying or spunbonding process, continuous fibers are collected as a loose web on a moving perforated surface, such as a wire mesh conveyor belt. When multiple spinnerets are used in a line for forming a multilayer nonwoven substrate, the subsequent nonwoven layer is placed on the outermost surface of the previously formed nonwoven layer. Spunlaid or spunbond nonwoven substrates can be multicomponent (eg, core and sheath, or segmented pie or sea-island etc.), multicomponent (ie, a mixture of multiple chemicals in one component) In addition to a spherical shape or a circular shape, it may have various cross sections such as a trilobal (trilobal) shape, an oval shape, or a hollow shape. Examples for producing such a wide range of spunlaid layers or fabrics are Hartmann et al., US Pat. No. 3,502,763, Dorschner et al., US Pat. US Pat. No. 3,692,618, Kinney US Pat. No. 3,338,992, Balk US Pat. No. 4,820,142, Geus et al. US Pat. US Pat. No. 5,460,500, Geus, et al. US Pat. No. 6,932,590, Pike, et al. US Pat. No. 5,382,400, Allen et al. (Allen, et al.) U.S. Pat. No. 7,320,581 and Allen (U.S. Pat. No. 7,476,350).

  The meltblowing process relates to a spun laying or spunbonding process that forms a layer of nonwoven substrate, where the molten polymer passes through an orifice in the spinneret or mold, typically in a small mold in the mold. Extruded from a single row of orifices. A high flow of hot, high velocity gas impinges and thins the fibers as they exit the mold and quickly draws them into fine fibers of a diameter on the order of 1-10 micrometers and indefinite length . This is different from the spunbond method, which generally preserves fiber continuity. The fibers are then sprayed and deposited on a collector, conveyor, or other web with high velocity air.

  Meltblown nonwoven layers are often added to spunlaid nonwoven layers, for example, spunbond-meltblown ("SM"), combining the attributes of S and M nonwoven structures, which are strong nonwoven substrates with some degree of barrier properties A nonwoven substrate or spunbond-meltblown-spunbond (“SMS”) nonwoven substrate is formed. Descriptions for producing such meltblown fibers, layers, and nonwoven substrates are described, for example, in “Superfine Thermoplastic Fibers” by Van A. Wente, Ind. Eng. Chem. Res. 48 (8) 1956, 1342-46, or Buntin et al., U.S. Pat. No. 3,849,241 and Balk, U.S. Pat. No. 5,098,636. Can be found inside.

  Other methods for producing finer fibers, including fibers having an average diameter ("N-fiber") of less than 1 micron or 1000 nanometers are melt fibrillation, advanced meltblowing techniques, or electrospinning. is there. Advanced meltblowing techniques are described, for example, in Lau, US Pat. No. 4,818,464, Nyssen et al., US Pat. No. 5,114,631, Watt et al. U.S. Pat. No. 5,620,785 and Bodaghi et al. U.S. Pat. No. 7,501,085.

  As an example of melt fibrillation, melt film fibrillation technology is a common type of manufacturing fiber where one or more polymers are melted and many possible configurations (eg, hollow tube of film) , Sheet of film, coextrusion, homogeneous or biocomponent film or filament), and then fibrillated or fiberized into filaments. Examples of such processes are Torobin US Pat. No. 4,536,361, Perez US Pat. No. 6,110,588, Johnson et al. US Pat. No. 7,666,343, and Gerking US Pat. No. 6,800,226. Electrospinning processes useful for producing fine fibers are described in US Pat. No. 1,975,504 of Formhals et al., US Pat. US Pat. No. 7,585,437, Chu et al., US Pat. No. 6,713,011, Qi et al. US Pat. No. 8,257,641, and “ By "Espinning", A. Greiner and J. Wendorff, Angew. Chem. Int. Ed. 2007, 46 (30), 5670-5703.

  Spunlaid or spunbond fibers typically have an average diameter in the range of about 8 microns to about 30 microns, or a fiber titer in the range of 0.5 to 10 denier. Meltblown fibers typically have an average diameter in the range of 0.5 microns to 10 microns, or 0.001 denier to 0.5 denier, and a range greater than about 0.1 microns to 10 microns. Fine fibers with an average or median diameter in the range of 0.1 microns to 2 microns, and some fine fibers have a number average diameter less than about 1 micron, a mass average diameter less than about 1.5 microns, and a number The ratio of mass average diameter to average diameter is less than about 2.

  Meltblown nonwoven layers ("M") are often added to spunlaid nonwoven layers ("S") to provide attributes of S and M nonwoven structures, for example, strong nonwoven substrates with some degree of liquid barrier properties. Combined to form a spunbond-meltblown (“SM”) nonwoven substrate, spunbond-meltblown spunbond (“SMS”) nonwoven substrate, SSMMS nonwoven substrate, SSMMSS nonwoven substrate, or other nonwoven substrate . The same can be done with fine fibers and layers of fine fibers, designated “N”, where SN, MN, SMN, SMNS, SMNMS, SNMN, SSMNS, SSMNS, or other suitable layer combinations Manufactured.

In addition to non-woven substrates produced from dry and wet non-woven fabric melt material fiber spinning technology, non-woven fabric substrates can be made from fibers (including natural fibers) pre-formed by dry or wet techniques, etc. You may manufacture by. Dry techniques include carding and airlaying. These techniques may be combined with each other to form, for example, a dry, multilayer, functional nonwoven substrate by melt spinning.

  The carding process uses fibers cut into individual lengths called staple fibers (short fibers). The type of fiber and the properties of the final product determine the fiber length and denier. Typical staple fibers have a length in the range of 20 mm to 200 mm and a linear density in the range of 1 dpf to 50 dpf (denier per fiber), but staple fibers beyond this range are also used for carding Has been. Carding technology processes these staple fibers into a formed substrate. Staple fibers are typically sold as compressed bales that need to be opened to produce a uniform nonwoven substrate. This unpacking step can be performed by a combination of bale opening, coarse opening, fine opening, or similar methods. Staple fibers are often blended to mix different types of fibers and / or to improve uniformity. The fibers can be mixed by blending fiber hoppers, bale openers, blending boxes, or similar methods. To produce a nonwoven substrate with the desired basis weight uniformity, the unpacked and blended fibers are as uniform in density as practical, and the fibers are deposited across the width of the card Carried to the shoot to do. The card includes a series of side-by-side rollers and / or fixed plates coated with a particular geometric shape of metal cloth, a solid serrated wire with staple fibers treated therebetween. Carding occurs when a tuft of fibers is carried between two surface contacts having differential surface velocities and opposing directions on the metal cloth. The card may have a single main cylinder or multiple cylinders. The card may have a single doffer or multiple doffers to remove carded fibers, and the card is highly isotropic of individual fibers in the web. In order to reduce general orientation, a randomizing roller or a condenser roller may be provided. The carding process may include a single card or multiple cards along each other, where the fibers of subsequent cards are deposited on the fibers from the preceding card, and thus, for example, Multiple layers of different fiber compositions can be formed. The orientation of these cards may be balanced for downstream operations or perpendicular to downstream operations by turning or cross-lapping.

  The airlaid process also uses individual lengths of fibers, which are often shorter than the staple fibers used for carding. The length of fibers used for air laying (air deposition) is typically in the range of 2 mm to 20 mm, although lengths exceeding this range can also be used. The particles may also be deposited in the fiber structure during the air laying process. Some fibers for air laying may be produced in the same way as carding, ie unpacking and blending as described above. Other fibers, such as pulp, can use a crusher, such as a hammer mill or a disk mill, to individualize the fibers. Various fibers may be blended to improve the uniformity of the properties of the finished nonwoven substrate. The air laying device combines external air and fibers and / or particles so that the fibers and / or particles are entrained in the air stream. After entrainment, the fibers and / or particles are collected as a loose web on a moving perforated surface, such as a wire mesh conveyor belt. The air laying process may include a single air laying forming device or a plurality of air laying forming devices connected to each other, where the fibers and / or particles of the subsequent air laying forming device are the former air laying forming devices. Deposited on the fibers and / or particles from the device, thereby allowing the production of multilayer nonwoven substrates.

  Wet nonwovens are manufactured with a modified papermaking process and typically use fibers in the range of 2 mm to 20 mm, although lengths beyond this range can also be used. Some fibers for wetlaying may be produced in the same manner as carding, ie unpacking and blending as described above. Other fibers, such as pulp, can use a crusher, such as a hammer mill or a disk mill, to individualize the fibers. The fiber is suspended in water, possibly with other additives such as binders, and this slurry is typically added to a headbox from which it flows to the wet forming apparatus. To form a sheet of material. After removing the initial water, the web is bonded and dried.

The bonded nonwoven fabric substrate may be bonded (linked) by a thermal, mechanical or chemical method. In the nonwoven fabric substrate made of a cellulosic material, the nonwoven fabric substrate may be hydrogen bonded. Bonding is typically done along the molding process, but may be performed off-line as well. Thermal bonding includes calender bonding with smooth and / or patterned rolls and thru-air bonding with flat belt and / or drum surfaces. Mechanical coupling includes needlepunching, stitchbonding, and hydroentangling (also known as spunlacing). Chemical bonding involves the application of adhesive, latex, and / or solvent to the fiber by spraying, printing, foaming, or saturation, and then drying to produce a useful nonwoven substrate with sufficient integrity. . Other post-treatments such as printing or coating may then be performed. The nonwoven substrate is then wound into rolls, cut / unwound, packaged, and shipped for further processing and / or converted into a final product.

Fiber and Filament Composition In various embodiments, the synthetic fibers of the nonwoven structure include, for example, polyesters including PET, PTT, PBT, and polylactic acid (PLA), and alkyd, polypropylene (PP), polyethylene (PE), And polyolefins including polybutylene (PB), olefinic copolymers from ethylene and propylene, thermoplastic polyurethane (TPU) and styrene block copolymers (linear and radial di and triblock copolymers such as various types of Kraton). It may comprise an elastomeric polymer, polystyrene, polyamide, PHA (polyhydroxyalkanolate) and a starch-based composition including, for example, PHB (polyhydroxybutyrate), and thermoplastic starch. The constituents of the fiber may be derived from a biological source, such as a plant, such as PLA or “Bio PE”. The above polymers may be used as homopolymers, copolymers, mixtures, and alloys thereof. In various embodiments, the natural fibers of the nonwoven structure include, but are not limited to, digested cellulose fibers from conifers (from conifers), hardwood (from deciduous trees) or cotton, esparto grass, bagasse, including rayon and cotton. It may be made from kemp, flax, jute, kenaf, sisal, and fibers from other lignaceous and cellulose fiber sources. The fibers may include other ingredients for coloration, strength, stability over time, odor control or other purposes, such as titanium dioxide to reduce gloss and improve opacity.

  Various mass-produced absorbent articles and merchandise employ nonwoven substrates such as SMS substrates in their manufacture. One of the largest users of these nonwoven substrates is the disposable diaper industry, the wipes industry, the substrate cleaning industry, and the women's care products industry.

  FIG. 1 shows a schematic view of a molding machine 110 used to produce a nonwoven substrate 112 of the present disclosure. In order to produce a nonwoven substrate, the molding machine 110 produces a first beam 120 for producing a first coarse fiber 135 (eg, spunbond fiber), an intermediate fiber 127 (eg, meltblown fiber). For producing an optional second beam 121, a third beam 122 for producing fine fibers 131 (eg N-fibers), and a second coarse fiber 124 (eg spunbond fibers). Shown as having a fourth beam 123. The forming machine 110 comprises an endless forming belt 114 that moves around rollers 116, 118, and the forming belt 114 is driven in the direction indicated by the arrow 114. In various embodiments, if an optional second beam 121 is utilized, it may be located, for example, intermediate the first beam 120 and the third beam 122 (as shown) Alternatively, it may be arranged between the third beam 122 and the fourth beam 124. Rolls 138 and 140 may form a nip for bonding or calendering the fibers in multiple layers together to form a nonwoven substrate. Element 136 may be a layer of spunbond fibers. Element 128 may be a layer of intermediate fibers, spunbond fibers, or fine fibers. Element 132 may be a layer of intermediate fibers, spunbond fibers, or fine fibers. Element 125 may be a layer of spunbond fibers. Each fiber layer may be formed by growing fibrils to extend outwardly after a predetermined time under atmospheric conditions, as will be described in more detail below. FIG. 2 shows a cross-sectional view of an SNS nonwoven fabric substrate or SMS nonwoven fabric substrate at the calendar binding site 168 in an embodiment. Fibrils may occur at the calendar binding site 168 after a predetermined time under atmospheric conditions, as described below. Spunbond, intermediate, and fine fibers may be monocomponent or bicomponent or mixed polymer.

  In an embodiment, referring to FIGS. 2 and 3, the nonwoven substrate 112 may comprise a first nonwoven layer 125, a second nonwoven layer 132, and a third nonwoven layer 136. The binding site 168 may have a binding region. The second nonwoven fabric layer 132 may be disposed between the first nonwoven fabric layer 125 and the third nonwoven fabric layer 136. Also, the first nonwoven layer 125, the second nonwoven layer 132, and the third nonwoven layer 136 are bonded to each other intermittently using any suitable bonding process such as, for example, a calendar bonding process. Also good. In an embodiment, the nonwoven fabric substrate 112 does not consist of a film. In various embodiments, the nonwoven substrate 112 includes a spunbond layer corresponding to the first nonwoven layer 125, an N-fiber layer or intermediate layer corresponding to the second nonwoven layer 132, and a third nonwoven layer 136. It may consist of a corresponding second spunbond layer.

  In an embodiment, referring to FIGS. 4 and 5, the nonwoven substrate 212 comprises a first nonwoven layer 225, a second nonwoven layer 232, a third nonwoven layer 236, and a fourth nonwoven layer 228. Also good. A binding site 268 such as a calendar binding site is shown in the nonwoven substrate 212. The binding site 268 has a binding region. The first nonwoven layer 225, the second nonwoven layer 232, the third nonwoven layer 236, and the fourth nonwoven layer 228 are intermittently connected to each other using any suitable bonding process, such as, for example, a calendar bonding process. May be bonded to. In an embodiment, the nonwoven fabric substrate 212 does not comprise a film. In various embodiments, the nonwoven substrate 212 corresponds to a spunbond layer corresponding to the first nonwoven layer 225, a meltblown layer or fine fiber layer corresponding to the fourth nonwoven layer 228, and a second nonwoven component layer 232. It may consist of a fine or N-fiber layer or meltblown layer and a second spunbond layer corresponding to the third nonwoven component layer 236. Other configurations of the nonwoven substrate include, for example, a nonwoven substrate comprising one or more spunbond layers, one or more meltblown or intermediate layers, and / or one or more fine or N-fiber layers, etc. Are within the scope of the present disclosure.

  In embodiments, the disclosed nonwoven substrates of the present invention include, but are not limited to, SMS, SMMS, SSMMS, SMMSS, SMN, SNS, SMNMS, SMMMS, SSMMNS, SSNNSS, SSSNSSS, SMMNNNSS, and SMMNMNMS, and other suitable variations May be formed from a plurality of nonwoven layers arranged by various combinations and permutations of a plurality of spunbond, meltblown, and N-fiber layers.

  In embodiments, the nonwoven substrate may consist of one or more layers of spunbond fibers “S”, meltblown fibers “M”, and / or fine fibers “N”. The one or more nonwoven layers are comprised of fibers, wherein at least a plurality of fibers, or all or most of the fibers are outwardly from the fiber surface or radially outer surface or mostly radially outward. It consists of fibrils extending to In embodiments, the fibrils are in one layer of the nonwoven substrate (in all or part of the fiber), in all layers of the nonwoven substrate (in all or part of the fiber), or It may be present in less than all layers of the nonwoven substrate (in all or part of the fibers). In one example, at least one of the nonwoven substrates of the present disclosure may have a plurality of fibers or all fibers that are free of fibrils or substantially free of fibrils.

  Scanning electron micrographs of non-woven substrates having spunbond fibers made of fibrils extending outward from the surface or radially outward are shown in FIGS. 6-8 are 22 gsm SMMS nonwoven substrates, wherein the nonwoven substrate spunbond fibers are formed from a composition consisting of about 10% ester lipid glycerin tristearate by weight of the composition. It was. The spunbond layers of the nonwoven fabric substrate each have a basis weight of 10 gsm, while the meltblown layers each have a basis weight of 1 gsm. Although the meltblown layers of FIGS. 6-8 do not have fibers made of fibrils, meltblown fibers (and fine fibers) with fibrils are within the scope of the present disclosure. 11 and 12 are further enlarged views of the nonwoven fabric substrate of FIG. FIGS. 9-11 are 14 gsm SM nonwoven substrates, wherein the nonwoven substrate spunbond fibers were formed from a composition consisting of 10% ester lipid glycerin tristearate by weight of the composition. . 14 and 15 are enlarged views of the nonwoven fabric substrate of FIG. The spunbond layer of the nonwoven substrate has a basis weight of 13 gsm and the meltblown layer has a basis weight of 1 gsm. Although the meltblown layers of FIGS. 9-11 do not have fibers composed of fibrils, meltblown fibers (and fine fibers) with fibrils are within the scope of the present disclosure.

  12 to 14 show SEM photographs of cross-sectional views of the SMNS nonwoven fabric substrate, where at least some of the spunbond fibers are made of fibrils. The nonwoven substrate has a total basis weight of 18 gsm. Spunbond fibers consisting of fibrils are formed from a composition consisting of 10% glycerin tristearate by weight of the composition. Although fine fibers having meltblown and fibrils are within the scope of the present disclosure, the meltblown layers and fine fiber layers of FIGS. 12-14 do not have fibers composed of fibrils.

  Some examples of non-woven substrate constructions having one or more layers with multiple fibers of fibrils or all fibers of fibrils are shown below. The “*” after the letter indicates that the layer has fibers, where at least some or all of the fibers have fibrils. Some examples of configurations are as follows: S * MS *, SM * S, S * M * S, SM * S *, S * M * S *, S * M * NS, S * M * NS *, S * M * N * S *, SM * N * S, S * MNS *, SMN * S, S * SMNS, S * S * MNS, S * S * MNS *, S * S * M * NS *, S * S * M * N * S *, S * SM * NS *, S * MNMS *, S * M * NMS *, SSM * N * MS, S * S * M * MS, S * SM * MS and / or S * MM * S. Any other suitable configuration of layers with or without fibrils is also within the scope of the present disclosure.

  In some embodiments, it may be desirable for one or more layers of fibers comprising fibrils to be located on a particular side of the nonwoven substrate or at a particular location within the nonwoven substrate. In one example, the fiber layer comprising fibrils may be disposed on both the wearer-facing side, the garment facing side, or the absorbent article, and the nonwoven substrate intermediate layer may be from fibrils. It may or may not be made of fibers. In another embodiment, the layer composed of fibers composed of fibrils may be disposed in the intermediate layer of the nonwoven fabric substrate. In yet another embodiment, the fibril fiber layers may alternate through the nonwoven substrate (e.g., fibril fiber layers, fibril non-fiber layers, fibril fibers). Fiber layer, etc.). In another embodiment, the layer of fibers made of fibrils may be arranged so that the surfaces are in contact with each other. The arrangement of layers of fibrils may be specific to a particular application. For wipes, the fiber layer of layers or fibrils may be placed on the side of the wipe that contacts the surface of the human body to be cleaned, wiped, scraped or scrubbed. Or may be arranged at other positions. Although the fibrils extend outward from the surface of the individual fibers, the fibrils can also be the same layer of the nonwoven substrate or other fibers (ie, contacts) in different layers and / or the same of the nonwoven substrate. It may extend to fibrils extending from fibers in layers or in different layers. An example of this feature is disclosed in FIGS. If the fibrils extend between the fibers and / or other fibrils, the nonwoven substrate may cause liquid penetration due to the narrow gaps or pores of the fibrils in the nonwoven substrate when engaged with other fibers or fibrils. Greater resistance to (eg, low surface tension liquid strike-through) can be achieved. In other words, fibrils extending between the fibers and / or other fibrils reduce the open area of the nonwoven substrate, thereby increasing its liquid barrier properties. In some cases, long fibrils can contact other fibrils and / or fibers than shorter fibrils. In various embodiments, the fibril has a length from the outer surface of the fiber, or radially outer surface, to the free end of the fibril (i.e., the end of the fibril furthest from the outer surface of the fiber). 0.2 μm to about 40 μm, about 0.5 μm to about 20 μm, about 1 μm to about 15 μm, about 1 μm to about 10 μm, about 1 μm to about 5 μm, about 2.5 μm to about 5 μm, about 2 μm to about 4 μm, about 2.5 to about 3.5 μm, or about 3 μm, especially in the above-mentioned range and all the ranges formed in or by it, with what is proposed in the range of every 0.1 μm increment Can do. The fibrils of the various fibers in one or more nonwoven layers may be the same length or length within the same range, substantially the same length or substantially the same range, or It may have different lengths or different ranges of lengths. In embodiments, the fibers in a layer of the nonwoven substrate, such as a spunbond layer, may have fibers having a first length or range of lengths of fibrils, and other spunbond layers, The fibers in the second layer of the nonwoven substrate, such as a meltblown layer or a fine fiber layer, may have fibers having fibrils in the second length or range of lengths. The first and second lengths and / or length ranges of the fibrils may be the same, substantially the same, or different. In embodiments, the first and second lengths and / or length ranges of the fibrils may be meltblown layer (s) or fine fiber layer (s) compared to that of the spunbond layer (s). (Multiple) may be small or large. Further, the first and second lengths and / or length ranges of the fibrils may be smaller or larger in the fine fiber layer (s) than that of the meltblown layer (s). The fibrils may have a uniform thickness or various thicknesses, and may have any suitable cross-sectional shape. One key factor that determines fibril length, thickness, and / or cross-sectional shape is added to the composition used to form the fibers, as described in more detail below. It is believed to be the amount by weight of the composition of a melt additive such as an ester lipid. Equally important is the selection of the bulk polymer composition into which the melt additive is inserted and from which the fibrils lift, and more specifically, the hardness, density, and crystallization of the bulk polymer matrix in the fiber. Degree is a factor. Another factor is the composition of the melt additive that can continue to grow as fibrils from the surface of certain types of ester lipids and fibers that can, for example, more or less easily diffuse through the bulk polymer matrix. . Other factors that affect fibril length, thickness, and / or cross-sectional shape are conditions that are significantly above or below environmental conditions, particularly atmospheric conditions. The length of the fibril is measured according to the fibril length measurement test described below.

In various embodiments, the fibrils may have a non-circular cross-sectional shape, and may instead be generally oval or even nearly rectangular. Therefore, it is useful to describe the fibril cross-sectional size (“thickness” or “width”) in terms of hydraulic diameter. The hydraulic diameter is determined by calculating the cross-sectional area (takes somewhere in the middle 1/3 of the fibril length), multiplied by 4 and divided by the perimeter of the cross-sectional shape. Hydraulic diameter D _H = 4 * area / perimeter length. For fibrils with a circular cross section, the hydraulic diameter is equal to the fibril diameter, and for fibrils with a rectangular cross section, the hydraulic diameter is DH = 4 * L * W / (2 * L + 2 * W), where L and W are rectangular sides of the cross section, and thus fibrils with cross-sectional dimensions of 300 nm (W) and 1500 nm (L) have a hydraulic diameter of 500 nm. An approximation of the perimeter of other cross-sectional shapes can be calculated according to known mathematical formulas.

  In various embodiments, the fibrils have an average hydraulic diameter (ie, cross-sectional thickness) ranging from about 50 nm to about 1100 nm, from about 100 nm to about 800 nm, from about 200 nm to about 800 nm, from about 300 nm to about 800 nm, from about 500 nm. From about 800 nm, from about 100 nm to about 500 nm, or about 600 nm, particularly in the ranges described above and in all the ranges formed therein or by it, are proposed in ranges that increase in every 1 nm increment. The hydraulic diameter of individual fibrils may be constant, substantially constant, or variable with respect to the fibril length. In an embodiment, the fibril hydraulic diameter may decrease with respect to the length of the fibril (from the beginning of the fibril to its furthest end). In an embodiment, the fibers in the layer of the nonwoven substrate, such as the spunbond layer, may have fibers having fibrils having a first average hydraulic diameter or average hydraulic diameter or range of average hydraulic diameters; And the fibers in the second layer of the nonwoven substrate, such as the meltblown layer or the fine fiber layer, may have fibers with fibrils having a second average hydraulic diameter or a range of average hydraulic diameters. The first and second average hydraulic diameter and / or range of average hydraulic diameters of the fibrils may be the same, substantially the same, or different. In embodiments, the first and second average hydraulic diameter and / or range of average hydraulic diameter of the fibrils may be smaller in the meltblown layer or fine fiber layer than that of the spunbond layer (s). May be large or identical. Further, the first and second average hydraulic diameters and / or ranges of average hydraulic diameters of the fibrils may be smaller, larger, or identical in the fine fiber layer compared to that of the meltblown layer. Good.

  In embodiments, the nonwoven substrate may have binding sites such as the binding sites 168, 268 shown in FIGS. 2 and 4 above. Each binding site may have a binding region. FIG. 15 shows a 200 × magnification SEM photograph of fibrils grown from a portion of the binding sites in the binding region after the binding sites were formed on the nonwoven substrate. The photograph was taken at least 100 hours after the binding sites (eg, calendar bonds) were formed on the nonwoven substrate. The nonwoven substrate of FIG. 15 is an SM nonwoven substrate, wherein the nonwoven substrate spunbond fibers were formed from a composition consisting of 10% ester lipid glycerin tristearate by weight of the composition. Although the meltblown layer of FIG. 15 is not composed of fibers having fibrils, meltblown fibers (and fine fibers) having fibrils are within the scope of the present disclosure. The spunbond layer is 13 gsm, while the meltblown layer is 1 gsm. The fibrils may extend outward from the surface of the binding site. In such embodiments, a nonwoven substrate fiber layer is formed and then calendered or otherwise bonded (eg, using rolls 138 and 140 of FIG. 1), and further the nonwoven substrate. Fibrils grew out of the surface of the binding site from the fibers in one or more layers. The disclosed packages, packaging materials, and wipes of the present invention may also consist of a nonwoven substrate consisting of a layer of fibers consisting of binding sites, where each binding site consists of a binding region, And here, the plurality of fibrils extend outward from the surface of the binding region.

  16 to 18 are SEM photographs of cross-sectional images taken of some binding sites of the SMNS nonwoven fabric substrate having a basis weight of 18 gsm. The spunbond fibers of the nonwoven substrate are formed from a composition consisting of 10% glycerin tristearate by weight of the composition. At least some of the spunbond fibers comprise fibrils. The meltblown layer and fine fiber layer consisting of the fibrils of FIGS. 16-18 have no fibers, but meltblown and fine fibers with fibrils are within the scope of the present disclosure.

  In an embodiment, the composition used to make the layer of fibers, wherein at least some or all of the fibers consist of fibrils extending outward therefrom, such as polyolefins and ester lipid melt additives, etc. It may consist of one or more melt additives or may consist of any of the materials described herein with respect to the fiber composition for the melt additive. The polyolefin may consist of polypropylene, polyethylene, or other polyolefins such as, for example, polybutylene or polyisobutylene. Melt additives or ester lipids may be present in the composition and are 2% to 45%, 11% to 35%, 11% to 30%, 11% to 25%, 11% by weight of the composition. -20%, 11% -18%, 11% -15%, 11% -15% range, 3%, 5%, 10%, 11%, 12%, 15%, 20%, 25%, 30% , 35%, or 40%, especially those mentioned above and in all the ranges formed therein or by it, may be proposed in the range of every 0.5% increment. Suitable melt additives for the present disclosure are hydrophobic melt additives. Thus, the melt additive can increase the hydrophobicity of the fibers in the fiber layer, particularly when the fibrils extend outside the fibers. This is because when compared to a nonwoven substrate that does not have at least one layer formed from a composition comprising one or more melt additives, the layer of fibers in the nonwoven substrate and / or the nonwoven substrate It leads to its own low surface tension liquid strike-through time and increased hydrophobicity. This can also provide good filtration and / or special capture properties when compared to conventional nonwoven substrates.

  The melt additive of the present disclosure, i.e., ester lipid, is in the range of 30C to 160C, 40C to 150C, 50C to 140C, 50C to 120C, 50C to 100C, 60C to 60C. 80 ° C., 60 ° C. to 70 ° C .; about 60 ° C., about 65 ° C., or about 70 ° C., especially in the above-mentioned range and all ranges formed therein or by it, the range increasing in every 1 ° C. It may have a melting point proposed in. In various embodiments, the melt additive of the present disclosure may have a melting point above 30 ° C, above 40 ° C, or above 50 ° C, but below 200 ° C or below 150 ° C. Good.

  The melt additive used in the composition may comprise a fatty acid derivative such as a fatty acid ester; typically, an alcohol having two or more hydroxyl groups and at least 8 carbon atoms, at least 12 carbon atoms. An ester formed from one or more fatty acids having carbon atoms or at least 14 carbon atoms, whereby different fatty acid-derived groups may be present in one ester compound (here Called fatty acid esters).

  The fatty acid ester compound may be an ester of an alcohol having two or more, or three or more functional hydroxyl groups per alcohol molecule, whereby all the hydroxyl groups form an ester bond with the fatty acid (either fatty acid or a mixture thereof). Or)

  In an embodiment, the alcohol may have three functional hydroxyl groups.

  In embodiments, it may consist of one or more melt additives mono and / or diglyceride esters and / or triglyceride esters (having groups derived from one, two or three fatty acids).

  The fatty acids used to form the ester compound include fatty acid derivatives for purposes of this disclosure. A mono-fatty acid ester or, for example, an aminoglyceride, consists of one fatty acid, for example glycerin; a di-fatty acid ester, or, for example, a diglyceride, consists of two fatty acids, for example glycerin. A trifatty acid ester or, for example, a triglyceride consists of three fatty acids, for example, glycerin. In embodiments, the melt additive may comprise at least a triglyceride ester of a fatty acid (ie, the same or different fatty acid).

  The triglyceride ester may have an esterified glycerol skeleton that does not have a non-hydrogen substituent on the glycerol skeleton; however, the glycerin skeleton may also consist of other substituents. Should be understood.

  In an embodiment, the glycerin skeleton of the glycerin ester may consist solely of hydrogen. The glyceride ester may also consist of polymerized (eg tri) glyceride esters, such as polymerized, saturated glyceride esters.

  In fatty acid esters having more than one ester bond, such as di- or triglycerides, the groups derived from fatty acids may be the same or they may be groups derived from two or even three different fatty acids.

  The melt additive consists of a mixture of mono, di, and / or tri fatty acid esters (eg, mono, di and / or triglycerides) esters having the same fatty acid-derived groups and / or different fatty acid-derived groups per molecule. It may be.

  Fatty acids may be derived from plants, animals, and / or synthetic sources. Some fatty acids may range from C8 fatty acids to C30 fatty acids, or may be C12 fatty acids to C22 fatty acids. Suitable plant fatty acids typically include unsaturated fatty acids such as oleic acid, palmitic acid, linoleic acid, and linolenic acid. The fatty acid may be arachidec acid, stearic acid, palmitic acid, myristic acid, myristoleic acid, oleic acid, limoleic acid, linolenic acid, and / or arachidonic acid.

  In other embodiments, substantially saturated fatty acids may be used, particularly when saturation occurs as a result of hydrogenation of the fatty acid precursor. In an embodiment, C18 fatty acids, i.e. octadecanoic acid, or more commonly called thearic acid, may be used here to form ester bonds of fatty acid esters; stearic acid is an animal fat and some vegetable oils You may derive from. Stearic acid can also be produced by hydrogenation of vegetable oils such as cottonseed oil. Here, the fatty acid esters may consist of fatty acids of mixed hydrogenated vegetable oils, such as those having CAS registration number 68334-28-1.

  At least one stearic acid, at least two or three stearic acids bind to glycerin to form glycerin tristearate, which is the melt additive here. Here, the melt additive may be composed of at least glycerin tristearate.

  In an embodiment, the melt additive consists of glycerin tristearate (CAS No. 555-43-1), also known by a name such as tristearin or 1,2,3-trioctadecanoyl glycerin. Also good. (In the following, the name glycerol tristearate is used and, if in doubt, CAS No. should be considered as the primary identifier).

  In embodiments, the fatty acid ester of the melt additive may have a number average molecular weight in the range of 500 to 2000, in the range of 650 to 1200, or in the range of 750 to 1000, in particular the ranges described above and its In all ranges formed in or by it, one can have what is proposed in a range increasing in all integer increments.

  The melt additive may be very low or free of any halogen atoms; for example, the melt additive may contain less than 5% by weight of halogen atoms (relative to the weight of the melt additive), or Less than 1% by weight of the melt additive, or less than 0.1% by weight; the melt additive may be substantially halogen-free.

  In embodiments, the melt additive may or may not consist of ester lipids or glycerin tristearate. In various embodiments, the fibrils are (i.e., 51% -100%, 51% -99%, 60% -99%, 70% -95%, 75% -95%, 80% -95%, especially as described above. Or in all the ranges formed therein or in it, which may be contained in a range of all 0.1% increments), or consisting solely of, or It may consist essentially only of it.

  The masterbatch added to the composition from which the fibers of the present disclosure are formed may be the masterbatch disclosed in US Pat. No. 8,026,188 to Mor.

  Once the melt additive composition and the polyolefin have been used to form a fiber layer, the fiber layer is incorporated into a nonwoven substrate as disclosed in the example of FIG. Based on the concentration of the melt additive in the composition used to form the fiber and based on how many layers of the nonwoven substrate fiber have fibers composed of the melt additive, a plurality of A nonwoven substrate having one or more layers of fibers with fibers may have fibrils extending therefrom and may comprise a melt additive in the range of 1% to 35% by weight of the nonwoven substrate. Other possible ranges of melt additives are 2% to 35%, 5% to 25%, 11% to 35%, 11% to 25%, 11% to 20%, 11% by weight of the nonwoven substrate. May be -18%, 11% -15%, 11%, 12%, 13%, 15%, or 18%, especially within the range specified in and within this paragraph In this range, it may be contained in a range that increases every 0.5%.

  In embodiments, the fibrils may grow on the outside of the fiber under atmospheric conditions under post nonwoven substrate formation (ie, after the process shown in FIG. 1). Fibrils may be recognized using SEM after about 6 hours under post nonwoven substrate forming atmosphere conditions. Fibril growth may reach a plateau after about 50 hours, 75 hours, 100 hours, 200 hours, or 300 hours under post-nonwoven substrate forming atmosphere conditions. Recognizable fibril growth post nonwoven substrate formation time ranges from 5 hours to 300 hours, 6 hours to 200 hours, 6 hours to 100 hours, 6 hours to 24 hours, 6 hours to 48 hours under atmospheric conditions. It may be hours, or 6 to 72 hours, and is proposed in a range increasing in every 1 minute, especially in the above-mentioned range and in all the ranges formed therein or thereby. The time allowing full fibril growth post nonwoven substrate formation would be, for example, 12 hours, 24 hours, 48 hours, 60 hours, 72 hours, 100 hours, or 200 hours under atmospheric conditions.

  Also provided is a method of forming an absorbent article having one or more nonwoven substrates of the present disclosure. As described in the method, the absorbent article may be, for example, a diaper, training pants, an adult incontinence product, and / or a sanitary tissue product.

  In an embodiment, the method of forming the absorbent article may comprise providing one or more nonwoven substrates each consisting of one or more layers of fibers, wherein one or more The plurality of fibers in the above layers, or all the fibers, consist of a plurality of fibrils extending outwardly or radially outwardly from the fiber body and / or surface. The fibrils may extend at least outward from the longitudinal center 1/3 of the fiber. Fibrils may consist of, consist solely of, or consist essentially of, one or more melt additives, such as ester lipids or glycerin tristearate. The method may further comprise incorporating one or more nonwoven substrates into the absorbent article. In embodiments, incorporation consists of forming a backsheet of at least some filmless liquid impervious material or absorbent article. In other embodiments, incorporation consists of forming a topsheet of at least some filmless liquid permeable material or absorbent article. In yet another embodiment, the incorporation is a barrier leg cuff or gasketing cuff of part of the absorbent article, or, for example, a core cover or dusting Forming other parts of the absorbent article, such as a layer.

  In an embodiment, the method of forming a component, or part of an absorbent article, package, or commodity may comprise forming fibers that are used to form the first layer of the nonwoven substrate. Well, here the fibers in the first layer are formed from a composition consisting of a thermoplastic polymer and an ester lipid such as glyceryl tristearate. This method may consist of forming the fibers used to form the second layer of the nonwoven substrate. The fibers of the second layer may or may not be formed from a composition composed of an ester lipid such as glycerin tristearate, but may be composed of at least a thermoplastic polymer. In an embodiment, the first layer may consist of spunbond fibers or meltblown fibers and the second layer may consist of spunbond fibers, meltblown fibers, or fine fibers. The method further bonds the first and second layers together and grows fibrils from at least some of the fibers under atmospheric conditions for a predetermined time (eg, 6 to 100 hours or 24 hours). It may consist of forming the nonwoven substrate after (time to 300 hours). The fibrils may grow at least outside the middle 1/3 of the longitudinal length of the fiber. The fibril growth process may occur before or after the bonding process. The bond may be a calendar bond, a mechanical bond, a thermal bond, and / or other bond types known to those skilled in the art. The method may consist of forming fibers that are used to form at least a third layer (ie, fourth, fifth layer, etc.) of the nonwoven substrate. The fibers of the third layer may or may not be formed from a composition composed of an ester lipid such as glycerin tristearate, but may be composed of at least a thermoplastic polymer. The bonding step may include bonding the first, second, and at least third layers together to form a nonwoven substrate. The third, fourth, fifth, etc. layers may consist of spunbond fibers, meltblown fibers, and / or fine fibers.

  In other embodiments, the method of forming the components of the absorbent article provides one or more nonwoven substrates, each comprising one or more layers of fibers, under post-nonwoven substrate forming atmosphere conditions. It may comprise allowing a plurality of fibrils to grow outside at least some or all of the fibers and incorporating a nonwoven substrate into one or more of the components of the absorbent article. The incorporation step may be performed before or after the allowing step. The component may be one or more of a barrier leg cuff, gasketing cuff, topsheet or liquid permeable material, backsheet or liquid impermeable material, wing, core cover, dusting layer, or other component. Good. Ingredients may be filmless or combined with a film. The period of fibril growth, post nonwoven substrate formation, or fiber formation may be at least 12 hours, at least 24 hours, at least 50 hours, at least 75 hours, at least 100 hours, or at least 200 hours.

  In another embodiment, a method of forming an absorbent article provides one or more nonwoven substrates composed of one or more layers of fibers, wherein the nonwoven substrate has a specific surface area of at least 10%, 15 %, 20%, 25%, 100%, 200% or more, less than 400%, 350% or 300%, 10% to 350%, or 20% to 200%, in particular within or by the above ranges In all the ranges to be formed, it is allowed to increase under the post-nonwoven fabric substrate forming atmosphere conditions up to the value proposed in the range of increasing in every 1% increment, Alternatively, it may consist of allowing the fibrils to grow outside of the further layers and incorporating the nonwoven substrate into part of the absorbent article. The incorporation process may be performed before or after the acceptance process. The fibers having fibrils may be spunbond fibers, meltblown fibers, and / or fine fibers. The time to increase the specific surface area under post nonwoven fabric substrate formation atmosphere conditions is at least 6 hours, at least 24 hours, at least 48 hours, at least 60 hours, at least 100 hours, at least 200 hours, but less than 300 hours. In particular, within the specified range, time increasing every 1 minute is also proposed.

  In yet another embodiment, the method of forming the absorbent article provides one or more nonwoven substrates each consisting of one or more layers of fibers, wherein the one or more nonwoven substrates are: Allow at least 10%, 15%, 20%, 25%, 100%, 200%, or 300% increase in its specific surface area under post fiber forming atmosphere conditions of one or more layers of fibers. And a step of incorporating the nonwoven fabric substrate into the absorbent article. The incorporation process may be performed before or after the acceptance process.

In embodiments, the nonwoven substrate of the present disclosure may consist of one or more layers of fibers comprising fibrils. The nonwoven substrate having been subjected to the post-fibril growth of under ambient ^conditions, the range of ^{0.3m 2 / g~7m 2 / g,} 0.5m 2 / g~5m 2 /g,0.6m 2 / g~3 ^{.5m 2 /g,0.7m 2 / g~3m 2 /g,0.7m} 2 /g~1.5m 2 /g,0.84m 2 /g~3.5m 2 / g, or 1.15m ^It may have a specific surface area of ² / g or more, especially including those increasing in every 0.1 μm in the above-mentioned range and all ranges formed therein or thereby.

  FIG. 19 shows the specific surface area of a conventional nonwoven substrate (various SM and SMN samples without the disclosed ester lipid melt additive) of the same nonwoven with the ester lipid melt additive according to the present disclosure. The graph compared with the specific surface area of the base material is displayed. The X axis in the figure represents the specific surface area not including fibrils, and the Y axis in the figure represents the specific surface area including fibrils. The nonwoven substrate of the present disclosure of FIG. 19 has 10% (triangle in the figure) or 15% (circle in the figure) of glycerin tristearate by weight of the composition in the spunbond layer of the sample. On the other hand, conventional nonwoven fabric substrates (diamonds in the figure) are those containing no glycerin tristearate in their fiber compositions. A dotted line represents the specific surface area of the conventional nonwoven fabric base material. The calculated specific surface area of a conventional nonwoven substrate that does not contain glycerin tristearate is shown as a hollow rectangle in the figure. As will be appreciated, the specific surface area of the nonwoven substrates of the present disclosure consisting of fibers formed from a composition having 10% or 15% glycerin tristearate, by weight of the composition of the spunlaid fibers, is The specific surface area of a conventional nonwoven fabric substrate that does not contain glycerin tristearate in the fiber composition is considerably higher. The asterisks in the figure are 13 gsm (low in the figure) containing 10-15% glycerin tristearate by weight of the composition used to form 1 gsm M and 1 gsm N, respectively, and spunbond fibers. Represents samples of SMN nonwoven substrates with spunbond layers with values of about 0.67) or 19 gsm (high values in the figure). These samples were not made without the melt additive of the present disclosure and, as expected, have a specific surface area of 20% to 100% higher than the sample without the melt additive. The predicted range is shown. In an embodiment, the nonwoven substrate of the present disclosure has a ratio of low surface tension liquid strike-through time (according to the following low surface tension liquid strike-through time test) to basis weight (according to the following basis weight test) of 0. .35 s / gsm to 5.0 s / gsm, 0.37 s / gsm to 5.0 s / gsm, 0.4 s / gsm to 4 s / gsm, 0.35 s / gsm to 15 s / gsm, 0.5 s / gsm to 15 s / Gsm, 1 s / gsm to 10 s / gsm, 2 s / gsm to 4 s / gsm, 0.37 s / gsm or more, 0.38 s / gsm or more, or 0.4 s / gsm or more, especially in the above-described range and in or Within the full range formed thereby, one can have an increase in every 0.1 s / gsm increments. This ratio will be higher when more ester lipid melt additive is present in the nonwoven substrate and lower when less ester lipid melt additive is present in the nonwoven substrate.

  FIG. 20 shows a graph of the ratio (seconds / gsm) of low surface tension liquid strike-through time (seconds) to basis weight (gsm) compared to the basis weight (gsm) of glycerin tristearate in the nonwoven substrate. . Diamonds represent SM or SMS nonwoven substrates and rectangular SMNS and SMN nonwoven substrates. Samples indicated with diamonds have the same basis weight for both SM and SMS nonwoven substrate samples. The sample indicated by the rectangle has the same basis weight for both the SMNS and SMS nonwoven substrate samples. The X axis in the figure represents the basis weight of glycerin tristearate in the tested nonwoven substrate. The Y axis in the figure represents the ratio (seconds / gsm) of the low surface tension liquid strike-through time (seconds) to the basis weight (gsm) of the tested nonwoven fabric substrate. For every 0.5 gsm of glycerin tristearate in the nonwoven substrate, there is a change of at least 30% in the ratio of strikethrough to basis weight. In some cases, there is an approximately 100% change in the ratio of strikethrough to basis weight for every 1 gsm of glycerin tristearate in the nonwoven substrate.

  In an embodiment, the absorbent article may consist of a nonwoven substrate consisting of one or more layers of fibers. The fibers may or may not consist of fibrils that extend outwardly from the surface of the fibers. The nonwoven substrate has a specific surface area of at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 50%, at least 100, exceeding the post nonwoven fabric substrate forming atmosphere conditions for a predetermined time. %, At least 200%, at least 300%, or from 10% to 300%, from 10% to 250%, or from 20% to 200%, particularly within and within the specified range Within all the ranges formed, it may be increased by every 0.5% step. The predetermined time may be longer than 6 hours and less than 200 hours, or longer than 12 hours and shorter than 120 hours. The post nonwoven substrate formation for a predetermined time may be the same as described herein.

While not intending to be bound by any particular theory, FIG. 21 shows that 15% glycerin tristearate by weight of the composition used to make spunbond fibers increases over time. An example of the graph of the specific surface area (m < ² > / g) of the nonwoven fabric base material of this indication containing this is shown. There is no glycerin tristearate in the meltblown or fine fibers of this sample. The nonwoven substrate shown as a graph in FIG. 21 is a 13 gsm SMN nonwoven substrate. The specific surface area increases under post fiber formation and / or post nonwoven substrate formation atmosphere conditions.

  Referring to FIG. 22, low surface tension liquid strike-through time (seconds) is graphed for various nonwoven substrates of the present disclosure. All disclosed nonwoven substrates of the present invention are 13 gsm SMN nonwoven substrates. An asterisk indicates a layer with GTS in the layer. The asterisk after the S layer indicates that spunbond fibers with fibrils were formed from a composition consisting of about 10% GTS by weight of the composition, while the asterisk after the N layer was , Indicating that the nanofibers were formed from a composition consisting of about 1% GTS by weight of the composition. As can be seen from FIG. 22, as the number of layers of glycerin tristearate and thereby fibrils increases, the low surface tension strike through time will be higher. The strike-through time for a conventional 13 gsm SMN nonwoven substrate is also graphed in FIG. 22 for comparison.

  Referring to FIG. 23, the low surface tension liquid strike-through time in seconds (Y-axis) shows that as the proportion of glycerin tristearate used to form the fiber increases with the weight of the composition, Increased in the nonwoven substrates of the present disclosure. The sample in FIG. 23 is a 50 gsm spunbond substrate with about 20 micrometer fibers.

  Referring to FIG. 24, the low surface tension liquid strike-through time in seconds (Y-axis) is the percentage of glycerin tristearate used to form the fiber (X-axis) and the nonwoven by weight of the composition. As the basis weight of the substrate increases, it increases in the nonwoven substrate of the present disclosure. The sample of FIG. 24 consists of a spunbond nonwoven substrate having a basis weight of 13 gsm (bottom line in the figure), a spunbond nonwoven substrate having a basis weight of 16 gsm (center line in the figure), and 19 gsm. 1 shows a spunbonded nonwoven fabric substrate having a basis weight of (top line in the figure). As can be seen from the graph of FIG. 24, the weight of the composition strikes as the proportion of glycerin tristearate used to form the fibers increases and as the basis weight of the nonwoven substrate increases. The slew time increases significantly.

  Referring to FIG. 25, the low surface tension liquid strike-through time in seconds (Y axis) of the nonwoven substrate of the present disclosure decreases as the fiber diameter increases. All samples contain 15% by weight of the composition of glycerin tristearate used to form the fibers. The sample in FIG. 25 is a 50 gsm spunbond substrate.

  Referring to FIG. 26, the low surface tension liquid strike-through time in seconds (Y-axis) of the nonwoven substrate of the present disclosure is increased as more fine fibers are added to the nonwoven substrate and / or the nonwoven substrate. It increases as the basis weight of the glycerin tristearate increases (X axis). The top line in the graph is a spunbond / meltblown formed from a 1 gsm composition of fine fibers containing 10% glycerin tristearate by weight of the composition and free of any glycerin tristearate. From a nonwoven substrate (SMN) containing fibers. The bottom line in the graph contains, by weight of the composition, spunbond / meltblown fibers formed from a composition containing 10% glycerin tristearate and no fine fibers (SM). From a nonwoven substrate. The top line has a 1 gsm margin in basis weight compared to the bottom line due to the addition of 1 gsm fine fibers.

  In embodiments, the nonwoven substrate of the present disclosure may consist of one or more layers, each consisting of a plurality of fibers, wherein at least some of the fibers or all of the fibers are on the outer side. Or fibrils extending radially outward from the surface thereof. The nonwoven substrate may be used as a receiving component in an absorbent article fastening system. The receiving component may be configured to receive a fastening tab of a securing system 70 or other fastening tab or member. In embodiments, the nonwoven substrate may form all or part of a nonwoven landing area for one or more fastening tabs or members. The fastening tab or member may have hooks (eg, sides of the hook and loop fastener) that engage the nonwoven substrate. Because of the increased specific surface area in post-nonwoven substrate formation of nonwoven substrates and for fibrils compared to conventional nonwoven substrates, the disclosed nonwoven substrates of the present invention have hooks to the nonwoven substrate. Good adhesion can be provided. Examples of suitable nonwoven landing zone bonding patterns and other considerations for the nonwoven substrate of the present disclosure are described in Horn et al., US Pat. No. 7,895,718, Horn et al. et al.) U.S. Patent No. 7,789,870 and Ashraf et al. U.S. Patent Application No. 13 / 538,140, Ashraf et al. 538,177, and US Patent Application No. 13 / 538,178 to Rane et al.

  When used as a liquid permeable layer (e.g., a topsheet), the disclosed nonwoven substrates tend to retain less liquid, flowing BM, or menstrual blood than conventional nonwoven substrates, and thus , Completely drained by the underlying absorbent core, thereby giving the topsheet a cleaner appearance and a clean sensation. Examples of nonwoven substrates that may be used as liquid permeable layers are non-porous low density structures such as spunlaid structures with relatively high calipers and porosity, or open nonwoven substrates. May be.

  The nonwoven substrate of the present disclosure having at least one layer of fibers composed of fibrils may be softer or harder than a conventional nonwoven substrate, or may have the same softness, and It may be rough, smooth or designed to have the same tactile feel as compared to conventional nonwoven substrates. The softness, hardness, and / or feel of the nonwoven substrate will vary depending on, for example, the type and amount of ester lipid present in the composition used to form the fiber and the length of the fibrils. Yes. Softness, hardness, and / or texture can also vary depending on where one or more layers of fibers with fibrils are located within the nonwoven substrate.

  In embodiments, one or more of the nonwoven substrates of the present disclosure can be used for various fluids (ie, liquid (eg, water) or gas (eg, air)), filtration media, filters, or the like. Used as part of The surface area of the fibrils and thereby increased fibers can allow for better and / or more efficient filtration of the liquid by filtering more particulates or undesirable substances in the liquid. . This can also increase the useful life of the filter and / or filtration media. The concentration by weight of the ester lipid composition used to make the fiber may be increased to further enhance the more efficient filtration and / or life of the filter and / or filtration media. .

  In an embodiment, the fibril may have a different color than the fiber on which it grows. In other words, the fibrils may have a first color, and the fibers from which the fibrils grow may have a second color in the non-fibrillar region of the fibers. . The first color may be different from the second color (eg, non-fibrillar fibers may be white and fibrils may be blue, or non-fibrillar fibers may be It may be light blue and the fibrils may be amber). This color change can be achieved by adding a colorant, such as a pigment or dye, to the ester lipid before they are mixed into the composition used to form the fibers. When ester lipids grow from fibers, they are of a different color than the fibers on which they grow, thereby creating a color contrast between the fibrils and the fibers on which they grow. In an embodiment, the layers of nonwoven substrate composed of fibers comprising fibrils are colored over a period of time (i.e., the period during which the fibrils or portions thereof grow), depending on the contrast of the fibrils to the fibers on which they grow. Show change. Different layers of fibers may have different colored fibrils and / or fibers within them within the same nonwoven substrate. In embodiments, the colorant added to the ester lipid is one that can be dissolved in urine, menstrual blood, flowable BM, other body fluids, or other fluids (eg, water). In various embodiments, a colorant that dissolves in the fibrils may be used, for example, as an indicator of wetness in the absorbent article. Fibers having a color different from those fibrils can be used in any part of a commodity such as a wipe or an absorbent article.

  The nonwoven substrates of the present disclosure can be used to form at least some or all, suitably any commodity. Examples of products include wet tissues, baby wet tissues, dry wipes, facial wipes, makeup remover / application wipes, medical wipes, bandages and wraps, scrub wipes, stores Towels, towels, cleaning wipes, sanitary wipes, cleaning substrates. The wipes can be used for non-woven substrates, for example, for better absorbency, scrubbing ability, particulate capture, particulate retention, soil aspiration, soil retention, and / or coating capabilities as a result of fibrils. Benefits can be obtained from fibrils in at least one layer of fiber. Fibrils can be formed with ester lipids or other melt additives, which may have a waxy feel or texture that can aid in the adsorption and retention of dirty particles and other materials.

  The wipe or one or more nonwoven substrates having the fibrils of the wipe may comprise the composition. The composition may be applied to the fibers of the nonwoven substrate and / or may form or be applied to at least a portion of the fibrils. The composition may consist of water, perfume, soap, cosmetics, skin care composition, lotion, brightener, cleaning composition, other suitable compositions, and / or combinations thereof. The composition may be in liquid, semi-liquid, paste, or solid form when applied over and / or to the fibrils. When the composition consists of water, such as water, the wipes are 100% to 600% by weight, 150% by weight relative to the dry weight of the wipe or the dry weight of the nonwoven substrate within the wipe. % To 550%, or 200% to 500% moisture, especially in the above-mentioned range and any range formed therein or by it, the amount increasing in every 1% increment It may be. The wipe or nonwoven substrate is at least 10%, 20%, 30%, 40%, 50%, 75%, 100% based on the total weight of the wipe or on the total weight of the nonwoven substrate. The composition may contain a weight of 150%, 200%, 300% or more. While not intending to be bound by any theory, a nonwoven substrate having one or more layers of fibers composed of fibrils has a better affinity for the composition and / or a nonwoven substrate. It is believed that it has a better ability to hold the composition. Therefore, it is considered that the non-woven fabric layer composed of fibrils and fibrils can absorb a larger amount of the composition and can be stably maintained as compared with a conventional non-woven fabric substrate having no fibrils. In addition, fibrils are more storage and prior to use (i.e., drying the top wipe of the deposit and wetting the wipe at the bottom of the deposit) than conventional nonwoven substrates without fibrils. Will better inhibit stratification by stacking multiple wipes).

  In embodiments, when the wipe is rubbed against a surface, such as a surface to be cleaned or a body surface, at least some fibrils comprising the composition are removable or separable from the fibers. There may be. Fibrils may be separated from the fibers so that the composition can be applied to the surface. Such separation is caused by the frictional force on the wipe when moved over the surface. In an exemplary embodiment, the fibrils comprised of the composition may be formed as a wipe with a skin lotion applied. As the user moves the wipe over the body surface, the fibrils separate from the fibers and a skin lotion is applied to the body surface. Other examples are also within the scope of the present disclosure.

  In an embodiment, the nonwoven substrate of the present disclosure consisting of one or more layers of fibers comprising fibrils causes the fibrils to increase the scattering of sound waves as sound passes through the nonwoven substrate. In addition, the acoustic damping properties of the nonwoven fabric substrate are increased compared to conventional nonwoven fabric substrates. Furthermore, the disclosed nonwoven substrate provides better masking or opaqueness compared to conventional nonwoven substrates due to the scattering of light waves caused by fibrils as the light waves pass through the nonwoven substrate. Has characteristics.

  The nonwoven fabric substrate of the present disclosure may be used as a packaging material or may be used to form at least a portion or the entire package. The package can take any suitable configuration, such as the configuration of one or more items within the package or any other configuration. The packaging material used herein is a sanitary napkin that is attached to, attached to or formed on a consumer product prior to sale or use, even if the ingredients do not form the outer portion of the package. Or a release liner covering the adhesive on the absorbent article or any other component. In embodiments, the nonwoven substrate may be used to form at least an outer portion, an inner portion, or other portion of the package. Referring to FIG. 27, the package 300 may consist of one or more items 302 and is formed at least in part by the nonwoven substrate 304 of the present disclosure. The product 302 may also have a packaging material formed from the nonwoven substrate of the present disclosure. A portion of the package 300 is cut out in FIG. 27 to show an example product 302 in the package 300. The hydrophobicity and high low surface tension liquid strike-through time of the nonwoven substrate of the present disclosure provides good resistance to moisture ingress into the package, thereby making the product dry or substantially It is kept dry, while providing some degree of breathability to the package. The nonwoven substrate may also be combined with other materials such as films to form a package or wrapping material. One typical packaging material for merchandise is a film. The nonwoven substrate of the present disclosure can save costs because it has no film or a small amount of film. Nonwoven substrates can provide a softer packaging material than films.

  In an embodiment, the ester lipid in the fibers having the fibrils of the nonwoven substrate of the present disclosure may not include ester lipid droplets. “Contains no droplets of ester lipid” means that the ester lipid (eg, GTS) is a very fine particle (ie, less than 300 nm, less than 200 nm, or less than 100 nm), substantially uniform or uniform To disperse in the composition used to form the fiber, and thereby disperse in the fiber formed from the composition, and not to form pockets of ester lipids in the fiber Means. In a cross section of a fiber composed of ester lipids of the present disclosure, the droplets cannot be seen at 8000 × magnification using a SEM (see, for example, FIG. 29 at 8000 × magnification). The droplets used here have a minimum dimension of at least 300 nm and, if present, can be seen in the SEMS cross section of the fiber at a magnification of 8,000 times. Furthermore, the fiber has no void volume left in it once the ester lipid has dissolved using the weight loss test described below. The void volume used here has a minimum dimension of 300 nm and can be viewed using a SEM at a magnification of 8,000 times that of the fiber. The disclosed fibers of the present invention do not have such droplets and therefore no void volume is formed in the fibers after the weight loss test.

  28 and 29 show cross-sectional views of the fiber post weight loss test performance (eg, after dissolution of ester lipids such as GTS in the fiber). The fibers of FIGS. 28 and 29 are 18 gsm SMNS material containing about 10% glycerin tristearate by weight of the composition used to form the S layer, where M layer + N layer is GTS Has a basis weight of 2 gsm. As shown, there is no void volume in the fiber due to the dispersion of the ester lipid within the fiber substantially uniformly or uniformly. The void volume would have been created in the fiber if the fiber had ester lipid droplets present therein. Since there are no droplets in the disclosed fiber of the present invention, there is no void volume in the post weight loss test performance fiber.

  The components, packages, and merchandise of the absorbent articles described herein are at least partially described in US Patent Publication No. 2007 / 0219521A1 by Hird et al., Published 20 September 2007. Of Hird et al., Published June 16, 2011, US Patent Publication No. 2011 / 0139658A1, published on June 16, 2011, Hird et al. US Patent Publication No. 2011 / 0139657A1, Hird et al., Published June 23, 2011, US Patent Publication No. 2011 / 0152812A1, published on June 16, 2011 (Hird et al.) U.S. Patent Publication No. 2011 / 0139662A1, and Hird et al. As described in Patent No. 2011 / 0139659A1, it may consist of bio-source components. These components include, but are not limited to, topsheet nonwoven fabric, backsheet film, backsheet nonwoven fabric, side panel nonwoven fabric, barrier leg cuff nonwoven fabric, super absorbent, nonwoven fabric acquisition layer, core wrap nonwoven fabric, adhesive, fastener hook, and fastener landing Includes zoned nonwoven and film base. In embodiments, the component of the disposable absorbent article, the component of the commodity, or the component of the package may comprise a biosource component value of about 10% to about 100% using ASTM 06866-10 Method B. In another embodiment, from about 25% to about 75%, and in another embodiment, from about 50% to about 60% using ASTM 06866-10 Method B.

  In order to apply the ASTM 06866-10 methodology for quantifying the biosource component of any absorbent article component, package component, or commodity component, the absorbent article component, package component, or commodity component A representative sample of ingredients must be obtained for testing. In an embodiment, the absorbent article component, package component, or commodity component is a fine particle of less than about 20 mesh using known grinding methods (eg, Wiley® mill). To a representative sample of appropriate mass taken from randomly mixed particles.

FIG. 30 shows a graph of an example of mass average fiber diameter (X axis) versus specific surface area (Y axis). The triangles represent the calculated theoretical specific surface areas of various S, SM, SMS, SMNS, and M nonwoven substrate samples without GTS in the fiber. “X” represents a calculated 20% increase in the calculated theoretical specific surface area + specific surface area of the nonwoven substrate sample in triangles. This 20% increase in specific surface area indicates that the spunbond fibers are formed from a composition consisting of about 10% to about 15% GTS by weight of the composition. If the fibers have a weight average fiber diameter of less than 5, those samples will not have a spunbond layer, so about 10% to about 15% GTS in the meltblown layer. Would have added. The diamonds represent samples of various SMN nonwoven substrates with fibers, where some fibers were formed from compositions consisting of GTS. The S layer is formed from a composition consisting of about 10% to about 15% GTS by weight of the composition, and one of the M or N layers is a composition consisting of 1% GTS by weight of the composition. Formed from objects. The squares represent various samples of the SMN nonwoven substrate that does not contain GTS in any of its fibers. The mass average fiber diameter is expressed in μm, and the specific surface area is expressed in m ² / g. For mass average fiber diameters greater than 8 μm, the specific surface area may be greater than or equal to about 1.2 m ² / g. For mass average fiber diameters greater than 10 μm, the specific surface area may be greater than or equal to about 1.2 m ² / g. For mass average fiber diameters greater than 12 μm, the specific surface area may be greater than or equal to about 0.8 m ² / g. In various embodiments, the specific surface area of the fibers of the present disclosure, from about 0.5 m ² / g to about 10.0 m ² / g, about 0.7 m ² / g to about 8.0 m ² / g, or may range from about 0.8 m ² / g to about 6.0 m ² / g, in all ranges formed range and or thereby therein specified otherwise, all of the 0.1 m ² / g You can propose things that increase in increments.

In embodiments, the absorbent article, packaging material, and / or wipe may each consist of one or more nonwoven substrates consisting of a plurality of fibers, wherein at least some fibers May have a mass average fiber diameter of greater than 8 μm and a specific surface area of at least 1.6 m ² / g. In embodiments, the absorbent article, packaging material, and / or wipe may each consist of one or more nonwoven substrates consisting of a plurality of fibers, wherein at least some fibers May have a mass average fiber diameter greater than 10 μm and a specific surface area of at least 1.2 m ² / g. In embodiments, the absorbent article, packaging material, and / or wipe may each consist of one or more nonwoven substrates consisting of a plurality of fibers, wherein at least some fibers May have a mass average fiber diameter of greater than 12 μm and a specific surface area of at least 0.8 m ² / g. The absorbent article may comprise a liquid permeable material, a liquid impermeable material, and an absorbent core disposed at least partially in between the liquid permeable material and the liquid impermeable material.

  In an embodiment, the absorbent article may consist of a liquid permeable material, a liquid impermeable material, and an absorbent core disposed at least partially in between the liquid permeable material and the liquid impermeable material. . The absorbent article may further comprise a nonwoven substrate composed of one or more layers of fibers. Each of the plurality of fibers may be composed of a plurality of fibrils extending outward from the surface of the fiber. The plurality of fibrils may consist of ester lipids. Some or all of the liquid impermeable material may comprise a nonwoven substrate and the liquid impermeable material may not comprise a film. Some or all of the liquid permeable material may comprise a nonwoven substrate and may not include a film. The absorbent article may consist of one or more barrier leg cuffs. Some, or all, one or more barrier leg cuffs may be comprised of a nonwoven substrate, and the barrier leg cuff, or part thereof, may not include a film. The plurality of fibrils may consist of glycerin tristearate. The glycerin tristearate may have a melting point greater than 35 ° C or may be in the range of 40 ° C to 150 ° C. The plurality of fibers may be formed from a composition comprising a polyolefin and an ester lipid. The composition may comprise at least 11% of the ester lipid by weight of the composition. The average length of the fibrils from the fiber surface to the free ends of the fibrils may be in the range of 0.5 μm to 20 μm. The average hydrodynamic diameter of the fibrils may be in the range of 100 nm to 800 nm. The fiber layer may consist of spunbond fibers, meltblown fibers, and / or fine fibers. At least some of the fibrils may extend radially outward from the surface of the fibers in the central longitudinal direction 1/3 of at least some of the fibers. The fiber composed of a plurality of fibrils may not include ester lipid droplets. The fiber layer may consist of a plurality of bonds, each bond comprising a bond region. At least some of the plurality of fibrils may extend outwardly from at least one surface of the binding region. The nonwoven substrate may consist of a second layer of fibers. The fibers of the second layer of fibers may be substantially free of fibrils or not at all, or may consist of a plurality of fibrils. In an embodiment, the fiber layer may consist of spunbond fibers and / or meltblown fibers, and the second layer of fibers may consist of meltblown fibers and / or fine fibers. The fibrils may be a first color (eg, blue, yellow) and the plurality of fibers may be a second color (eg, light blue, green, red, turquoise) in the non-fibrillar region of the fiber. It's okay. The first color and the second color may be the same or different.

Test Liquid Surface Tension The liquid surface tension is determined by applying a force to a platinum Wilhelmy plate at the gas-liquid interface. A Kruss tensiometer K11 or equivalent device is used. (Made by Cruz USA (www.kruss.de)). The test is performed in a laboratory environment at 23 ± 2 ° C. and 50 ± 5% relative humidity. The test liquid is placed in a container provided by the manufacturer and the surface tension is recorded by the instrument and its software.

Basis weight test A 9.00 cm ² large piece of non-woven substrate, that is, a width of 1.0 cm and a length of 9.0 cm is used. The sample may be cut from consumer products such as wipes, absorbent articles or packaging materials thereof. The sample should be dry and free of other materials such as adhesives or dust. The sample is conditioned for 2 hours at 23 ° C. (± 2 ° C.) and about 50% (± 5%) relative humidity until equilibrium is reached. The weight of the cut nonwoven fabric substrate is measured on a scale with an accuracy of 0.0001 g. The resulting mass is divided by the specimen area and the result in g / m ² (gsm) is obtained. The same procedure is repeated for at least 20 specimens from 20 identical consumer products or their packaging materials. If the consumer product or its packaging material is sufficiently large, more than one specimen can be obtained from each. Examples of the sample include a part of the top sheet of the absorbent article. If a local basis weight variation test is performed, these same samples and data are used for calculation and average basis weight reporting.

Fiber Diameter and Denier Test Fiber diameter in nonwoven substrate samples is quantified using a scanning electron microscope (SEM) and image analysis software. A magnification of 500 to 10,000 times was selected so that the fibers were reasonably expanded for measurement. The sample is sputtered with gold or palladium compounds to avoid fiber charging and vibration in the electron beam. A manual procedure is used to determine the fiber diameter. Use the mouse and cursor tools to find the end of a randomly selected fiber and then traverse its width (ie perpendicular to the fiber direction at that point) to the other end of the fiber And measure. For non-circular fibers, the cross-sectional area is measured using image analysis software. The effective diameter is then calculated by calculating the diameter as if the found area is that of a circle. A measured and calibrated image analysis tool provides scaling to obtain actual readings in micrometers (μm). Some fibers are thus randomly selected between samples of the nonwoven substrate using SEM. At least two specimens from the nonwoven substrate are cut and tested in this manner. Overall, at least 100 such measurements are made and then all data is recorded for statistical analysis. The recorded data is used to calculate the mean value (intermediate value) of the fiber diameter, the standard deviation of the fiber diameter, and the median value of the fiber diameter. Another useful statistic is the calculation of the amount of fiber population that is below a certain upper limit. To determine this statistic, count how many fiber diameter results are below the upper limit, and divide that count (divide by the total number of data and multiply by 100%), eg, 1 micron The software is programmed to report in percent as a percent of a meter diameter or% submicron or less.

If the result is to be reported in denier, then the following calculation is made.
Fiber diameter in denier = cross-sectional area (m ² ) * density (kg / m ³ ) * 9000 m * 1000 g / kg.
Cross-sectional area, [pi * diameter ^2/4. The density of polypropylene may be, for example, 910 kg / m ³ .
If the fiber diameter is given in denier, the physical circular fiber diameter in meters (or micrometers) is calculated from their relationship, and vice versa. It measured the diameter of the individual circular fiber (microns) and d _i.
If the fiber has a non-circular cross section, as described above, the fiber diameter measurement is determined as the hydraulic diameter and is set equal to it.

Low Surface Tension Liquid Strike Through Time Test The low surface tension liquid strike through time test is a non-woven fabric substrate sample placed on a reference absorbent pad with a specific amount of low surface tension liquid discharged at a predetermined rate. Used to determine the amount of time it takes to fully penetrate. By default, this is also referred to as the 32 mN / m low surface tension liquid strike-through test because of the surface tension of the test liquid, and each test simply laminated a nonwoven substrate sample on top of each other Done by two layers.
In this test, the reference absorbent pad is a 5 layer Ahlstrom grade 989 filter paper (10 cm × 10 cm) and the test liquid is a low surface tension liquid of 32 mN / m.

Scope This test is designed to characterize the low surface tension liquid strike-through performance (in seconds) of nonwoven substrates intended to provide a barrier to low surface tension liquids such as, for example, a mixture of urine and defecation or soft defecation. Has been.

Equipment Lister Strike Through Tester: Equipment equipment is the same as described in EDANA ERT 153.0-02, Section 6 with the following exception: Strike through plate is 10.0 mm long And a narrow slot with a slot width of 1.2 mm, a three slot star orifice at an angle of 60 °. The orifice 2000 is shown in FIG. This apparatus is described in Lenzing Instruments (Austria) and W.L. Available from W. Fritz Metzger Corp (USA). This unit needs to be set not to time out after 100 seconds.

  Reference absorbent pad: Allstrom grade 989 filter paper in the 10 cm x 10 cm area is used. The average strike-through time is 3.3 ÷ 0.5 seconds for 5 layers of filter paper using 32 mN / m test liquid and no web sample. Filter paper may be purchased from Empirical Manufacturing Company, Inc. (EMC) 7616, Reinhold Drive Cincinnati, Ohio 45237.

Test solution: A liquid with a surface tension of 32 mN / m is prepared from distilled water and 0.42 ± 0.001 g / l Triton X-100. All liquids are kept at ambient conditions.
Electrode cleaning solution: 0.9% sodium chloride (CAS 7647-14-5) aqueous solution (9 g NaCl per liter of distilled water) is used.

Test Procedure—Verify that the surface tension of the liquid test described herein is 32 mN / m ± 1 mN / m. If not, re-prepare the test solution.
Prepare a 0.9% NaCl aqueous electrode cleaning solution.
-Check if the strike-through target for the reference absorbent pad (3.3 ± 0.5 seconds) is suitable for testing in 5 layers with a test solution of 32 mN / m as follows:
-Stack the five layers of reference absorbent pad properly on the base plate of the strike-through tester.
-Place five strike-through plates on top of each other and check that the center of the plates overlaps the center of the paper. Center this collection under the distribution funnel.
-Make sure that the upper assembly of the strike-through tester is lowered to the preset stop point.
-Make sure the electrode is connected to the timer.
-Turn on the strikethrough tester and zero the timer.
Dispense 5 ml of 32 mN / m test solution into the funnel using a 5 ml fixed volume pipette and tip.
Open the funnel solenoid valve (eg by pressing a button on the device) and drain 5 ml of the test solution. The first flow of liquid completes the electrical circuit and starts a timer. The timer stops when liquid penetrates the reference absorbent pad and falls below the level of the electrode in the strike-through plate.
-Record the time indicated on the electronic timer.
-Remove the test assembly and discard the used reference absorbent pad. In preparation for the next test, the electrode is washed with 0.9% NaCl aqueous solution. Dry the recess above the electrode and the back of the strike-through plate, and wipe the dispenser exit orifice and the surface of the table on which the bottom plate or filter paper is located.

-Repeat this test procedure at least three times to ensure that the strike-through target of the reference absorbent pad is met. If the target is not met, the reference absorbent pad is out of specification and should not be used.
-After the performance of the reference absorbent pad has been verified, the nonwoven substrate sample can be tested.
Cut out the required number of nonwoven substrate specimens. About the nonwoven fabric base material which extract | collected the sample from the roll, a sample is cut out to the square test piece of a size of 10 cm x 10 cm. For nonwoven substrates from which samples are taken from consumer products, the samples are cut into 15 x 15 mm square test pieces. The liquid flows from the strike-through plate over the nonwoven substrate specimen. A nonwoven fabric base material test piece touches only an edge part.
-Stack the five layers of reference absorbent pad properly on the base plate of the strike-through tester.
-Place the non-woven fabric substrate test piece on top of the 5 layers of filter paper. Two-layer nonwoven substrate specimens are used in this test method. If the nonwoven substrate sample is facing (ie, having a different layer configuration such that either side faces in a particular direction), the wearer (for absorbent products) The side facing is facing upward during the test.
-Place the strike-through plate on the nonwoven substrate specimen and verify that the center of the strike-through plate is on the center of the nonwoven substrate specimen. Center this assembly under the distribution funnel.
-Make sure that the upper assembly of the strike-through tester is lowered to a preset stop point.
-Make sure the electrode is connected to the timer. Turn on the strikethrough tester and set the timer to zero.
-Run as described above.
-Repeat this operation as many times as necessary for the nonwoven fabric specimen. A minimum of 5 specimens are required for each different nonwoven substrate sample. Average represents low surface tension strike-through time in seconds of 32 mN / m

Specific surface area The specific surface area of the nonwoven substrate of the present disclosure is determined by continuous saturated vapor pressure (Po) method (ASTM D-6556-10) by krypton gas adsorption using Micromeritic ASAP 2420 or equivalent equipment. Was then quantified according to Brunauer, Emmett, and Teller principles and calculation methods by Kr-BET gas adsorption techniques including automatic degassing and thermal correction. Note that the specimen should not be degassed at 300 ° C. as recommended by this method, but should instead be degassed at room temperature. The specific surface area should be reported in m ² / g.

Obtaining a sample of the nonwoven substrate Each surface area measurement is taken from a total of 1 g of the nonwoven substrate disclosed herein. Depending on whether the absorbent article, package, or wipe is tested to achieve 1 g of material, the plurality of test strips can be one or more absorbent articles, one or more packages, or Taken from one or more wipes. The wet wipe specimen is dried at 40 ° C. for 2 hours or under light pressure until no liquid leaks from the specimen. The test specimen is made of an absorbent article, package, or wipe (absorbent article, package, or wipe) in an area that is free of or substantially free of adhesive using scissors. (Based on whether or not is tested). The ultraviolet fluorescence analysis cabinet is then used to detect the presence of adhesive on the specimen as the adhesive fluoresces under this light. Other methods for detecting the presence of adhesive may also be used. The area of the specimen that indicates the presence of adhesive is cut from the specimen, so that the specimen is free of adhesive. The specimen is then tested using the specific surface area method described above.

Obtaining a sample of the nonwoven barrier cuff Each surface area measurement consists of a nonwoven barrier cuff (eg, 50, 51) specimen taken from the absorbent article until a total sample mass of 1 g is reached. The specimen is cut from the barrier cuff in the region that is not directly bonded to the absorbent article (eg, region 11 in FIG. 3) using scissors. The ultraviolet fluorescence analysis cabinet is then used to detect the presence of adhesive on the specimen as the adhesive fluoresces under this light. Other methods for detecting the presence of adhesive may also be used. The area of the specimen that indicates the presence of adhesive is cut from the specimen, so that the specimen is free of adhesive. The specimen is then tested using the specific surface area method described above.

Fibril length measurement test 1) Using a software program such as Image J software, using a straight line (that is, a line having a length but not a thickness) on an SEM image of the nonwoven fabric substrate Measure the number of pixels within the length of the legend. Record the line length and the number of microns corresponding to the legend.
2) Select the fibril that is best visualized and measure its length from its free end to the end emanating from the fiber. Record the length of the line.
3) Divide this length by the length of the legend in pixels, then multiply by the length of the legend in microns to get the length of the fibrils in microns.
If the fibril is long and wound, the length of such fibril is converted to a straight line.

Mass average diameter The mass average diameter of the fiber is calculated as follows.

Where
The fibers in the sample are assumed to be circular / cylindrical,
d _i = measured diameter of the i th fiber in the sample,
δX = the very small longitudinal section of the fiber, measuring its diameter, the same for all the fibers in the sample,
m _i = mass of the i-th fiber in the sample,
n = number of samples whose diameter was measured in the sample,
ρ = density of fibers in the sample, the same for all fibers in the sample,
V _i = volume of the i th fiber in the sample.
The mass average fiber diameter should be reported in μm.

Weight Loss Test The weight loss test is used to determine the amount of ester lipid (eg, GTS) of the nonwoven substrate of the present disclosure. One or more samples of the nonwoven substrate are placed in acetone at a ratio of 1 g of nonwoven substrate sample per 100 g of acetone, using a reflux flask system with the narrowest sample not exceeding 1 mm. . First, the sample is weighed before being placed in the reflux flask, and then the mixture of sample and acetone is heated at 60 ° C. for 20 hours. The sample is then removed and then air dried for 60 minutes and the final weight of the sample is quantified. The formula for calculating the weight percent of ester lipid in a sample is:
% By weight of ester lipid = ([initial mass of sample−final mass of sample] / [initial mass of sample]) × 100%.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values proposed. Instead, unless otherwise specified, each such dimension is intended to mean both the proposed value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.

  All references cited herein, including patents or patent applications arbitrarily assigned or related, are hereby incorporated by reference in their entirety, unless expressly excluded or otherwise limited. The Citation of any document shall be prior art with respect to the invention disclosed and claimed herein, or on its own, or in any combination with any other citation or citations. However, no admission is made that any such invention is taught, suggested or disclosed. In addition, to the extent that the meaning or definition of any term in this document conflicts with the meaning or definition of any of the same terms in the literature incorporated by reference, the meaning or definition given to that term in this document applies. Shall be.

  While particular embodiments of the present invention have been illustrated and described, those skilled in the art will recognize that various other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, the appended claims are intended to cover all such changes and modifications that are within the scope of this invention.

Claims (15)

  A nonwoven fabric substrate comprising a fiber layer, wherein each of the plurality of fibers includes a plurality of fibrils extending outward from the surface of the fiber, and the plurality of fibrils include an ester lipid.   A plurality of fibers are formed from a composition comprising a polyolefin and an ester lipid, the composition comprising at least 11% ester lipid by weight of the composition, the ester lipid preferably in the range of 40 ° C to 150 ° C. The nonwoven fabric substrate according to claim 1, which has a melting point.   The nonwoven substrate according to claim 1, wherein the average length of the fibrils from the surface of the fiber to the free ends of the fibrils ranges from about 0.5 m to about 20 m.   The nonwoven substrate of claim 1, wherein the fibril has an average hydraulic diameter in the range of about 100 nm to about 800 nm.   The nonwoven fabric substrate according to claim 1, wherein the fiber layer is made of spunbond fibers, meltblown fibers, or fine fibers.   The nonwoven fabric substrate according to claim 1, wherein at least some of the fibrils extend radially outward from the surface of the fibers in the direction of the central longitudinal direction 1/3 of at least some of the fibers.   The nonwoven fabric substrate according to claim 1, wherein the plurality of fibrils grow from the surface of the fiber to the outside in at least 24 hours under post-woven fabric substrate formation atmosphere conditions.   2. The nonwoven fabric substrate according to claim 1, wherein the fiber composed of a plurality of fibrils does not contain ester lipid droplets.   The fiber layer is composed of a plurality of bonds, each bond is composed of a bond region, and the plurality of fibrils extend outward from the surface of at least one bond region. Nonwoven substrate.   The nonwoven fabric substrate according to claim 1 or 9, wherein the plurality of fibrils are substantially composed only of ester lipids.   The plurality of fibrils consists of glycerin tristearate, wherein the glycerin tristearate has a melting point greater than 35 ° C. and / or the plurality of fibers consist of fibrils extending radially outward from the surface of the fibers and / or Alternatively, the nonwoven substrate consists of a second layer of fibers, wherein the fibers of the second layer of fibers are substantially free of fibrils and / or the nonwoven substrate consists of a second layer of fibers. Wherein the plurality of fibrils extends radially outward from the surface of at least a portion of the fibers in the second layer of fibers and / or the nonwoven substrate comprises the second layer of fibers; Here, the layer of fibers consists of spunbond fibers, wherein the second layer of fibers consists of meltblown fibers or fine fibers and / or the fibers contain at least 11 ester lipids by weight of the composition. Nonwoven substrate according to claim 9, wherein a and is formed from a composition comprising.   A layer of fibers, the plurality of fibers consisting of fibrils extending outwardly only after a certain time, wherein the certain time consists of post nonwoven substrate forming atmosphere conditions longer than about 24 hours A nonwoven fabric substrate.   The non-woven fabric substrate according to claim 12, wherein the predetermined time is a post-nonwoven fabric substrate forming atmosphere condition longer than about 100 hours.   The nonwoven fabric substrate according to claim 12, wherein the fibril is a first color, the plurality of fibers are a second color, and the first color and the second color are different.   The nonwoven fabric substrate according to claim 12, wherein the plurality of fibers do not contain ester lipid droplets.