Multilayered apertured film wrapping element for absorbent articles

Abstract

A multilayered apertured film wrapping element for an absorbent article is disclosed. At least one outer layer of the fluid-impervious plastic material has a continuous phase of a thermoplastic polymeric component and an immiscible, dispersed phase of a thermoplastic polymeric component having a lower melting point. The wrapping element is useful in applications involving heat sealing and similar thermal processes in absorbent articles, such as sanitary napkins, diapers, bandages, tampons, and the like.

What is claimed is:  
     
         1 . A wrapping element useful in absorbent articles comprising fluid-impervious plastic material in the form of a resilient three-dimensional web exhibiting a fiber-like appearance and tactile impression, the fluid-impervious plastic material comprises a laminate having at least three layers: 
 a) a first layer, forming a first outer surface of the laminate, comprising a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond;    b) a second layer forming a second outer surface of the laminate, opposite the first outer surface; and    c) at least one intermediate layer, disposed between the first and second layers,    wherein the web has first and second surfaces, the first surface being defined at least in part by the either of the first and second layers and having a multiplicity of apertures therein, each of the apertures being defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, each of the fiber-like elements exhibiting a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion, the sidewall portions extending generally in the direction of the second surface of the web, the intersecting sidewall portions being interconnected to one another intermediate the first and the second surfaces of the web, the interconnected sidewall portions terminating substantially concurrently with one another in the plane of the second surface.    
     
     
         2 . The wrapping element of  claim 1  wherein the first thermoplastic polymeric component is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         3 . The wrapping element of  claim 2  wherein the first thermoplastic polymeric component comprises a polyolefin.  
     
     
         4 . The wrapping element of  claim 1  wherein the second thermoplastic polymeric component is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         5 . The wrapping element of  claim 4  wherein the second thermoplastic polymeric component comprises a polyolefin.  
     
     
         6 . The wrapping element of  claim 1  wherein the difference between the first melting point temperature and the second melting point temperature is greater than about 20° C.  
     
     
         7 . The wrapping element of  claim 1  wherein the first layer comprises about 45 to about 95 wt-% of the thermoplastic polymeric component and about 55 to about 5 wt-% of the second thermoplastic polymeric component.  
     
     
         8 . The wrapping element of  claim 7  wherein the first layer comprises about 60 to about 80 wt-% of the thermoplastic polymeric component and about 40 to about 20 wt-% of the second thermoplastic polymeric component.  
     
     
         9 . The wrapping element of  claim 1  wherein the first layer further comprises one or more components selected from the group comprising antioxidants, UV absorbers, lubricants, antiblock agents, slip agents, plasticizers, nucleating agents, antistatic agents, flame retardants, pigments, dyes, and fillers.  
     
     
         10 . The wrapping element of  claim 1  wherein the second layer comprises a component selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         11 . The wrapping element of  claim 1  wherein the second layer comprises a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond;  
     
     
         12 . The wrapping element of  claim 11  wherein the first thermoplastic polymeric component of the second layer is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         13 . The wrapping element of  claim 12  wherein the first thermoplastic polymeric of the second layer component comprises a polyolefin.  
     
     
         14 . The wrapping element of  claim 11  wherein the second thermoplastic polymeric component of the second layer is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         15 . The wrapping element of  claim 14  wherein the second thermoplastic polymeric component of the second layer comprises a polyolefin.  
     
     
         16 . The wrapping element of  claim 11  wherein the difference between the first melting point temperature and the second melting point temperature of the components of the second layer is greater than about 20° C.  
     
     
         17 . The wrapping element of  claim 11  wherein the second layer comprises about 45 to about 95 wt-% of the thermoplastic polymeric component and about 55 to about 5 wt-% of the second thermoplastic polymeric component.  
     
     
         18 . The wrapping element of  claim 17  wherein the second layer comprises about 60 to about 80 wt-% of the thermoplastic polymeric component and about 40 to about 20 wt-% of the second thermoplastic polymeric component.  
     
     
         19 . The wrapping element of  claim 11  wherein the first and second layers are substantially identical.  
     
     
         20 . The wrapping element of  claim 1  wherein the intermediate layer comprises a component selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         21 . The wrapping element of  claim 20  wherein the intermediate layer comprises a polyolefin or a polyolefin copolymer.  
     
     
         22 . The wrapping element of  claim 21  wherein the intermediate layer comprises a blend of polyethylene and ethylene-vinyl acetate copolymer.  
     
     
         23 . The wrapping element of  claim 1  wherein the intermediate layer further comprises one or more components selected from the group comprising antioxidants, UV absorbers, lubricants, antiblock agents, slip agents, plasticizers, nucleating agents, antistatic agents, flame retardants, pigments, dyes, and fillers.  
     
     
         24 . The wrapping element of  claim 23  wherein the intermediate layer comprises greater than about 5 wt-% of a pigment.  
     
     
         25 . The wrapping element of  claim 1  wherein the intermediate layer comprises a blend of polymeric materials.  
     
     
         26 . The wrapping element of  claim 25  wherein the intermediate layer comprises a blend of about  45  to about 99 wt-% of a first polymeric component and about 1 to about 55 wt-% of a second polymeric component.  
     
     
         27 . The wrapping element of  claim 1  which further comprises an additional intermediate layer.  
     
     
         28 . The wrapping element of  claim 1  wherein the first surface of the web is defined, at least in part, by the first layer of the laminate.  
     
     
         29 . A tampon comprising an absorbent structure substantially enclosed by a cover wherein: 
 (1) the cover comprises fluid-impervious plastic material in the form of a resilient three-dimensional web exhibiting a fiber-like appearance and tactile impression,    (2) the fluid-impervious plastic material comprises a laminate having at least three layers: 
 a first layer, forming a first outer surface of the laminate, comprising a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond;  
 a second layer forming a second outer surface of the laminate, opposite the first outer surface; and at least one intermediate layer, disposed between the first and second layers; and  
   (3) the web has first and second surfaces, the first surface being defined at least in part by the first layer and having a multiplicity of apertures therein, each of the apertures being defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, each of the fiber-like elements exhibiting a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion, the sidewall portions extending generally in the direction of the second surface of the web, the intersecting sidewall portions being interconnected to one another intermediate the first and the second surfaces of the web, the interconnected sidewall portions terminating substantially concurrently with one another in the plane of the second surface.    
     
     
         30 . The tampon of  claim 29  wherein the first thermoplastic polymeric component is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         31 . The tampon of  claim 30  wherein the first thermoplastic polymeric component comprises a polyolefin.  
     
     
         32 . The tampon of  claim 29  wherein the second thermoplastic polymeric component is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         33 . The tampon of  claim 32  wherein the second thermoplastic polymeric component comprises a polyolefin. polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         38 . The tampon of claim  37  wherein the first thermoplastic polymeric of the second layer component comprises a polyolefin.  
     
     
         39 . The tampon of claim  36  wherein the second thermoplastic polymeric component of the second layer is selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         40 . The tampon of  claim 39  wherein the second thermoplastic polymeric component of the second layer comprises a polyolefin.  
     
     
         41 . The tampon of claim  36  wherein the difference between the first melting point temperature and the second melting point temperature of the components of the second layer is greater than about 20° C.  
     
     
         42 . The tampon of claim  36  wherein the second layer comprises about 45 to about 95 wt-% of the thermoplastic polymeric component and about 55 to about 5 wt-% of the second thermoplastic polymeric component.  
     
     
         43 . The tampon of claim  36  wherein the first and second layers are substantially identical.  
     
     
         44 . The tampon of  claim 29  wherein the intermediate layer comprises a component selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polystyrenes, halogenated polymers, and copolymers thereof.  
     
     
         45 . The tampon of  claim 44  wherein the intermediate layer comprises a polyolefin or a polyolefin copolymer.  
     
     
         46 . The tampon of  claim 45  wherein the intermediate layer comprises a blend of polyethylene and ethylene-vinyl acetate copolymer.  
     
     
         47 . The tampon of  claim 29  wherein the intermediate layer further comprises one or more components selected from the group comprising antioxidants, UV absorbers, lubricants, antiblock agents, slip agents, plasticizers, nucleating agents, antistatic agents, flame retardants, pigments, dyes, and fillers.  
     
     
         48 . The tampon of  claim 47  wherein the intermediate layer comprises greater than about 5 wt-% of a pigment.  
     
     
         49 . The tampon of  claim 29  wherein the intermediate layer comprises a blend of polymeric materials.  
     
     
         50 . The tampon of  claim 49  wherein the intermediate layer comprises a blend of about 45 to about 99 wt-% of a first polymeric component and about 1 to about 55 wt-% of a second polymeric component.  
     
     
         51 . The tampon of  claim 29  which further comprises an additional intermediate layer.  
     
     
         52 . A method of forming a wrapping element useful in absorbent articles, comprising the steps of: 
 forming a laminate having at least three layers having 
 a first layer, forming a first outer surface of the laminate, comprising a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond;  
 a second layer forming a second outer surface of the laminate, opposite the first outer surface; and  
 at least one intermediate layer, disposed between the first and second layers;  
   applying fluid at a temperature greater than ambient temperature to the laminate while it is supported on a three-dimensional surface to form a resilient three-dimensional web exhibiting a fiber-like appearance and tactile impression, wherein the web has first and second surfaces, the first surface being defined at least in part by the either of the first and second layers and having a multiplicity of apertures therein, each of the apertures being defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, each of the fiber-like elements exhibiting a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion, the sidewall portions extending generally in the direction of the second surface of the web, the intersecting sidewall portions being interconnected to one another intermediate the first and the second surfaces of the web, the interconnected sidewall portions terminating substantially concurrently with one another in the plane of the second surface.-dimensional web exhibiting a fiber-like appearance and tactile impression; and    separating the web into individual pieces of material of a size appropriate for a wrapping element.    
     
     
         53 . The method of  claim 52  wherein the step of forming the laminate comprises extruding thermoplastic polymeric components through an extruder.  
     
     
         54 . The method of  claim 53  wherein the first and second layers are extruded together to envelope the intermediate layer.  
     
     
         55 . A method of making a tampon comprising the steps of: 
 separating a cover from a supply of a resilient three-dimensional web exhibiting a fiber-like appearance and tactile impression, 
 the web comprising fluid-impervious plastic material which comprises a laminate having at least three layers: 
 a first layer, forming a first outer surface of the laminate, comprising a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond;  
 a second layer forming a second outer surface of the laminate, opposite the first outer surface, comprising a blend of at least two thermoplastic polymeric components, a continuous phase of a first thermoplastic polymeric component that exhibits a first melting point temperature and a dispersed phase of an immiscible, second thermoplastic polymeric component that exhibits a second melting point temperature, less than the first melting point temperature, such that when the web is heated to a temperature between the first melting point temperature and the second melting point temperature, the second thermoplastic polymeric component is capable of forming an adhesive bond; and  
 at least one intermediate layer, disposed between the first and second layers; and  
 
 the web has first and second surfaces, the first surface being defined at least in part by the first layer and having a multiplicity of apertures therein, each of the apertures being defined by a multiplicity of intersecting fiber-like elements interconnected to one another substantially in the plane of the first surface, each of the fiber-like elements exhibiting a cross-section comprising a base portion in the plane of the first surface and a sidewall portion joined to each edge of the base portion, the sidewall portions extending generally in the direction of the second surface of the web, the intersecting sidewall portions being interconnected to one another intermediate the first and the second surfaces of the web, the interconnected sidewall portions terminating substantially concurrently with one another in the plane of the second surface; substantially enclosing an absorbent structure with the cover; and  
   applying thermal energy to the cover to heat it to a temperature between the first melting point temperature and the second melting point temperature of the first layer to form an adhesive bond.