Historically, within the cosmetics industry, personal care articles such as gloves, socks and wraps have been used in conjunction with formulations to provide moisturization or to deliver actives to the skin. Traditionally, users apply a formulation to their hands or feet, then wrap the article over the treated regions. Alternatively, users slip on a pre-treated glove or sock, which then transfers the saturated formulation to the skin due to intimate skin contact. Unfortunately, such items typically have been made of a polymeric material, e.g. neoprene rubber, which lacks a clothlike appearance and feel. Oftentimes, such items also do not readily conform to the complex surfaces and contours of a foot or hand, or they cannot adequately hold the formulation, resulting in leakage of the product.
To address these shortcomings, a personal care article was recently developed1 comprising a three-layered laminated elastic composite with a structure that is generally described as a spunbond-film-spunbond (SFS) material. Spunbond is a strong, flexible material manufactured using wood pulp and continuous fibers of polypropylene that are thermally bonded to create a fabric.2 This material enables a biaxial stretch to ensure proper fit and general ease of use.
Specifically, the laminated substrate within the personal care article was made by sandwiching an elastomeric film between two 50% stretched spunbound nonwoven substrates. The elastomeric film layer included 96%w/w olefin elastomer resina and 4% w/w filler compound containing calcium carbonate blended with polypropylene and polypropylene random copolymers. The substrates were bonded with heat at specific points with the film layer in a stretched state and the resulting composite sample was allowed to retract to give a three-dimensional texture. This texture gave the product a clothlike appearance and helped create better contact between the skin and saturated substrate.1