U.S. patent application number 14/844358 was filed with the patent office on 2016-03-17 for absorbent article comprising a topsheet/acquisition layer laminate.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Aniruddha CHATTERJEE, Adrien GRENIER, James T. KNAPMEYER, Jill Marlene ORR, Matthew S. RITTER, Rodrigo ROSATI, John B. STRUBE.
Application Number | 20160074245 14/844358 |
Document ID | / |
Family ID | 54140723 |
Filed Date | 2016-03-17 |
United States Patent
Application |
20160074245 |
Kind Code |
A1 |
ROSATI; Rodrigo ; et
al. |
March 17, 2016 |
ABSORBENT ARTICLE COMPRISING A TOPSHEET/ACQUISITION LAYER
LAMINATE
Abstract
An absorbent article for personal hygiene comprises a
longitudinal axis, a transversal axis parallel to the longitudinal
axis, a liquid permeable topsheet and an acquisition layer. A width
of the acquisition layer in a direction parallel to the transversal
axis is less than a width of the topsheet in a direction parallel
to the transversal axis. The absorbent article comprises a
topsheet/acquisition layer laminate comprising the liquid permeable
topsheet and the acquisition layer in a face to face relationship.
The topsheet/acquisition layer laminate comprises three-dimensional
protrusions extending from a plane of the topsheet/acquisition
layer laminate. The three-dimensional protrusions are formed from
the fibers of the topsheet and the acquisition layer. A majority of
the three-dimensional protrusions each comprises a base forming an
opening, an opposed distal portion, and one or more side walls
between the bases and the distal portions of the majority of the
three-dimensional protrusions.
Inventors: |
ROSATI; Rodrigo; (Frankfurt
Am Main, DE) ; ORR; Jill Marlene; (Liberty Township,
OH) ; GRENIER; Adrien; (Frankfurt Am Main, DE)
; KNAPMEYER; James T.; (Cincinnati, OH) ; STRUBE;
John B.; (Okeana, OH) ; CHATTERJEE; Aniruddha;
(Kelkheim, DE) ; RITTER; Matthew S.; (Liberty
Township, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
54140723 |
Appl. No.: |
14/844358 |
Filed: |
September 3, 2015 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62049516 |
Sep 12, 2014 |
|
|
|
62049521 |
Sep 12, 2014 |
|
|
|
62049408 |
Sep 12, 2014 |
|
|
|
62049406 |
Sep 12, 2014 |
|
|
|
62049404 |
Sep 12, 2014 |
|
|
|
62049403 |
Sep 12, 2014 |
|
|
|
62049401 |
Sep 12, 2014 |
|
|
|
62049397 |
Sep 12, 2014 |
|
|
|
62049392 |
Sep 12, 2014 |
|
|
|
62210057 |
Aug 26, 2015 |
|
|
|
62210005 |
Aug 26, 2015 |
|
|
|
62210020 |
Aug 26, 2015 |
|
|
|
62210014 |
Aug 26, 2015 |
|
|
|
Current U.S.
Class: |
604/378 |
Current CPC
Class: |
A61F 2013/15463
20130101; A61F 13/535 20130101; A61F 13/534 20130101; A61F 13/5116
20130101; A61F 2013/51355 20130101; A61F 13/15723 20130101; A61F
2013/530131 20130101; A61F 13/51 20130101; A61F 13/51104 20130101;
A61F 2013/530175 20130101; A61F 13/15707 20130101; A61F 2013/51009
20130101; A61F 2013/530481 20130101; A61F 2013/530715 20130101;
A61F 2013/51026 20130101; A61F 13/55115 20130101; A61F 2013/15365
20130101; A61F 13/53 20130101; A61F 2013/51023 20130101; A61F
2013/530664 20130101; A61F 2013/5386 20130101; A61F 2013/4587
20130101; A61F 2013/51377 20130101; A61F 13/536 20130101; A61F
13/55105 20130101; A61F 2013/5307 20130101; A61F 2013/5395
20130101; A61F 13/45 20130101; A61F 13/511 20130101; A61F 13/551
20130101; A61F 2013/51002 20130101; A61F 2013/427 20130101; A61F
13/5121 20130101; A61F 13/51394 20130101; A61F 2013/530489
20130101; A61F 2013/8497 20130101; A61F 13/513 20130101; A61F
2013/51092 20130101; A61F 13/15699 20130101; A61F 13/51108
20130101; A61F 2013/51007 20130101; A61F 2013/4568 20130101; A61F
2013/53472 20130101; A61F 2013/15284 20130101; A61F 2013/53908
20130101; A61F 2013/51147 20130101; A61F 2013/421 20130101; A61F
13/15203 20130101; A61F 13/55145 20130101; A61F 13/537 20130101;
A61F 2013/15715 20130101; A61F 2013/530007 20130101 |
International
Class: |
A61F 13/511 20060101
A61F013/511; A61F 13/53 20060101 A61F013/53; A61F 13/534 20060101
A61F013/534; A61F 13/513 20060101 A61F013/513 |
Claims
1. An absorbent article for personal hygiene comprising: a
longitudinal axis, a transversal axis perpendicular to the
longitudinal axis, a liquid permeable topsheet and an acquisition
layer; wherein a width of the acquisition layer in a direction
parallel to the transversal axis is less than a width of the
topsheet in a direction parallel to the transversal axis; a
topsheet/acquisition layer laminate comprising the liquid permeable
topsheet and the acquisition layer in a face to face relationship,
wherein the topsheet/acquisition layer laminate comprises
three-dimensional protrusions extending from a plane of the
topsheet/acquisition layer laminate; wherein the three-dimensional
protrusions are formed from the fibers of the topsheet and the
acquisition layer, wherein a majority of the three-dimensional
protrusions each comprises a base forming an opening, an opposed
distal portion, and one or more side walls between the bases and
the distal portions of the majority of the three-dimensional
protrusions, wherein the base, distal portion and the one or more
side walls are formed by fibers such that the majority of the
three-dimensional protrusion has only an opening at the base; the
topsheet/acquisition layer laminate having a first surface
comprising the acquisition layer; a liquid impermeable backsheet;
and wherein the first surface of the topsheet/acquisition layer
laminate is facing towards the backsheet.
2. The absorbent article of claim 1 wherein the absorbent article
comprises a dry-laid fibrous structure or a wet-laid fibrous
structure located between the topsheet/acquisition layer laminate
and the backsheet.
3. An absorbent article for personal hygiene comprising: a
longitudinal axis, a transversal axis perpendicular to the
longitudinal axis, a liquid permeable topsheet and an acquisition
layer; wherein a width of the acquisition layer in a direction
parallel to the transversal axis is less than a width of the
topsheet in a direction parallel to the transversal axis; a
topsheet/acquisition layer laminate comprising the liquid permeable
topsheet and the acquisition layer in a face to face relationship,
wherein the topsheet/acquisition layer laminate comprises
three-dimensional protrusions extending from a plane of the
topsheet/acquisition layer laminate; wherein the three-dimensional
protrusions are formed from the fibers of the topsheet and the
acquisition layer, wherein a majority of the three-dimensional
protrusions each comprises a base forming an opening, an opposed
distal portion, and one or more side walls between the bases and
the distal portions of the majority of the three-dimensional
protrusions, wherein the base, distal portion and the one or more
side walls are formed by fibers such that the majority of the
three-dimensional protrusion has only an opening at the base; the
topsheet/acquisition layer laminate having a first surface
comprising the acquisition layer; a carrier layer having a first
and second surface, a dry-laid fibrous structure and a liquid
impermeable backsheet; and wherein the dry-laid fibrous structure
is located on the first surface of the carrier layer such that the
second surface of the carrier layer is facing towards the first
surface of the topsheet/acquisition layer laminate or the
backsheet.
4. The absorbent article of claim 3 wherein the topsheet and the
acquisition layer are in an intimate contact with each other.
5. The absorbent article of claim 3 wherein the absorbent article
comprises an absorbent core, and wherein the absorbent core
comprising an absorbent material.
6. The absorbent article of claim 5 wherein the absorbent material
comprises at least 80% of superabsorbent polymers, up to
substantially 100% of superabsorbent polymers, by total weight of
the absorbent material.
7. The absorbent article of claim 3 wherein the carrier layer is
disposed between the topsheet/acquisition layer laminate and the
dry-laid fibrous structure.
8. The absorbent article of claim 3 wherein the carrier layer is
attached to the absorbent core and/or to the topsheet/acquisition
layer laminate.
9. The absorbent article of claim 3 wherein the carrier layer is
disposed between the dry-laid fibrous structure and the absorbent
core.
10. The absorbent article of claim 3 wherein the carrier layer is
colored.
11. The absorbent article of claim 3 wherein a length of the
acquisition layer in a direction parallel to the longitudinal axis
is less to a length of the topsheet in a direction parallel to the
longitudinal axis.
12. The absorbent article of claim 6 wherein the absorbent core
comprises a core wrap enclosing the absorbent material, wherein the
core wrap comprises a top side facing the topsheet/acquisition
layer laminate and a bottom side facing the backsheet, wherein the
absorbent core comprises one or more substantially absorbent
material free area(s) through which a portion of the top side of
the core wrap is attached by one or more core wrap bond(s) to a
portion of the bottom side of the core wrap.
13. The absorbent article of claim 3 wherein the absorbent article
is notionally divided into a front region, a back region and a
crotch region located between the front and back region, wherein
each of the front, back and crotch region is 1/3 of the length of
the absorbent article in a direction parallel to the longitudinal
axis, wherein the acquisition layer of the topsheet/acquisition
layer laminate is positioned in the front region and at least
partially in the crotch region of the absorbent article, or wherein
the acquisition layer in the topsheet/acquisition layer laminate is
positioned in the back region and at least partially in the crotch
region of the absorbent article.
14. The absorbent article of claim 3 wherein the three-dimensional
protrusions of the topsheet/acquisition layer laminate protrude
towards the backsheet or towards the body of the wearer when the
absorbent article is in use.
15. The absorbent article of claim 3 wherein the three-dimensional
protrusions have shape selected from the group consisting of a
bulbous shape, a conical shape, a mushroom shape and combinations
thereof when the three-dimensional protrusions are viewed from a
cross-sectional view.
16. The absorbent article of claim 3 wherein the topsheet and the
acquisition layer are nested such that the three-dimensional
protrusions of the topsheet and of the acquisition layer coincide
with and fit.
17. The absorbent article of claim 3 wherein one of the topsheet or
the acquisition layer may be interrupted in the area of the
three-dimensional protrusions of the topsheet/acquisition layer
laminate such that the three-dimensional protrusions made of the
respective other non-interrupted topsheet or acquisition layer
interpenetrate the interruptions of the topsheet or of the
acquisition layer.
18. The absorbent article of claim 3 wherein the topsheet or the
acquisition layer is interrupted in the area of the
three-dimensional protrusions of the topsheet/acquisition layer
laminate such that the three-dimensional protrusions of the
respective other non-interrupted topsheet or acquisition layer at
least partially fit together with the three-dimensional protrusions
of the interrupted topsheet or the acquisition layer.
19. The absorbent article of claim 3 wherein the topsheet and the
acquisition layer are interrupted in the area of the
three-dimensional protrusions of the topsheet/acquisition layer
laminate and the three-dimensional protrusions of the topsheet
coincide with and fit together with the three-dimensional
protrusions of the acquisition layer, and wherein the interruptions
in the topsheet in the area of the three-dimensional protrusions of
the topsheet/acquisition layer laminate does not coincide with the
interruptions in the acquisition layer in the area of the
three-dimensional protrusions of the topsheet/acquisition layer
laminate.
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application Ser. Nos.
62/049,516 (P&G 13530P), 62/049,521 (P&G 13531PQ),
62/049,408 (P&G CM4137FPQ), 62/049,406 (P&G CM4136FPQ),
62/049,404 (P&G CM4135FPQ), 62/049,403 (P&G CM4134FPQ),
62/049,401 (P&G CM4133FPQ), 62/049,397 (P&G CM4132FPQ), and
62/049,392 (P&G CM4131FPQ), all of which were filed on Sep. 12,
2014, and to U.S. Provisional Patent Application Ser. Nos.
62/210,005 (P&G 13971PQ), 62/210,014 (P&G 13972PQ),
62/210,020 (P&G 13973PQ), and 62/210,057 (P&G CM 4131P2Q),
all of which were filed on Aug. 26, 2015. The entire disclosures of
all of the above-referenced U.S. Provisional patent applications
are fully incorporated herein by reference.
FIELD OF THE INVENTION
[0002] An absorbent article comprising a topsheet/acquisition layer
laminate is provided. Specifically, an absorbent article comprising
a topsheet/acquisition layer laminate, a dry-laid fibrous structure
and an optional carrier layer is provided.
BACKGROUND OF THE INVENTION
[0003] An absorbent article typically comprises a topsheet, a
backsheet, and an absorbent core disposed between the topsheet and
the backsheet. The absorbent article includes an acquisition layer
and optionally a distribution layer. The acquisition layer is able
to receive the liquid bodily exudates from the topsheet in order to
temporary store them. Then, the distribution layer can receive the
liquid bodily exudates from the acquisition layer and distribute
and transfer them to the absorbent core in order to make efficient
the use of the absorbent core. Such absorbent articles exhibit
satisfactory fluid handling properties.
[0004] Three-dimensional topsheets have been developed; see for
example U.S. Patent application US 2014/0121625 A1.
[0005] There still remains a need to further improve
three-dimensional topsheets.
[0006] There is a need to develop an absorbent article comprising a
skin facing layer having a three-dimensional structure which can
provide improved dryness perception and improved fluid handling
properties e.g. less rewet on the skin facing layer, while the
physical and perceptional comfort of the wearer as well as the
leakage prevention are still met.
[0007] There is also a need to provide a skin facing layer having a
three-dimensional structure in order to reduce the contact of the
liquid bodily exudates with the skin of the wearer. Also, the skin
facing layer shall provide softness/cushiness feeling for the
caregiver and the wearer.
SUMMARY OF THE INVENTION
[0008] An absorbent article for personal hygiene is provided and
comprises a longitudinal axis, a transversal axis perpendicular to
the longitudinal axis, a liquid permeable topsheet and an
acquisition layer. A width of the acquisition layer in a direction
parallel to the transversal axis is less than a width of the
topsheet in a direction parallel to the transversal axis. The
absorbent article comprises a topsheet/acquisition layer laminate
comprising the liquid permeable topsheet and the acquisition layer
in a face to face relationship. The topsheet/acquisition layer
laminate comprises three-dimensional protrusions extending from a
plane of the topsheet/acquisition layer laminate. The
three-dimensional protrusions are formed from the fibers of the
topsheet and the acquisition layer. A majority of the
three-dimensional protrusions each comprises a base forming an
opening, an opposed distal portion, and one or more side walls
between the bases and the distal portions of the majority of the
three-dimensional protrusions. The base, distal portion and the one
or more side walls are formed by fibers such that the majority of
the three-dimensional protrusions has only an opening at the base.
The topsheet/acquisition layer laminate has a first surface
comprising the acquisition layer. The absorbent article further
comprises a liquid impermeable backsheet such that the first
surface of the topsheet/acquisition layer laminate is facing
towards the backsheet.
[0009] A majority of the three-dimensional protrusions may be more
than 50% or more than 60% or more than 70% or more than 80% or more
than 90% or more than 95% or more than 98% of the three-dimensional
protrusions in the topsheet/acquisition layer laminate.
[0010] The absorbent article may comprise a dry-laid fibrous
structure or a wet-laid fibrous structure located between the
topsheet/acquisition layer laminate and the backsheet.
[0011] An absorbent article for personal hygiene is provided and
comprises a longitudinal axis, a transversal axis perpendicular to
the longitudinal axis, a liquid permeable topsheet and an
acquisition layer. A width of the acquisition layer in a direction
parallel to the transversal axis is less than a width of the
topsheet in a direction parallel to the transversal axis. The
absorbent article comprises a topsheet/acquisition layer laminate
comprising the liquid permeable topsheet and the acquisition layer
in a face to face relationship. The topsheet/acquisition layer
laminate comprises three-dimensional protrusions extending from a
plane of the topsheet/acquisition layer laminate. The
three-dimensional protrusions are formed from the fibers of the
topsheet and the acquisition layer. A majority of the
three-dimensional protrusions each comprises a base forming an
opening, an opposed distal portion, and one or more side walls
between the bases and the distal portions of the majority of the
three-dimensional protrusions. The base, distal portion and the one
or more side walls are formed by fibers such that the majority of
the three-dimensional protrusions has only an opening at the base.
The topsheet/acquisition layer laminate has a first surface
comprising the acquisition layer. The absorbent article further
comprises a carrier layer having a first and second surface, a
dry-laid fibrous structure and a liquid impermeable backsheet. The
dry-laid fibrous structure is located on the first surface of the
carrier layer such that the second surface of the carrier layer is
facing towards the first surface of the topsheet/acquisition layer
laminate or the backsheet.
[0012] The topsheet and the acquisition layer in the
topsheet/acquisition layer laminate may be in an intimate contact
with each other.
[0013] The maximum interior width of the void area at the distal
portion may be greater than the protrusion base width of the base
of the majority of the three-dimensional protrusions. Measurements
of the protrusion base width of the base or the maximum interior
width of the void area at the distal portion can be made on a
photomicrograph at 20.times. magnification.
[0014] The fibers of the topsheet and acquisition layer in the area
of the three-dimensional protrusions of the topsheet/acquisition
layer laminate may substantially or completely surround the one or
more side walls of the majority of the three-dimensional
protrusions.
[0015] The majority of the three-dimensional protrusions may be
configured to collapse in a controlled manner such that each base
forming an opening remains open, and the protrusion base width of
each base forming an opening is greater than 0.5 mm after
compression according to Accelerated Compression Method.
[0016] The width of the acquisition layer of the
topsheet/acquisition layer laminate may not wider more than 40% of
the width of the distribution layer and/or more than 20% of the
width of the absorbent core.
[0017] The absorbent article may comprise gasketing cuffs.
[0018] The majority of the three-dimensional protrusions of the
topsheet/acquisition layer laminate may at least or only be present
in the area where the topsheet overlaps the acquisition layer in
the topsheet/acquisition layer laminate.
[0019] The majority of the three-dimensional protrusions of the
topsheet/acquisition layer laminate may be present in the area
which extends parallel to the transversal axis of the absorbent
article. The majority of the three-dimensional protrusions of the
topsheet/acquisition layer laminate may be present in the area
which extends parallel to the longitudinal axis of the absorbent
article, but which does not extend beyond the area where gasketing
cuffs is attached to the absorbent article. In that case, the
three-dimensional protrusions which are formed in the topsheet of
the topsheet/acquisition layer laminate, are formed from the fibers
of the topsheet.
[0020] The majority of the three-dimensional protrusions of the
topsheet/acquisition layer laminate may protrude towards the
backsheet. The majority of the three-dimensional protrusions of the
topsheet/acquisition layer laminate may comprise a distal end in
contact with the second surface of the carrier layer. The second
surface of the carrier layer may be attached to the distal ends of
the majority of the three-dimensional protrusions of the
topsheet/acquisition layer laminate.
[0021] The absorbent article may comprise the topsheet having a
first region of the topsheet and the acquisition layer having a
first region of the acquisition layer; wherein the concentration of
fibers in the first region of the acquisition layer and in the
distal ends of the majority of the three dimensional protrusions is
greater than the concentration of fibers in the side walls of the
majority of the three dimensional protrusions in the acquisition
layer; and wherein the concentration of fibers in the first region
of the topsheet and in the distal ends of the majority of the three
dimensional protrusions is greater than the concentration of fibers
in the side walls of the majority of the three dimensional
protrusions in the topsheet.
[0022] The absorbent article may comprise the topsheet having a
first region of the topsheet and the acquisition layer having a
first region of the acquisition layer; wherein the concentration of
fibers in the first region of the acquisition layer is greater than
the concentration of fibers in the distal ends of the majority of
the three dimensional protrusions in the acquisition layer; and
wherein the concentration of fibers in the first region of the
topsheet and the distal ends of the majority of the three
dimensional protrusions is greater than the concentration of fibers
in the side walls of the majority of the three dimensional
protrusions in the topsheet.
[0023] The absorbent article may comprise the topsheet having a
first region of the topsheet and the acquisition layer having a
first region of the acquisition layer; wherein the concentration of
fibers in the first region of the acquisition layer is greater than
the concentration of fibers in the side walls of the majority of
the three dimensional protrusions in the acquisition layer; and
wherein the concentration of fibers in the side walls of the
majority of the three dimensional protrusions in the acquisition
layer is greater than the concentration of fibers forming the
distal ends of the majority of the three dimensional protrusions in
the acquisition layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] While the specification concludes with claims particularly
pointing out and distinctly claiming the present invention, it is
believed that the same will be better understood from the following
description read in conjunction with the accompanying drawings in
which:
[0025] FIG. 1 is an absorbent article in the form of a diaper
comprising an exemplary topsheet/acquisition layer laminate wherein
the length of the acquisition layer is less that the length of the
topsheet according to the present invention with some layers
partially removed;
[0026] FIG. 2 is a transversal cross-section of the diaper of FIG.
1;
[0027] FIG. 3 is a transversal cross-section of the diaper of FIG.
1;
[0028] FIG. 4 is an absorbent article in the form of a diaper
comprising an exemplary topsheet/acquisition layer laminate wherein
the three-dimensional protrusions of the topsheet/acquisition layer
laminate are only formed where the topsheet overlaps the
acquisition layer in the topsheet/acquisition layer laminate,
according to the present invention with some layers partially
removed;
[0029] FIG. 5 is an absorbent article in the form of a diaper
comprising an exemplary topsheet/acquisition layer laminate with
another type of absorbent core according to the present invention
with some layers partially removed;
[0030] FIG. 6 is a transversal cross-section of a diaper of FIG.
5;
[0031] FIG. 7 is a transversal cross-section of the absorbent
article of FIG. 5 taken at the same point as FIG. 6 where channels
have formed as a result the absorbent article being loaded with
liquid bodily exudates;
[0032] FIG. 8 is a side schematic view of an example of a process
suitable for the present invention;
[0033] FIG. 9 is a side schematic view of another example of a
process suitable for the present invention;
[0034] FIG. 10 is a side schematic view of another example of a
process suitable for the present invention;
[0035] FIG. 11 is an absorbent article in the form of a diaper
comprising an exemplary topsheet/acquisition layer laminate with a
carrier layer according to the present invention with some layers
partially removed;
[0036] FIG. 12A is a transversal cross-section of the diaper of
FIG. 11;
[0037] FIG. 12B is another transversal cross-section of the diaper
of FIG. 11;
[0038] FIG. 13 is an absorbent article in the form of a diaper
comprising an exemplary topsheet/acquisition layer laminate with a
carrier layer according to the present invention with some layers
partially removed;
[0039] FIG. 14 is a transversal cross-section of the diaper of FIG.
13;
[0040] FIG. 15 is an absorbent article in the form of a diaper
comprising an exemplary topsheet/acquisition layer laminate with an
acquisition layer positioned in a front region of the absorbent
article according to the present invention with some layers
partially removed;
[0041] FIG. 16 is an absorbent article in the form of a diaper
comprising an exemplary topsheet/acquisition layer laminate with an
acquisition layer positioned in a rear region of the absorbent
article according to the present invention with some layers
partially removed;
[0042] FIG. 17A is a perspective view of an apparatus comprising a
first and second forming member for forming the
topsheet/acquisition layer laminate web of the present
invention;
[0043] FIG. 17B is a perspective view of a portion of the first
forming member of the apparatus shown in FIG. 17A;
[0044] FIG. 17C is a perspective view of the apparatus shown in
FIG. 17A, showing the first forming member intermeshing the second
forming member;
[0045] FIG. 18A is a perspective view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0046] FIG. 18B is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0047] FIG. 18C is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0048] FIG. 18D is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0049] FIG. 18E is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0050] FIG. 18F is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0051] FIG. 19A is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0052] FIG. 19B is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0053] FIG. 19C is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0054] FIG. 19D is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A;
[0055] FIG. 19E is a schematic view of a three-dimensional
protrusion of the topsheet/acquisition layer laminate obtained with
the apparatus shown in FIG. 17A.
DETAILED DESCRIPTION OF THE INVENTION
Definition of Terms
[0056] The term "absorbent article" as used herein refers to
disposable products such as diapers, pants or feminine hygiene
sanitary napkins and the like which are placed against or in
proximity to the body of the wearer to absorb and contain the
various liquid bodily exudates discharged from the body. Typically
these absorbent articles comprise a topsheet, backsheet, an
absorbent core and optionally an acquisition layer and/or
distribution layer and other components, with the absorbent core
normally placed between the backsheet and the acquisition system or
topsheet. The absorbent article of the present invention may be a
diaper or pant.
[0057] The term "diaper" as used herein refers to an absorbent
article that is intended to be worn by a wearer about the lower
torso to absorb and contain liquid bodily exudates discharged from
the body. Diapers may be worn by infants (e.g. babies or toddlers)
or adults. They may be provided with fastening elements.
[0058] The term "pant" as used herein refers to an absorbent
article having fixed edges, a waist opening and leg openings
designed for infant or adult wearers. A pant is placed in position
on the wearer by inserting the wearer's legs into the leg openings
and sliding the pant-type absorbent article into position about the
wearer's lower torso. A pant may be preformed by any suitable
technique including, but not limited to, joining together portions
of the absorbent article using refastenable and/or non-refastenable
bonds (e.g., seam, weld, adhesive, cohesive bond, fastener, etc.).
A pant may be preformed anywhere along the circumference of the
article (e.g., side fastened, front waist fastened).
[0059] The term "extensible" as used herein refers to a material,
which, upon application of a force, is capable of undergoing an
apparent elongation of equal to or greater than at least 100% of
its original length along longitudinal and/or transversal axis of
the absorbent article at or before reaching the breaking force if
subjected to the following test:
[0060] The longitudinal and/or transversal axis tensile properties
are measured using a method using WSP 110.4 (05) Option B, with a
50 mm sample width, 60 mm gauge length, and 60 mm/min rate of
extension.
[0061] It may be desirable that a material is capable of undergoing
an apparent elongation of equal to or greater than at least 100% or
110% or 120% or 130% up to 200% along longitudinal and/or
transversal axis of the absorbent article at or before reaching the
breaking force according to the Test Method as set out above.
[0062] If a material is capable of undergoing an apparent
elongation of less than 100% of its original length if subjected to
the above described test, it is "non-extensible" as used
herein.
[0063] The term "topsheet/acquisition layer laminate" as used
herein refers to an intimate combination of a topsheet with an
acquisition layer, both disposed in a face to face relationship.
The topsheet has a first and second surface. The first surface of
the topsheet is facing towards the body of the wearer when the
absorbent article is in use. The acquisition layer is facing the
backsheet or the optional distribution layer. A topsheet web and an
acquisition layer can have undergone a simultaneous and joint
mechanical deformation while the topsheet web and the acquisition
layer are combined with each other to form a topsheet/acquisition
layer laminate web which provides each topsheet/acquisition layer
laminate in each individual absorbent article. The
topsheet/acquisition layer laminate comprises deformations forming
three-dimensional protrusions.
[0064] In the topsheet/acquisition layer laminate, the topsheet and
acquisition layer may be in an intimate contact with each
other.
[0065] The topsheet/acquisition layer laminate may be formed by
nesting together the topsheet and acquisition layer, wherein the
three-dimensional protrusions of the topsheet coincide with and fit
together with the three-dimensional protrusions of the acquisition
layer, as shown in FIGS. 18B and 19A. The topsheet and acquisition
layer may be both extensible such that the topsheet and acquisition
layer are able to stretch.
[0066] Alternatively or in addition to what has been set out above,
the topsheet/acquisition layer laminate may be formed by
interrupting one of the topsheet or acquisition layer such that the
three-dimensional protrusions of the respective other
non-interrupted topsheet or acquisition layer interpenetrate the
interrupted topsheet or acquisition layer, as shown in FIGS. 18C
and 19B.
[0067] In still another alternative or in addition to what has been
set out above, the topsheet/acquisition layer laminate may be
formed by interrupting one of the topsheet or acquisition layer in
the area of the three-dimensional protrusions of the
topsheet/acquisition layer laminate such that the three-dimensional
protrusions of the respective other non-interrupted topsheet or
acquisition layer at least partially fit together with the
three-dimensional protrusions of the interrupted topsheet or
acquisition layer, as shown in FIGS. 18D, 18E, 19C and 19D.
[0068] In another alternative or in addition to what has been set
out above, the topsheet/acquisition layer laminate may be formed by
interrupting the topsheet and acquisition layer in the area of the
three-dimensional protrusions of the topsheet/acquisition layer
laminate and the three-dimensional protrusions of the topsheet
coincide with and fit together with the three-dimensional
protrusions of the acquisition layer. If the topsheet and
acquisition layer comprise interruptions in the area of the
three-dimensional protrusions, the interruptions in the topsheet in
the area of the three-dimensional protrusions of the
topsheet/acquisition layer laminate will not coincide with the
interruptions in the acquisition layer in the area of the
three-dimensional protrusions of the topsheet/acquisition layer
laminate, as shown in FIGS. 18F and 19E.
[0069] The terms "interruptions", as used herein, refer to holes
formed in the topsheet and/or acquisition layer during the
formation of the topsheet/acquisition layer laminate, and does not
include the pores and interstices between fibers typically present
in nonwovens.
[0070] The term "mechanically deforming and combining" as used
herein means that the topsheet and acquisition layer are put in a
face to face relationship and can be simultaneously mechanically
deformed between a first and second roll and intimately combined at
the same time. The mechanical deformation of the topsheet and
acquisition layer depends on the process, the required apparatus
but also on the properties of the topsheet and acquisition layer,
i.e. apparent elongation of the fibers, fiber mobility, ability to
deform and stretch in the area where the three-dimensional
protrusions of the topsheet/acquisition layer laminate are formed,
ability to undergo plastic deformation which sets after existing
the first and second roll, or springing partially back due to
elastic recovery.
[0071] The mechanical deformation may comprise engaging the
topsheet and the acquisition layer together between a first and
second forming member such that a plurality of deformations
comprising three-dimensional protrusions are obtained. The
three-dimensional protrusions are formed form the fibers of the
topsheet and the acquisition layer. The three-dimensional
protrusion is defined by a base forming an opening, an opposed
distal portion and the one or more side wall between the base and
the distal portion of the three-dimensional protrusion. The base,
distal portion and one or more side wall are formed by fibers such
that the three-dimensional protrusion has only an opening at the
base, as shown in FIG. 18A.
[0072] For the majority of the three-dimensional protrusions of the
topsheet/acquisition layer laminate: [0073] The topsheet may be
nested into the acquisition layer or vice versa such that the
three-dimensional protrusions of the topsheet and of the
acquisition layer coincide with and fit together, as shown in FIGS.
18B and 19A. [0074] Alternatively or in addition to what has been
set out above, one of the topsheet or acquisition layer may be
interrupted in the area of the three-dimensional protrusions of the
topsheet/acquisition layer laminate such that the three-dimensional
protrusions made of the respective other non-interrupted topsheet
or acquisition layer interpenetrate the interruptions of the
topsheet or of the acquisition layer, as shown in FIGS. 18C and
19B. [0075] Alternatively or in addition to what has been set out
above, one of the topsheet or acquisition layer may be interrupted
in the area of the three-dimensional protrusions of the
topsheet/acquisition layer laminate such that the three-dimensional
protrusions made of the respective other non-interrupted topsheet
or acquisition layer at least partially fit together with the
three-dimensional protrusions of the interrupted topsheet or of the
interrupted acquisition layer, as shown in FIGS. 18D, 18E, 19C and
19D. [0076] Alternatively or in addition to what has been set out
above, the topsheet and acquisition layer may be interrupted in the
area of the three-dimensional protrusions of the
topsheet/acquisition layer laminate and the three-dimensional
protrusions of the topsheet coincide with and fit together with the
three-dimensional protrusions of the acquisition layer. The
interruptions in the topsheet in the area of the three-dimensional
protrusions of the topsheet/acquisition layer laminate may not
coincide with the interruptions in the acquisition layer in the
area of the three-dimensional protrusions of the
topsheet/acquisition layer laminate, as shown in FIGS. 18F and
19E.
[0077] The term "a majority of the three-dimensional protrusions"
as used herein means that more than 50% or more than 60% or more
than 70% or more than 80% or more than 90% or more than 95% or more
than 98% of the three-dimensional protrusions in the
topsheet/acquisition layer laminate of the absorbent article, each
comprises a base forming an opening, an opposed distal portion and
the one or more side wall between the base and the distal portion
of the three-dimensional protrusion. The base, distal portion and
one or more side wall are formed by fibers such that the
three-dimensional protrusion has only an opening at the base (as
exemplary shown in a FIG. 18A).
[0078] The term "machine direction" or "MD" as used herein means
the path that material, such as a web, follows through a
manufacturing process.
[0079] The term "cross-machine direction" or "CD" as used herein
means the path that is perpendicular to the machine direction in
the plane of the web.
[0080] The term "cellulosic fiber" as used herein refers to natural
fibers which typically are wood pulp fibers. Applicable wood pulps
include chemical pulps, such as Kraft, sulfite, and sulfate pulps,
as well as mechanical pulps including, for example, groundwood,
thermomechanical pulp and chemically modified thermomechanical
pulp. Pulps derived from both deciduous trees (hereinafter, also
referred to as "hardwood") and coniferous trees (hereinafter, also
referred to as "softwood") may be utilized. The hardwood and
softwood fibers can be blended, or alternatively, can be deposited
in layers to provide a stratified web.
[0081] The term "dry-laid fiber" as used herein means fibers which
have been provided in a fluid medium which is gaseous (air).
[0082] The term "wet-laid fiber" as used herein comprises
cellulosic fibers which have been suspended in an aqueous medium,
such as water, before being converted into a web and dried
according to a wet-laid papermaking process.
[0083] The term "web" as used herein means a material capable of
being wound into a roll. Webs may be nonwovens.
[0084] The term "nonwoven web" as used herein refers to a
manufactured material, web, sheet or batt of directionally or
randomly oriented fibers, bonded by friction, and/or cohesion
and/or adhesion, excluding paper and products which are woven,
knitted, tufted, stitch-bonded, incorporating binding yarns or
filaments, or felted by wet milling, whether or not additionally
needled. The fibers may be of natural or man-made origin. The
fibers may be staple or continuous filaments or be formed in situ.
The porous, fibrous structure of a nonwoven may be configured to be
liquid permeable or impermeable, as desired.
[0085] The term "absorbent core" as used herein refers to a
component, which is placed or is intended to be placed within an
absorbent article and which comprises an absorbent material
enclosed in a core wrap. The term "absorbent core" does not include
an acquisition or distribution layer or any other component of an
absorbent article which is not either an integral part of the core
wrap or placed within the core wrap. The absorbent core is
typically the component of an absorbent article which comprises
all, or at least the majority of, superabsorbent polymer and has
the highest absorbent capacity of all the components of the
absorbent article.
[0086] The term "substantially free of absorbent material" or
"substantially absorbent material free" as used herein means that
the basis weight of the absorbent material in the substantially
absorbent material free areas is at least less than 10%, in
particular less than 5%, or less than 2%, of the basis weight of
the absorbent material in the rest of the absorbent core.
[0087] The term "superabsorbent polymers" (herein abbreviated as
"SAP") as used herein refer to absorbent materials which are
cross-linked polymeric materials that can absorb at least 10 times
their weight of an aqueous 0.9% saline solution as measured using
the Centrifuge Retention Capacity (CRC) test (EDANA method WSP
241.2-05E). The SAP of the invention may in particular have a CRC
value of more than 20 g/g, or more than 25 g/g, or from 20 to 50
g/g, or from 20 to 40 g/g, or 25 to 35 g/g. The SAP useful in the
invention includes a variety of water-insoluble, but
water-swellable polymers capable of absorbing large quantities of
liquid bodily exudates.
[0088] The term "joined to" as used herein encompasses
configurations in which an element is directly secured to another
element by affixing the element directly to the other element; and
configurations in which the element is indirectly secured to the
other element by affixing the element to intermediate member(s)
which in turn are affixed to the other element. The term "joined
to" encompasses configurations in which an element is secured to
another element at selected locations, as well as configurations in
which an element is completely secured to another element across
the entire surface of one of the elements. The term "joined to"
includes any known manner in which elements can be secured
including, but not limited to mechanical entanglement.
[0089] The term "joined adjacent to the transversal edges" as used
herein means that when a first and/or second transversal edge of a
first layer is/are joined adjacent to a first and/or second
transversal edges of a second layer, the first and/or second
transversal edge of the first layer are disposed within an area
spaced inboard from the first and/or second transversal edge of the
second layer. The area has a width which is from 1 to 30% of the
width of the second layer.
[0090] "Comprise," "comprising," and "comprises" are open ended
terms, each specifies the presence of the feature that follows,
e.g. a component, but does not preclude the presence of other
features, e.g. elements, steps, components known in the art or
disclosed herein. These terms based on the verb "comprise" should
be read as encompassing the narrower terms "consisting essential
of" which excludes any element, step or ingredient not mentioned
which materially affect the way the feature performs its function,
and the term "consisting of" which excludes any element, step, or
ingredient not specified. Any preferred or exemplary embodiments
described below are not limiting the scope of the claims, unless
specifically indicated to do so. The words "typically", "normally",
"advantageously" and the likes also qualify features which are not
intended to limit the scope of the claims unless specifically
indicated to do so.
General Description of the Absorbent Article 20
[0091] An exemplary absorbent article 20 in which the absorbent
core 28 of the invention can be used is a taped diaper 20 as
represented in FIG. 1; FIG. 4 and FIG. 5 with a different absorbent
core construction. FIG. 1; FIG. 4 and FIG. 5 are top plan views of
the exemplary diaper 20, in a flat-out state, with portions of the
structure being cut-away to more clearly show the construction of
the diaper 20. This diaper 20 is shown for illustration purpose
only as the invention may be used for making a wide variety of
diapers or other absorbent articles.
[0092] The absorbent article 20 comprises a topsheet/acquisition
layer laminate 245 formed from a liquid permeable topsheet 24 and
an acquisition layer 52. In other words, the absorbent article 20
comprises a liquid permeable topsheet 24 and an acquisition layer
52 characterized in that the topsheet 24 and acquisition layer 52
are joined to form a topsheet/acquisition layer laminate 245. The
absorbent article 20 comprises a liquid impermeable backsheet 25
and an absorbent core 28 between the topsheet 24 and the backsheet
25. The absorbent article 20 comprises a front edge 10, a back edge
12, and two longitudinal side edges 13. The front edge 10 is the
edge of the absorbent article 20 which is intended to be placed
towards the front of the user when worn, and the back edge 12 is
the opposite edge. The absorbent article 20 may be notionally
divided by a longitudinal axis 80 extending from the front edge 10
to the back edge 12 of the absorbent article 20 and dividing the
absorbent article 20 in two substantially symmetrical halves
relative to this axis, when viewing the absorbent article 20 from
the wearer facing side in a flat out configuration, as exemplarily
shown in FIG. 1, FIG. 4 and FIG. 5.
[0093] The absorbent article 20 may comprise a distribution layer
54 which may comprise a dry-laid fibrous structure or a wet-laid
fibrous structure. The topsheet/acquisition layer laminate 245 is
facing towards the body of the wearer when the absorbent article 20
is in use.
[0094] The wet-laid fibrous structure comprising wet-laid fibers
may have a Wet burst Strength from 50 to 500 g according to the Wet
Burst Strength Test Method and combinations thereof.
[0095] The distribution layer 54 may comprise a dry-laid fibrous
structure. The dry-laid fibrous structure may comprise dry-laid
fibers. The dry-laid fibrous structure may comprise a mixture
including superabsorbent polymers and dry-laid fibers. The dry-laid
fibers may comprise intra-fiber cross-linked cellulosic fibers.
[0096] The distribution layer 54 may comprise a wet-laid fibrous
structure. The wet-laid fibrous structure may comprise wet-laid
fibers.
[0097] The distribution layer 54 may have an average basis weight
of from 30 to 400 gsm, in particular from 100 to 300 gsm or from 50
to 250 gsm.
[0098] As explained more in a process detailed below, a topsheet 24
and an acquisition layer 52 can be simultaneously mechanically
deformed and combined together to form a topsheet/acquisition layer
laminate 245. The topsheet/acquisition layer laminate 245 comprises
mechanical deformations forming three-dimensional protrusions 250.
The mechanical deformations provide a three-dimensional structure
to the topsheet/acquisition layer laminate 245.
[0099] The absorbent article 20 may comprise elasticized gasketing
cuffs 32 present between the topsheet 24 and the backsheet 25 and
upstanding barrier leg cuffs 34. FIGS. 1, 4 and 5 also show other
typical diaper components such as a fastening system comprising
fastening tabs 42 attached towards the back edge 12 of the
absorbent article 20 and cooperating with a landing zone 44 towards
the front edge 10 of the absorbent article 20. The absorbent
article 20 may also comprise other typical components, which are
not represented in the Figures, such as a back elastic waist
feature, a front elastic waist feature, transverse barrier cuff(s),
a lotion application, etc.
[0100] As shown in FIG. 7, the barrier leg cuffs 34 may be
delimited by a proximal edge 64 joined to the rest of the article
20, typically the topsheet 24 and/or the backsheet 25, and a free
terminal edge intended to contact and form a seal with the wearer's
skin. The barrier leg cuffs 34 may be joined at the proximal edge
64 by a bond 65 which may be made for example by adhesive bonding,
fusion bonding or combination of known bonding means. Each barrier
leg cuff 34 may comprise one, two or more elastic strings 35 to
provide a better seal. The gasketing cuffs 32 may be placed
laterally outwardly relative to the barrier leg cuffs 34. The
gasketing cuffs 32 can provide a better seal around the thighs of
the wearer. Usually each gasketing leg cuff 32 will comprise one or
more elastic string or elastic element 33 for example between the
topsheet 24 and the backsheet 25 in the area of leg openings.
[0101] The absorbent article 20 can also be notionally divided by a
transversal axis 90 in a front region and a back region of equal
length measured on the longitudinal axis, when the absorbent
article 20 is in a flat state. The absorbent article's transversal
axis 90 is perpendicular to the longitudinal axis 80 and placed at
half the length of the absorbent article 20. The length of the
absorbent article 20 can be measured along the longitudinal axis 80
from the front edge 10 to the back edge 12 of the absorbent article
20. The topsheet 24, acquisition layer 52, distribution layer 54
and absorbent core 28 each have a width which can be measured from
their respective transversal edges and in parallel to the
transversal axis 90.
[0102] The absorbent article 20 is notionally divided in a front
region 36, a back region 38 and a crotch region 37 located between
the front and the back region of the absorbent article 20. Each of
the front, back and crotch region is 1/3 of the length of the
absorbent article 20. The absorbent article may also comprise front
ears 46 and back ears 40 as it is known in the art.
[0103] The absorbent core 28 of the present invention may comprise
as absorbent material 60 a blend of cellulosic fibers (so called
"airfelt") and superabsorbent polymers in particulate form
encapsulated in one or more substrates, see for example U.S. Pat.
No. 5,151,092 (Buell). Alternatively, the absorbent core 28 may be
airfelt free as described in detail below.
[0104] Generally, the absorbent cores 28 useful for the present
invention (see below) can be defined by the periphery of the layer
formed by the absorbent material 60 within the core wrap 160, as
seen from the top side of the absorbent core 28. The absorbent core
28 can take various shapes, in particular display a so-called "dog
bone" or "hour-glass" shape, which shows a tapering along its width
towards the middle or "crotch" region of the core. In this way, the
absorbent core 28 may have a relatively narrow width in an area of
the absorbent core 28 intended to be placed in the crotch region of
the absorbent article. This may provide for example better wearing
comfort. The absorbent core 28 may thus have a width (as measured
in the transversal direction) at its narrowest point which is less
than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm or even less than
about 50 mm. The absorbent core 28 can also be generally
rectangular, see for example as shown in FIG. 5, but other
deposition areas can also be used such as a "T" or "Y" or
"hour-glass" or "dog-bone" shape (See for example FIG. 4). Some
components of the absorbent article 20 will now be discussed in
more details.
"Airfelt-Free" Absorbent Core 28
[0105] The absorbent core 28 of the invention may comprise an
absorbent material 60 enclosed within a core wrap 160. The
absorbent material 60 may comprise from 80% to 100% of SAP, such as
SAP particles, by total weight of the absorbent material 60. The
core wrap 160 is not considered as an absorbent material 60 for the
purpose of assessing the percentage of SAP in the absorbent core
28.
[0106] By "absorbent material" it is meant a material which has at
least some absorbency and/or liquid retaining properties, such as
SAP, cellulosic fibers as well as some hydrophilically treated
synthetic fibers. Typically, adhesives used in making absorbent
cores have no absorbency properties and are not considered as
absorbent material. The SAP content may be substantially higher
than 80%, for example at least 85%, at least 90%, at least 95% and
even up to and including 100% of the weight of the absorbent
material 60 contained within the core wrap 160. This above SAP
content substantially higher than 80% SAP may provide a relatively
thin absorbent core 28 compared to conventional absorbent cores
typically comprising between 40-60% SAP and 40-60% of cellulosic
fibers. The absorbent material 60 of the invention may in
particular comprise less than 10% weight percent, or less than 5%
weight percent, or even be substantially free of natural and/or
synthetic fibers. The absorbent material 60 may advantageously
comprise little or no cellulosic fibers, in particular the
absorbent core 28 may comprise less than 15%, 10%, or 5% (airfelt)
cellulosic fibers by weight of the absorbent core 28, or even be
substantially free of cellulose fibers. Such absorbent core 28 may
be relatively thin and thinner than conventional airfelt cores.
FIG. 1, FIG. 2 and FIG. 3 are illustrations of an absorbent article
20 comprising an "airfelt-free" absorbent core 28.
[0107] "Airfelt-free" absorbent cores 28 comprising relatively high
amount of SAP with various absorbent core designs have been
proposed in the past, see for example in U.S. Pat. No. 5,599,335
(Goldman), EP1447066A1 (Busam), WO95/11652 (Tanzer),
US2008/0312622A1 (Hundorf), and WO2012/052172 (Van Malderen).
[0108] The absorbent core 28 of the invention may comprise adhesive
for example to help immobilizing the SAP within the core wrap 160
and/or to ensure integrity of the core wrap 160 in particular when
the core wrap 160 is made of one or more substrates. The core wrap
160 will typically extend over a larger area than strictly needed
for containing the absorbent material 60 within.
Core Wrap
[0109] The absorbent material 60 is encapsulated in one or more
substrates.
[0110] The core wrap 160 comprises a top side 16 facing the
topsheet 24 and a bottom side 16' facing the backsheet 25. The core
wrap 160 may be made of a single substrate folded around the
absorbent material 60. The core wrap 160 may be made of two
substrates (one mainly providing the top side 16 and the other
mainly providing the bottom side 16') which are attached to
another, as exemplarily shown in FIG. 2. Typical configurations are
the so-called C-wrap and/or sandwich wrap. In a C-wrap, as
exemplarily shown in FIG. 6, the longitudinal and/or transversal
edges of one of the substrate are folded over the other substrate
to form flaps. These flaps are then bonded to the external surface
of the other substrate, typically by bonding with an adhesive. The
so called C-wrap construction can provide benefits such as improved
resistance to bursting in a wet loaded state compared to a sandwich
seal.
[0111] The core wrap 160 may be formed by any materials suitable
for receiving and containing the absorbent material 60. The core
wrap 160 may in particular be formed by a nonwoven web, such as a
carded nonwoven, spunbond nonwoven ("S") or meltblown nonwoven
("M"), and laminates of any of these. For example spunmelt
polypropylene nonwovens are suitable, in particular those having a
laminate web SMS, or SMMS, or SSMMS, structure, and having a basis
weight range of about 5 gsm to 15 gsm. Suitable materials are for
example disclosed in U.S. Pat. No. 7,744,576, US2011/0268932A1,
US2011/0319848A1 or US2011/0250413A1. Nonwoven materials provided
from synthetic fibers may be used, such as polyethylene (PE),
polyethylene terephthalate (PET) and in particular polypropylene
(PP).
"Airfelt-Free" Absorbent Core 28 Comprising Substantially Absorbent
Material Free Areas 26
[0112] The absorbent core 28 may comprise an absorbent material
deposition area 8 defined by the periphery of the layer formed by
the absorbent material 60 within the core wrap 160.
[0113] The absorbent core 28 may comprise one or more substantially
absorbent material free area(s) 26 which is/are substantially free
of absorbent material 60 and through which a portion of the top
side 16 of the core wrap 160 is attached by one or more core wrap
bond(s) 27 to a portion of the bottom side 16' of the core wrap
160, as shown in FIGS. 5 and 6. In particular, there can be no
absorbent material 60 in these areas. Minimal amount such as
contaminations with absorbent material 60 that may occur during the
making process are not considered as absorbent material 60. The one
or more substantially absorbent material free area(s) 26 may be
advantageously confined by the absorbent material 60, which means
that the substantially absorbent material free area(s) 26 do(es)
not extend to any of the edge of the absorbent material deposition
area 8.
[0114] If the substantially absorbent material free area 26 extends
to any of the edges of the absorbent material deposition area 8,
each substantially absorbent material free area 26 may have areas
of absorbent material 60 on either side of each substantially
absorbent material free area 26.
[0115] The absorbent core 28 may comprise at least two
substantially absorbent material free areas 26 symmetrically
disposed on both sides of the longitudinal axis of the absorbent
core 28, as shown in FIG. 5.
[0116] The substantially absorbent material free area(s) 26 may be
straight and completely oriented longitudinally and parallel to the
longitudinal axis but also may be curved or have one or more curved
portions.
[0117] Furthermore, in order to reduce the risk of liquid bodily
exudate leakages, the substantially absorbent material free area(s)
26 advantageously do not extend up to any of the edges of the
absorbent material deposition area 8, and are therefore surrounded
by and fully encompassed within the absorbent material deposition
area 8 of the absorbent core 28. Typically, the smallest distance
between a substantially absorbent material free area 26 and the
closest edge of the absorbent material deposition area 8 is at
least 5 mm.
[0118] Airfelt free" absorbent cores 28 comprising substantially
absorbent material free areas 26 have been proposed, see for
example in EP Patent Application No. 12196341.7.
[0119] One or more channel(s) 26' along the substantially absorbent
material free area(s) 26 in the absorbent core 28 may start forming
when the absorbent material 60 absorbs a liquid and starts
swelling. As the absorbent core 28 absorbs more liquid, the
depressions within the absorbent core 28 formed by the channel(s)
26' will become deeper and more apparent to the eye and the touch.
The formation of the channel(s) 26' may also serve to indicate that
the absorbent article 20 has been loaded with liquid bodily
exudates. The core wrap bond(s) 27 should remain substantially
intact at least during a first phase as the absorbent material 60
absorbs a moderate quantity of liquid bodily exudates.
[0120] As shown in FIG. 7, when the absorbent material swells, the
core wrap bonds 27 remain at least initially attached in the
substantially absorbent material free areas 26. The absorbent
material 60 swells in the rest of the absorbent core 28 when it
absorbs a liquid, so that the core wrap thus forms channels 26'
along the substantially absorbent material free areas 26 comprising
the core wrap bonds 27.
Absorbent Article Having a Topsheet/Acquisition Layer Laminate
[0121] A topsheet/acquisition layer laminate 245 having a
three-dimensional structure is provided.
[0122] A process 100 suitable for making an absorbent article 20
may comprise the step of providing a liquid permeable topsheet web
240 extending substantially continuously in a machine direction,
the topsheet web 240 having a first and second surface, a liquid
impermeable backsheet web 2555 extending substantially continuously
in the machine direction, and an acquisition layer 52 having a
first and second surface. In the absorbent article 20, the first
surface of the topsheet 24 will be facing towards the body of the
wearer when the absorbent article 20 is in use. The topsheet web
240 and thus the topsheet 24 and the acquisition layer 52 comprise
fibers.
[0123] The topsheet web 240 and acquisition layer 52 are aligned in
a face to face relationship such that the second surface of the
topsheet web 240 is in contact with the first surface of the
acquisition layer 52. The topsheet web 240 and the acquisition
layer 52 can be simultaneously mechanically deformed and combined
together to provide a topsheet/acquisition layer laminate web 2450
having three-dimensional protrusions 250. This means that both
topsheet web 240 and acquisition layer 52 can be mechanically
deformed and combined together at the same time. A majority of the
three-dimensional protrusions 250 extend from a plane of the
topsheet/acquisition layer laminate 245 of the absorbent article
20.
[0124] The majority of the three-dimensional protrusions 250 are
formed from the fibers of the topsheet 24 and the acquisition layer
52. The majority of the three-dimensional protrusions 250 each
comprises a base 256 forming an opening having a protrusion base
width, an opposed distal portion 257, and one or more side walls
255 between the base 256 and the distal portion 257 of the majority
of the three-dimensional protrusions. The base 256, distal portion
257 and the one or more side walls 255 are formed by fibers such
that the majority of the three-dimensional protrusions 250 has only
an opening at the base, as e.g. shown in FIG. 18A. At least 50% or
at least 80% of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 may only have openings at
the base 256. The majority of the three-dimensional protrusions 250
can be obtained by the mechanical process described in detail
below.
[0125] The majority of the three-dimensional protrusions 250 may be
more than 50% or more than 60% or more than 70% or more than 80% or
more than 90% or more than 95% or more than 98% of the
three-dimensional protrusions 250 in the topsheet/acquisition layer
laminate web 2450 or in the topsheet/acquisition layer laminate
245.
[0126] The fibers may substantially or completely surround the one
or more side walls 255 of the majority of the three-dimensional
protrusions 250. This means that there are multiple fibers which
contribute to form a portion of the side walls 255 and distal
portion 257 of a three-dimensional protrusion 250. The term
"substantially surround" does not require that each individual
fiber be wrapped substantially or completely around the side walls
255 of the majority of the three-dimensional protrusions 250.
[0127] The topsheet/acquisition layer laminate 245 has a first
surface comprising the second surface of the acquisition layer 52.
A portion of the backsheet 25 can be joined to a portion of the
topsheet 24 of the topsheet/acquisition layer laminate 245 such
that the first surface of the topsheet/acquisition layer laminate
245 is facing towards the backsheet 25.
[0128] The process 100 of making an absorbent article 20 may
comprise the step of providing a dry-laid fibrous structure or a
wet-laid fibrous structure, as shown in FIG. 8.
[0129] As shown in FIG. 8, the topsheet web 240 and acquisition
layer 52 can be mechanically deformed and combined between a first
and second roll (211, 212) to form a topsheet/acquisition layer
laminate web 2450. Dry-laid fibers 540 of a dry-laid fibrous
structure (as shown in FIG. 8, provided from a distribution
material feeder 210) or a wet-laid fibrous structure may be
deposited on the first surface of the topsheet/acquisition layer
laminate web 2450 or the backsheet web 2555.
[0130] A portion of the backsheet 25 may be joined to a portion of
the topsheet 24 of the topsheet/acquisition layer laminate 245 such
that the dry-laid fibrous structure or the wet-laid fibrous
structure are between the topsheet/acquisition layer laminate 245
and the backsheet 25.
[0131] The dry-laid fibrous structure may comprise a mixture
including superabsorbent polymers (SAP) and dry-laid fibers 540.
The dry-laid fibers may comprise intra-fiber cross-linked
cellulosic fibers. The distribution layer may be free of tow
fibers.
[0132] The distribution layer 54 may for example comprise at least
50% by weight of cross-linked cellulose fibers. The cross-linked
cellulosic fibers may be crimped, twisted, or curled, or a
combination thereof including crimped, twisted, and curled. This
type of material has been used in the past in disposable diapers as
part of an acquisition system, for example US 2008/0312622 A1
(Hundorf).
[0133] Exemplary chemically cross-linked cellulosic fibers suitable
for a distribution layer 54 are disclosed in U.S. Pat. No.
5,549,791; U.S. Pat. No. 5,137,537; WO95/34329 or US2007/118087.
Exemplary cross-linking agents may include polycarboxylic acids
such as citric acid and/or polyacrylic acids such as acrylic acid
and maleic acid copolymers.
[0134] The distribution layer may typically have an average basis
weight of from 30 to 400 g/m.sup.2, in particular from 100 to 300
g/m.sup.2. The density of the distribution layer may vary depending
on the compression of the article, but may be of between 0.03 to
0.15 g/cm.sup.3, in particular 0.08 to 0.10 g/cm.sup.3 measured at
0.30 psi (2.07 kPa).
[0135] The process may comprise the step of providing an absorbent
core 28 which comprises an absorbent material 60. The absorbent
material 60 may comprise from 80% to 100% of SAP, such as SAP
particles, by total weight of the absorbent material 60.
[0136] Another type of absorbent material may be water-absorbing
foams based on cross-linked monomers comprising acid groups, see
for example from EP 0 858 478 B1, WO 97/31971 A1, WO 99/44648 A1
and WO 00/52087 A1.
[0137] Hence, the first surface of the topsheet/acquisition layer
laminate 245 can carry the material of the distribution layer 54 or
the absorbent material 60 of the absorbent core 28.
[0138] The absorbent article 20 may comprise gasketing cuffs 32.
The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 may at least be present in
the acquisition layer 52 and in the topsheet 24, in the area where
the topsheet 24 overlaps the acquisition layer 52 in the
topsheet/acquisition layer laminate 245. However, the majority of
the three-dimensional protrusions 250 of the topsheet/acquisition
layer laminate 245 may be present in the area which extends
parallel to the transversal axis 90 of the absorbent article 20.
The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 may be present in the area
which extends parallel to the longitudinal axis 80 of the absorbent
article 20, but which does not extend beyond the area where
gasketing cuffs 32 is attached to the absorbent article 20, in
particular to the topsheet 24, as shown in FIG. 2 or 3. In that
case, the majority of the three-dimensional protrusions 250 which
are formed in the topsheet 24 of the topsheet/acquisition layer
laminate 245, are formed from the fibers of the topsheet 24.
[0139] Alternatively, the majority of the three-dimensional
protrusions 250 of the topsheet/acquisition layer laminate 245 may
be present in the acquisition layer and in the topsheet in the area
which extends parallel to the transversal axis 90 of the absorbent
article 20 such that the area comprising the three-dimensional
protrusions of the topsheet 24 overlaps the acquisition layer 52.
The length of the area of the majority of the three-dimensional
protrusions 250 of the topsheet/acquisition layer 245 may be from
5% to 60% or from 10% to 40% wider than the length of the
acquisition layer 52 of the topsheet/acquisition layer laminate
245. The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer 245 may be present in the area which
extends parallel to the longitudinal axis 80 of the absorbent
article 20 such that the area comprising the majority of the
three-dimensional protrusions of the topsheet 24 overlaps the
acquisition layer 52. The width of the area of the majority of the
three-dimensional protrusions of the topsheet/acquisition layer 245
may be from 5% to 60% or from 10% to 40% wider than the width of
the acquisition layer 52 of the topsheet/acquisition layer laminate
245. In that case, the majority of the three-dimensional
protrusions 250 which are formed in the topsheet 24 of the
topsheet/acquisition layer laminate 245, are formed from the fibers
of the topsheet 24.
[0140] In still another alternative, the majority of the
three-dimensional protrusions 250 of the topsheet/acquisition layer
laminate 245 may only be present where the topsheet 24 overlaps the
acquisition layer 52 in the topsheet/acquisition layer laminate
245, as shown in FIG. 4.
[0141] Hence, the three-dimensional protrusions 250 can provide an
impression of depth and can support the caregiver's perception that
the absorbent article 20 is well able to absorb the liquid bodily
exudates.
[0142] The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 may have a measured
protrusion height from 0.3 mm to 5 mm or from 0.5 mm to 3 mm or
from 1.0 mm to 2.0 mm according to the Protrusion Height Test
Method as described below.
[0143] The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 may have a measured
protrusion base width of the three-dimensional protrusions 250 from
0.5 mm to 10 mm or from 0.5 to 5 mm or from 0.5 mm to 3.0 mm or
from 1.0 mm to 2.5 mm or from 1.5 mm to 2.5 mm according to the
Protrusion Base Width Test Method as described below. The majority
of the three-dimensional protrusions 250 having a shape with a
specific height and protrusion base width can contribute to provide
an impression of depth and can support the caregiver's perception
that the absorbent article 20 is well able to absorb the liquid
bodily exudates.
[0144] These three-dimensional protrusions 250 provide void volume
to receive the liquid bodily exudates. At the same time, the
topsheet/acquisition layer laminate 245 is in close contact with
the underlaying layer, i.e. the distribution layer 54. The
distribution layer 54 made of unconsolidated dry-laid fibers 540 of
the dry-laid fibrous structure or the wet-laid fibrous structure
may sink in the depressions provided by the three-dimensional
protrusions 250 of the topsheet/acquisition layer laminate 245 (not
shown in the schematic Figures). The distribution layer 54 may
follow the shape of the three-dimensional protrusions. Hence, the
liquid bodily exudates are transmitted more efficiently from the
topsheet/acquisition layer laminate 245 to the distribution layer
54, which can improve the dryness of the topsheet 24 of the
topsheet/acquisition layer laminate 245. Rewet can be reduced at
the skin of the wearer. The topsheet/acquisition layer laminate 245
may also enable more efficient use of an absorbent core 28.
Overall, the topsheet 24 of the topsheet/acquisition layer laminate
245 can have an improved dryness than a three-dimensional topsheet
24 placed on top of an acquisition layer 52.
[0145] The majority of the three-dimensional protrusions 250 may
comprise void areas 253 which do not contact the skin of the
wearer. The absorbent article 20 may be in less contact with the
skin of the wearer in comparison with a flat topsheet. The void
areas 253 of the topsheet/acquisition layer laminate 245 can help
the air to permeate between the skin of the wearer and the
topsheet/acquisition layer laminate 245. The void areas 253 of the
topsheet/acquisition layer laminate 245 can improve the
breathability of the topsheet/acquisition layer laminate 245.
[0146] In addition to improve dryness, the void areas 253 of the
topsheet/acquisition layer laminate 245 can also allow feces to be
absorbed and acquired within them. In that case, the present
invention is suitable to absorb feces of relatively low
viscosity.
[0147] A width of the acquisition layer 52 is less than a width of
the topsheet web 240 in a cross direction. In the absorbent article
20 comprising the longitudinal axis 80 and the transversal axis 90
perpendicular to the longitudinal axis 80, the width of the
acquisition layer 52 in a direction parallel to the transversal
axis 90 is less than the width of the topsheet 24 in a direction
parallel to the transversal axis 90. If the width of both topsheet
24 and acquisition layer 52 were the same, wicking of the liquid
bodily exudates underneath the gasketing cuffs 32 might occur.
Hence, the liquid bodily exudates might not be properly absorbed by
the absorbent core 28, which may lead to leakage of the liquid
bodily exudates out of the absorbent article 20. If the width of
the acquisition layer 52 is less that the width of the topsheet 24
in a direction parallel to the transversal axis 90, the acquisition
layer 52 which may receive the liquid bodily exudates from the
topsheet 24 can directly transmit the liquid bodily exudates to the
distribution layer 54 in order to be subsequently absorb by the
absorbent core 28. Hence, the liquid bodily exudates temporary
stored in the acquisition layer 52 of the topsheet/acquisition
layer laminate 245 will not readily be drawn towards and underneath
the gasketing cuffs 32 by capillary forces. Leakage can thus be
reduced by having the width of the acquisition layer 52 in a
direction parallel to the transversal axis 90 less that the width
of the topsheet 24 in the topsheet/acquisition layer laminate 245
in a direction parallel to the transversal axis 90.
[0148] In order to help reducing leakage and rewet, the width of
the acquisition layer 52 in a direction parallel to the transversal
axis 90 of the topsheet/acquisition layer laminate 245 may not be
more than 40% wider than the width of the distribution layer 54
and/or more than 20% wider than the width of the absorbent core 28
in a direction parallel to the transversal axis 90. In that case,
the liquid bodily exudates may not accumulate at or adjacent to the
transversal edges of the acquisition layer 52. Wicking of the
liquid bodily exudates underneath the gasketing cuffs 32 is
prevented. Indeed, when the acquisition layer 52 of the
topsheet/acquisition layer laminate 245 is no more than 20% wider
than the width of the absorbent core 28, the liquid bodily exudates
can readily be transported into the absorbent core 28, which can
efficiently drain the fluid from the acquisition layer 52 into the
absorbent core 28. Wicking of the liquid bodily exudates form the
acquisition layer 52 underneath the gasketing cuffs 32 is
prevented.
[0149] The acquisition layer 52 can receive the liquid bodily
exudates that pass through the topsheet 24 and can distribute them
to underlying absorbent layers. In such a case, the topsheet 24 in
the topsheet/acquisition layer laminate 245 may be less hydrophilic
than the acquisition layer 52. The topsheet 24 of the
topsheet/acquisition layer laminate 245 can be readily
dewatered.
[0150] In order to enhance dewatering of the topsheet 24 of the
topsheet/acquisition layer laminate 245, the pore size of the
acquisition layer 52 may be reduced. For this, the acquisition
layer 52 may made of fibers with relatively small denier. The
acquisition layer 52 may also have an increased density.
[0151] The process suitable for making the absorbent article 20 may
comprise the step of joining the portion of the backsheet web 2555
to the portion of the topsheet web 240 at or adjacent to the
transversal edges of the first surface of the topsheet/acquisition
layer laminate web 2450 in the cross direction. The transversal
edges of the first surface of the topsheet/acquisition layer
laminate web 2450 do not comprise any acquisition layer 52. When
the portion of the backsheet web 2555 is joined to the portion of
the topsheet web 240 of the topsheet/acquisition layer laminate web
2450, the acquisition layer 52 is then enveloped between the
topsheet web 240 and the backsheet web 2555.
[0152] The process may comprise the step of cutting into individual
absorbent articles comprising a backsheet 25, a topsheet 24 and an
acquisition layer 52, characterized in that the topsheet 24 and
acquisition layer 52 are joined to form a topsheet/acquisition
layer laminate 245.
[0153] The topsheet/acquisition layer laminate web 2450 may be
produced at a particular location in the process setup. Hence, the
topsheet/acquisition layer laminate web 2450 might be not available
to carry the dry-laid fibrous structure of the distribution layer
54 at the desired location of the process.
[0154] A process suitable for making an absorbent article can
comprise the step of providing a liquid permeable topsheet web 240
extending substantially continuously in a machine direction, the
topsheet web 240 having a first and second surface, a liquid
impermeable backsheet web 2555 extending substantially continuously
in the machine direction, an acquisition layer 52 having a first
and second surface, a dry-laid fibrous structure and a carrier
layer web 170 having a first and second surface (171, 172), as
shown in FIGS. 9 and 10. The topsheet web 240 and the acquisition
layer 52 comprise fibers.
[0155] The topsheet web 240 and acquisition layer 52 are aligned in
a face to face relationship with the acquisition layer 52 such that
the second surface of the topsheet web 240 is in contact with the
first surface of the acquisition layer 52. The topsheet web 240 and
the acquisition layer 52 can be simultaneously mechanically
deformed and combined together to provide a topsheet/acquisition
layer laminate web 2450 having three-dimensional protrusions.
[0156] The three-dimensional protrusions 250 are formed from the
fibers of the topsheet web 240 and the acquisition layer 52. The
majority of the three-dimensional protrusions 250 each comprises a
base 256 forming an opening, an opposed distal portion 257, and one
or more side walls 255 between the base 256 and the distal portion
257 of the majority of the three-dimensional protrusions 250. The
base 256, distal portion 257 and one or more side walls 255 are
formed by fibers such that the majority of the three-dimensional
protrusions 250 has only an opening at the base 256. The majority
of the three-dimensional protrusions 250 may be obtained by the
mechanical process described in detail below.
[0157] The topsheet/acquisition layer laminate web 2450 has a first
surface comprising the second surface of the acquisition layer
52.
[0158] The fibers 540 of the dry-laid fibrous structure can be
deposited on the first surface 171 of the carrier layer web 170 as
shown in FIGS. 9 and 10. A portion of the backsheet web 2555 can be
joined to a portion of the topsheet web 240 of the
topsheet/acquisition layer laminate web 2450 such that the second
surface 172 of the carrier layer web 170 is facing the
topsheet/acquisition layer laminate web 2450 or the backsheet web
2555.
[0159] Hence, the carrier layer web 170 can carry out the material
of the distribution layer 54 wherever the topsheet/acquisition
layer laminate web 2450 is produced and provided in the
process.
[0160] According to the method used for making the
three-dimensional structure of the topsheet/acquisition layer
laminate web 2450, when the topsheet web 240 and acquisition layer
52 are mechanically deformed together, holes might unintentionally
occur. When the distribution layer 54 comprises the dry-laid
fibrous structure, the fibers 540 of the dry-laid fibrous structure
may pass through the unintentional holes formed at the resulting
topsheet/acquisition layer laminate 245 and contact undesirably the
skin of the wearer. It may be desirable to prevent the fibers 540
of the dry-laid fibrous structure can pass through the
unintentional holes of the resulting topsheet/acquisition layer
laminate 245.
[0161] The carrier layer web 170 may be disposed between the
topsheet/acquisition layer laminate web 2450 and the dry-laid
fibrous structure, as shown in FIG. 9. In the absorbent article 20,
the carrier layer 17 may act as a barrier layer to impede the
fibers 540 of the dry-laid fibrous structure from passing through
the holes of the topsheet/acquisition layer laminate 245
unintentionally formed by the three-dimensional mechanical
deformation of the topsheet 24 with the acquisition layer 52, as
shown in FIGS. 11 and 12(A-B). Also, the carrier layer 17 may help
the transfer of the liquid bodily exudates from the
topsheet/acquisition layer laminate 245 to the dry-laid fibrous
structure.
[0162] The first surface 171 of the carrier layer 17 in the
absorbent article 20 may be attached at or adjacent to its
longitudinal edges to the absorbent core 28. Hence, when the
carrier layer 17 is disposed between the topsheet/acquisition layer
laminate 245 and the dry-laid fibrous structure, and the first
surface 171 of the carrier layer 17 is attached to the absorbent
core 28, the fibers 540 of the dry-laid fibrous structure may be
not able to escape between the carrier layer 17 and the absorbent
core 28, as exemplified in FIG. 12B. The attachment of the carrier
layer 17 to the longitudinal edges of the absorbent core 28 may
include a uniform continuous layer of adhesive 173, a discontinuous
patterned application of adhesive or an array of separate lines,
spirals, or spots of adhesive.
[0163] Alternatively, the carrier layer 17 may be disposed between
the dry-laid fibrous structure and the absorbent core 28, as shown
in FIG. 10. Hence, the carrier layer 17 in the absorbent article 20
may help to distribute and transfer of the liquid bodily exudates
from the distribution layer 54 to the absorbent core 28, as shown
in FIGS. 13 and 14, which enables more efficient use of the
absorbent core 28.
[0164] The carrier layer 17 may be attached at or adjacent to its
longitudinal edges to the first surface of the topsheet/acquisition
layer laminate 245. Hence, when the carrier layer 17 is disposed
between the dry-laid fibrous structure and the absorbent core 28,
and the carrier layer 17 is attached to the first surface of the
topsheet/acquisition layer laminate 245, the fibers 540 of the
dry-laid fibrous structure may be not able to escape between the
topsheet/acquisition layer laminate 245 and the carrier layer 17.
The attachment of the carrier layer 17 to the longitudinal edges to
the first surface of the topsheet/acquisition layer laminate 245
may include a uniform continuous layer of adhesive, a discontinuous
patterned application of adhesive or an array of separate lines,
spirals, or spots of adhesive.
[0165] The process may comprise the step of cutting into individual
absorbent articles 20 comprising a backsheet 25, a carrier layer
17, a topsheet 24 and an acquisition layer 52 characterized in that
the topsheet 24 and acquisition layer 52 are joined to form a
topsheet/acquisition layer laminate 245.
[0166] The acquisition layer 52 of the topsheet/acquisition layer
laminate 245 may be provided continuously in the machine direction.
A length of the acquisition layer 52 of the topsheet/acquisition
layer laminate 245 in a direction parallel to the longitudinal axis
80 may be equal of the length of the topsheet 24 in a direction
parallel to the longitudinal axis 80 of the absorbent article
20.
[0167] Alternatively, the acquisition layer 52 of the
topsheet/acquisition layer laminate 245 may be provided
intermittently in the machine direction. The length of the
acquisition layer 52 of the topsheet/acquisition layer laminate 245
in a direction parallel to the longitudinal axis 80 may be less
than the length of the topsheet 24 in a direction parallel to the
longitudinal axis 80 of the absorbent article 20, as shown in FIG.
4. When the length of the acquisition layer 52 in the
topsheet/acquisition layer laminate 245 is less than the length of
the topsheet 24, the liquid bodily exudates cannot be readily drawn
towards the longitudinal edges (10, 12) of the absorbent article
20, which reduces leakage.
[0168] The length of the acquisition layer 52 in the
topsheet/acquisition layer laminate 245 may be less than the length
of the absorbent core 28 taken along the longitudinal axis 80 of
the absorbent article 20, see for example FIG. 4.
[0169] The acquisition layer 52 of the topsheet/acquisition layer
laminate 245 may be positioned in the front region 36 and at least
partially in the crotch region 37 of the absorbent article 20, as
shown in FIG. 15. In that case, positioning the acquisition layer
52 of the topsheet/acquisition layer laminate 245 in the front
region 36 of the absorbent article 20 helps for acquiring and
distributing the liquid bodily exudates such as urine, around the
pee point of the wearer.
[0170] The acquisition layer 52 of the topsheet/acquisition layer
laminate 245 may be positioned in the back region 38 and at least
partially in the crotch region 37 of the absorbent article 20, as
shown in FIG. 16. Positioning the acquisition layer 52 of the
topsheet/acquisition layer laminate 245 in the back region 38 of
the absorbent article 20 helps at acquiring the feces of the
wearer, especially when the feces have a low viscosity.
[0171] The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 may protrude towards the
backsheet 25 or towards the body of the wearer when the absorbent
article is in use.
[0172] The topsheet/acquisition layer laminate 245 may be
notionally divided into a first and second area. The first area may
comprise three-dimensional protrusions 250 which protrude towards
the backsheet 25. The second area may comprise three-dimensional
protrusions 250 which protrude towards the body of the wearer when
the absorbent article is in use.
[0173] For instance, the first area may be located in the front
region 36 and at least partially in the crotch region 37 of the
absorbent article 20.
[0174] Having the first area where the three-dimensional
protrusions 250 of the topsheet/acquisition layer laminate 245
protrude towards the backsheet 25 can help acquiring and absorbing
the liquid bodily exudates to the absorbent core 28. Having the
second area where the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 protrude towards the body
of the wearer when the absorbent article is in use can improve
cleaning the body from the exudates. Hence, a combination of the
first and second area can allow the absorbent article 20 to better
perform.
[0175] The topsheet 24 of the topsheet/acquisition layer laminate
245 may be coated with a lotion composition. The lotion composition
may be located in the areas of the topsheet 24 which are between
the three-dimensional protrusions 250 of the topsheet/acquisition
layer laminate 245.
[0176] Typical lotion compositions used in diapers are disclosed in
U.S. Pat. No. 6,426,444 B2. The resulting lotion composition may be
applied to the topsheet/acquisition layer laminate by spraying,
printing (e.g., flexographic printing), coating (e.g., contact slot
coating, gravure coating), extrusion, microencapsulation or
combinations of these application techniques.
[0177] The majority of the three-dimensional protrusions 250 may be
disposed in any suitable arrangement across the plane of the
topsheet/acquisition layer laminate 245. Suitable arrangements
include, but are not limited to: staggered arrangements, and zones.
In some cases, the topsheet/acquisition layer laminate 245 may
comprise both three-dimensional protrusions 250 and other features
known in the art such as embossments and apertures. The
three-dimensional protrusions 250 and other features may be in
separate zones, be intermixed, or overlap. Intermixed arrangements
can be created in any suitable manner. In some cases, intermixed
arrangements can be created by using the techniques described in
U.S. Patent Publication No. US 2012/0064298 A1, Orr, et al. In
other cases, overlapping arrangements can be created by forming the
three-dimensional protrusions 250 and then subsequently passing the
topsheet/acquisition layer laminate web 2450 between a forming
member having male forming elements thereon and a compliant
surface, and applying pressure to the web with the forming member
and compliant surface. These techniques for producing overlapping
arrangements enable three-dimensional protrusions 250 and other
features to be combined so they are disposed in different locations
on the topsheet/acquisition layer laminate 245 or they can cause at
least some of the three-dimensional protrusions 250 and at least
some of the other features (apertures, embossments) to be disposed
in the same location on the topsheet/acquisition layer laminate
245.
The Carrier Layer
[0178] The carrier layer 17 may be selected from the group
consisting of nonwovens, tissues, or films and combinations
thereof.
[0179] Examples of a nonwoven web used for the carrier layer 17 may
include various types of known nonwoven webs such as a spunbonded
nonwoven web, a meltblown nonwoven web, and a
spunbond-meltblown-spunbond nonwoven web. These nonwoven webs are
made of thermoplastic polymers.
[0180] A material for fibers composing the nonwoven web used for
the carrier layer 17 may include various types of known fibers such
as polyethylene, polypropylene, polyester, and acryl, conjugate
fibers such as polyethylene/polypropylene,
polyethylene/polyethylene terephthalate, and
polypropylene/polyethylene terephthalate, i.e., fibers formed of
core-in-sheath fibers and side-by-side fibers. The fibers may be
used alone or in combination. Further, the carrier layer 17 may
have a monolayer structure or a multilayer structure.
[0181] The carrier layer 17 may comprise a tissue made of wet-laid
fibers comprising cellulose fibers having a Wet burst Strength from
50 to 500 g according to the Wet Burst Strength Test Method and
combinations thereof.
[0182] The carrier layer 17 may be treated with a surfactant to
render the carrier layer 17 hydrophilic. The carrier layer 17 may
be made of one material of the group as set out above, which has
been chemically modified to render it hydrophilic. The hydrophilic
carrier layer 17 may thus improve the transfer of the liquid bodily
exudates from the distribution layer 54 to the absorbent core 28 of
the absorbent article 20.
[0183] The carrier layer 17 may have a basis weight of at least 5
gsm to 60 gsm or at least 5 gsm to 20 gsm or at least 5 to 15
gsm.
[0184] The carrier layer 17 may be wider and longer than the
distribution layer 54. The carrier layer can help preventing the
fibers 540 of the dry-laid fibrous structure getting to the skin of
the wearer when the distribution layer 54 comprises the dry-laid
fibrous structure and if the topsheet/acquisition layer laminate
245 comprises some holes.
[0185] The carrier layer 17 may be colored. Color may be imparted
to the carrier layer 17 by color pigmentation. The term "color
pigmentation" encompasses any pigments suitable for imparting a
non-white color to the carrier layer 17. This term therefore does
not include "white" pigments such as TiO.sub.2 which are typically
added to the layers of conventional absorbent articles to impart
them with a white appearance. Pigments are usually dispersed in
vehicles or substrates for application, as for instance in inks,
paints, plastics or other polymeric materials.
[0186] The pigments may for example be introduced in a
polypropylene masterbatch. A masterbatch comprises a high
concentration of pigment and/or additives which are dispersed in a
carrier medium which can then be used to pigment or modify the
virgin polymer material into a pigmented bicomponent nonwoven. An
example of suitable colored masterbatch material that can be
introduced is Pantone color 270 Sanylen violet PP 42000634 ex
Clariant, which is a PP resin with a high concentration of violet
pigment. Typically, the amount of pigments introduced by weight of
the carrier layer 17 may be of from 0.3%-2.5%.
[0187] Alternatively, color may be imparted to the carrier layer 17
by way of impregnation of a colorant into the substrate. Colorants
such as dyes, pigments, or combinations may be impregnated in the
formation of substrates such as polymers, resins, or nonwovens. For
example, the colorant may be added to molten batch of polymer
during film, fiber, or filament formation.
[0188] When viewing the absorbent article 20 from the topsheet 24,
the colored carrier layer 17 may provide to a caregiver an enhanced
impression of depth to support to the impression given by the
three-dimensional protrusions 250 as such, as long as the colored
carrier layer 17 are visible from the topsheet 24. Hence, a colored
carrier layer 17 can support the caregiver's perception that the
absorbent article 20 is well able to absorb the liquid bodily
exudates.
[0189] The topsheet 24 and/or acquisition layer 52 of the
topsheet/acquisition layer laminate 245 may be colored, for the
same reasons.
[0190] The carrier layer 17 may be porous, may have a relatively
high permeability and have a relatively high level of saturation
when exposed to fluid at suction pressures such as 20 cm water. The
relatively high level of saturation of the carrier layer 17 can be
defined as the ratio between the volume of liquid bodily exudates
in the pores of the carrier layer 17 and the total void volume of
the carrier layer 17. The carrier layer 17 can help providing
connectivity between the acquisition layer 52 of the
topsheet/acquisition layer laminate 245 and the distribution layer
54.
[0191] Also, the carrier layer 17 may comprise some relative small
sized holes such that the fibers 540 of the dry-laid fibrous
structure of the distribution layer 54 may partially pass through
the holes of the carrier layer. Hence, the fibers 540 of the
dry-laid fibrous structure can entangle and contact the acquisition
layer 52 of the topsheet/acquisition layer laminate 245. The
carrier layer 17 may comprise holes having a size from 0.02 mm to
10 mm.
The Mechanical Deformations and the Resulted Three-Dimensional
Protrusions
[0192] The step of the process 100 related to mechanically
deforming and combining the topsheet 24 with the acquisition layer
52 may comprise the following step of providing a first and second
forming member (211, 212) having a machine direction and a cross
direction orientation, as shown in FIGS. 17A, 17B and 17C. The
first and second forming member (211, 212) may be drum-shaped,
generally cylindrical or plate-shaped.
[0193] The first forming member 211 of the apparatus 200 may have a
surface comprising a plurality of discrete, spaced apart male
forming elements 213 having a base that is joined to the first
forming member 211, a top that is spaced away from the base, and
sides that extend between the base and the top of the male forming
elements 213. The male forming elements 213 may have a plan view
periphery, and a height.
[0194] The top on the male forming elements 213 may have a rounded
diamond shape, see for example FIG. 17A, with vertical sidewalls
and a radiused or rounded edge at the transition between the top
and the sidewalls of the male forming element 213.
[0195] The second forming member 212 may have a surface comprising
a plurality of recesses 214 in the second forming member 212. The
recesses 214 may be aligned and configured to receive the
respective male forming elements 213 therein. Hence, each recess
214 of the second forming member 212 may be sufficiently large to
be able to receive each respective male forming element 213 of the
first forming member 211. The recesses 214 may have a similar shape
as the male forming elements 213. The depth of the recesses 214 may
be greater than the height of the male forming elements 213.
[0196] The first and second forming member (211, 212) may be
further defined by a depth of engagement (DOE) which is a measure
of the level of intermeshing of the first and second forming member
(211, 212), as shown in FIG. 17C. The depth of engagement (DOE) may
be measured from the tip of the male forming elements 213 to the
outermost portion of the surface of the second forming member 212
which portions are not within a recess 214. The depth of engagement
(DOE) may range from 1.5 mm to 5.0 mm or from 2.5 mm to 5.0 mm or
from 3.0 mm to 4.0 mm.
[0197] The first and second forming member (211, 212) may be
defined by a clearance between the first and second forming member
(211, 212) as shown in FIG. 17C. The clearance is the distance
between the side wall of the male forming element 213 and the side
wall of the recess 214. The clearance may range from 0.1 mm to 2 mm
or from 0.1 mm to 1.5 mm from 0.1 mm to 1 mm.
[0198] The topsheet 24 and the acquisition layer 52 may be engaged
together between the first and second forming members (211, 212)
and be mechanically deformed and combined together to form the
topsheet/acquisition layer laminate 245. The topsheet/acquisition
layer laminate 245 comprises thus deformations forming
three-dimensional protrusions 250.
[0199] The topsheet/acquisition layer laminate 245 may be
notionally divided into a first and second area. The first and/or
second area of the topsheet/acquisition layer laminate 245 may
comprise the majority of the three-dimensional protrusions 250
having different shapes.
[0200] Viewed from a cross-sectional view, i.e. in a Z-direction,
the majority of the three-dimensional protrusions 250 may have any
suitable shapes which include, but are not limited to:
bulbous-shaped, conical-shaped and mushroom shaped.
[0201] Viewed from above, the majority of the three-dimensional
protrusions 250 may have any suitable shapes which include, but are
not limited to: circular, diamond-shaped, round diamond-shaped,
U.S. football-shaped, oval-shaped, clover-shaped,
triangular-shaped, tear-drop shaped and elliptical-shaped
protrusions. The majority of the three-dimensional protrusions 250
may be non-circular.
[0202] The majority of the three-dimensional protrusions 250 may
form, in conjunction, one or more graphics. Having graphics can
support the caregiver's perception that the absorbent article is
well able to absorb the liquid bodily exudates.
[0203] Also, the majority of the three-dimensional protrusions 250
may form, in conjunction, one or more graphics such as a logo, e.g.
the Pampers Heart logo.
[0204] The majority of the three-dimensional protrusions 250 may
have similar plan view dimensions in all directions, or the
majority of the three-dimensional protrusions 250 may be longer in
one dimension than another. The majority of the three-dimensional
protrusions 250 may have different length and width dimensions. The
majority of the three-dimensional protrusions 250 may, thus, have a
ratio of length to width. The ratio of length to width can range
from 10:1 to 1:10.
[0205] The topsheet/acquisition layer laminate 245 may comprise a
plurality of three-dimensional protrusions 250 which may extend
towards the distribution layer 54 (see also FIG. 2) or towards the
carrier layer 17 (see FIGS. 11, 12A). When the majority of the
three-dimensional protrusions 250 extend towards the distribution
layer 54, the area of contact between the acquisition layer 52 of
the topsheet/acquisition layer laminate 245 and the underneath
distribution layer 54 is improved. The distribution layer 54 will
follow the shape of the majority of the three-dimensional
protrusions 250. Hence, the transfer of the liquid bodily exudates
from the topsheet/acquisition layer laminate 245 to the
distribution layer 54 can be increased.
[0206] FIG. 18A-FIG. 18F shows different alternatives of
three-dimensional protrusions 250. A bulbous-shaped protrusion may
be one type of three-dimensional protrusions 250 which may be
obtained by the process step described above using the apparatus
200. The topsheet/acquisition layer laminate 245 may comprise the
majority of the three-dimensional protrusions 250 protruding
towards the backsheet 25.
[0207] As shown in FIG. 18A, the three-dimensional protrusion 250
is formed from the fibers of the topsheet 24 and the acquisition
layer 52. The majority of the three-dimensional protrusions 250 is
defined by a base 256 forming an opening having a protrusion base
width, an opposed enlarged distal portion 257 that extends to a
distal end 259 and one or more side walls 255 between the base 256
and the distal portion 257. The base 256, distal portion 257 and
the one or more side walls 255 are formed by fibers such that the
majority of the three-dimensional protrusions 250 has only an
opening at the base 256, as shown in FIG. 18A. The side wall 255
may be substantially continuous. For instance, the side wall 255
may be spherical or conical. The majority of the three-dimensional
protrusions 250 may comprise more than one side wall 255, e.g. in a
pyramidal-shaped protrusion. The fibers may substantially or
completely surround the one or more side walls 255 of the majority
of the three-dimensional protrusions 250.
[0208] As shown in FIG. 18B, a three-dimensional protrusion 250
comprising an inner and outer three-dimensional protrusion 251A and
251B may be made from engaging the topsheet web 240 with the
acquisition layer 52 between the first and second forming member
(211, 212) such as the inner three-dimensional protrusion 251A from
the topsheet 24 and the outer three-dimensional protrusion 251B
from the acquisition layer 52 coincide with and fit together.
Hence, as shown in FIG. 18B, the inner three-dimensional protrusion
251A of the topsheet 24 and the outer three-dimensional protrusion
251B of the acquisition layer 52 are nested together.
[0209] The inner three-dimensional protrusion 251A may comprise a
plurality of fibers 254A which constitutes the topsheet 24. The
outer three-dimensional protrusion 251B in which the inner
three-dimensional protrusion 251A may be nested, may comprise a
plurality of fibers 254B which constitutes the acquisition layer
52. The plurality of fiber (254A, 254B) composing the
three-dimensional protrusion 250 may surround the side walls 255 of
the three-dimensional protrusions 250.
[0210] The topsheet 24 and the acquisition layer 52 may be both
extensible. The fibers composing the topsheet 24 and acquisition
layer 52 may elongate and/or may be mobile, such that the topsheet
24 and acquisition layer 52 are able to stretch to be nested
together.
[0211] Generally, the extensibility of the materials composing the
topsheet 24 and acquisition layer 52 can be selected according to
the desired sizes of the three-dimensional protrusions 250. If
relatively large three-dimensional protrusions 250 are desired,
materials with a relatively higher extensibility will be
chosen.
[0212] For instance, the topsheet 24 or acquisition layer 52 may be
capable of undergoing an apparent elongation of equal to or greater
than at least 100% or 110% or 120% or 130% up to 200% along
longitudinal and/or transversal axis of the absorbent article at or
before reaching the breaking force according to the Test Method as
set out above
[0213] In some cases, it might be desired to have three-dimensional
protrusions 250 which are larger either along the longitudinal or
transversal axis of the absorbent article. For this, the materials
composing the topsheet 24 and acquisition layer 52 can be thus more
extensible in either along the longitudinal versus transversal axis
of the absorbent article or vice versa.
[0214] The majority of the three-dimensional protrusions 250 may
comprise a void area 253 which is the portion of the
three-dimensional protrusion 251A which does not comprise any
fibers or very little fibers. The majority of the three-dimensional
protrusions 250 may be defined by a protrusion base width WB.sub.1
of the base 256 forming an opening which is measured from two side
walls of the inner portion 251A at the base 256. The majority of
the three-dimensional protrusions 250 may be defined by a width
WD.sub.2 of the void area 253 which is the maximum interior width
measured between two side walls of the inner three-dimensional
protrusion 251A or which is the maximum diameter of the side wall
when the distal portion has a substantially circular shape. The
maximum interior width WD.sub.2 of the void area 253 at the distal
portion may be greater than the protrusion base width WB.sub.1 of
the base 256 of the majority of the three-dimensional protrusions
250. This is the case for some types of three-dimensional shapes,
such as bulbous shapes as exemplified in FIG. 18B but nor for
conical shape. The protrusion base width WB.sub.1 of the base 256
of the three-dimensional protrusion 250 may range from 1.5 mm to 15
mm or from 1.5 mm to 10 mm or from 1.5 mm to 5 mm or from 1.5 mm to
3 mm. Measurements of the dimensions of the protrusion base width
WB.sub.1 of the base 256 and the width WD.sub.2 of the distal
portion 257 can be made on a photomicrograph.
[0215] When the size of the protrusion base width WB.sub.1 of the
base 256 is specified herein, it will be appreciated that if the
openings are not of uniform width in a particular direction, the
protrusion base width, WB.sub.1, is measured at the widest portion.
Measurements of the protrusion base width WB.sub.1 of the base 256
or the maximum interior width WD.sub.2 of the void area 253 at the
distal portion 257 can be made on a photomicrograph at 20.times.
magnification.
[0216] As the plurality of fiber (254A, 254B) composing the
majority of the three-dimensional protrusions 250 may be present in
the one or more side walls 255 of the majority of the
three-dimensional protrusions 250, the majority of the
three-dimensional protrusions 250 may not collapse on one side and
close off the opening at the base 256 when compressive forces are
applied on the topsheet/acquisition layer laminate 245. The opening
at the base 256 may be maintained and may create a ring of
increased opacity around the opening at the base 256 when the
three-dimensional protrusion has been compressed. Hence, the
majority of the three-dimensional protrusions 250 can be preserved
and remain visible to the consumer when viewing the absorbent
article 20 from the topsheet 24. The majority of the
three-dimensional protrusions 250 can be preserved after being
subjected to any inherent compressive forces due to the process or
the step of compressing the absorbent articles comprising the
topsheet/acquisition layer laminate 245 prior to be filled in a
packaging.
[0217] In other words, the majority of the three-dimensional
protrusions 250 may have a degree of dimensional stability in the
X-Y plane when a Z-direction force is applied to the majority of
the three-dimensional protrusions 250. It is not necessary that the
collapsed configuration of the majority of the three-dimensional
protrusions 250 be symmetrical, only that the collapsed
configuration prevent the majority of the three-dimensional
protrusions 250 from flopping over or pushing back into the
original plane of the topsheet/acquisition layer laminate 245.
Without wishing to be bound to any particular theory, the wide base
256 and large cap 52 (greater than the protrusion base width of the
base opening 256), combined with the lack of a pivot point, causes
the three-dimensional protrusions 250 to collapse in a controlled
manner (the large distal portion 257 prevents the three-dimensional
protrusion 250 from flopping over and pushing back into the
original plane of the topsheet/acquisition layer laminate 245).
Thus, the three-dimensional protrusions 250 are free of a hinge
structure that would otherwise permit them to fold to the side when
compressed.
[0218] It may be desirable for at least one of the
three-dimensional protrusions 250 in the topsheet/acquisition layer
laminate 245 to collapse in a controlled manner described below
under the 7 kPa load when tested in accordance with the Accelerated
Compression Method in the Test Methods section below.
[0219] Alternatively, at least some, or in other cases, a majority
of the three-dimensional protrusions 250 may collapse in the
controlled manner described herein.
[0220] Alternatively, substantially all of the three-dimensional
protrusions 250 may collapse in the controlled manner described
herein. The ability of the three-dimensional protrusions 250 to
collapse may also be measured under a load of 35 kPa. The 7 kPa and
35 kPa loads may simulate manufacturing and high compression
packaging conditions. Wear conditions can range from 2 kPa or less
up to 7 kPa.
[0221] Generally, the majority of the three-dimensional protrusions
250 may be configured to collapse in a controlled manner such that
each base 256 forming an opening remains open, and the protrusion
base width of each base 256 forming an opening is greater than 0.5
mm after compression.
[0222] In the area of the three-dimensional protrusions 250, the
topsheet 24 and/or acquisition layer 52 may comprise one or more
interruptions. The formation of the one or more interruptions may
be due to the properties of the topsheet 24 and acquisition layer
52. The topsheet 24 may less extensible with regard to fiber
mobility and/or fiber extensibility than the acquisition layer 52
or vice versa such that a hole starts to form in the topsheet 24
and/or acquisition layer 52.
[0223] As shown in FIG. 18C, the acquisition layer 52 may be
interrupted in the area of the three-dimensional protrusion 250 of
the topsheet/acquisition layer laminate 245.
[0224] Generally, the acquisition layer 52 may have a lower
extensibility than the topsheet 24. In such cases, the acquisition
layer 52 may start to rupture and form an interruption, i.e. the
fibers composing the acquisition layer 52 may be less extensible
and/or mobile than the fibers composing the topsheet 24.
[0225] The three-dimensional protrusion 251A made of the respective
other non-interrupted topsheet interpenetrates the interrupted
acquisition layer 52. In such case, the interruptions may be formed
by locally rupturing the acquisition layer 52 by the process
described in detail above. The interpenetration may be achieved by
pushing the topsheet web 240 through the acquisition layer 52. In
order to obtain these three-dimensional protrusions, the depth of
engagement (DOE) of the apparatus 200 may be adequately selected
from 2 to 10 mm, or from 3 to 7 mm. The interrupted acquisition
layer 52 may have any suitable configuration in the area of the
three-dimensional protrusion 250. The rupture may involve a simple
splitting open of the acquisition layer 52 such that the
interruption in the acquisition layer 52 remains a simple
two-dimensional hole. It might happen that a portion of the
acquisition layer 52 in the area of the three-dimensional
protrusion 250 may be slightly deflected or urged out-of-place to
form flaps 269.
[0226] When the respective other non-interrupted topsheet 24
interpenetrates the interrupted acquisition layer 52, the topsheet
24 can be brought in direct contact with the underlying layer, e.g.
the carrier layer 17, the distribution layer 54 or the absorbent
core 28 leading to an efficient topsheet dewatering, which can
improve the dryness of the topsheet/acquisition layer laminate
245.
[0227] Alternatively, as shown in FIG. 18D or 18E, the acquisition
layer 52 may be interrupted in the area of the three-dimensional
protrusion 250 of the topsheet/acquisition layer laminate 245. The
three-dimensional protrusion 251B of the interrupted acquisition
layer 52 may comprise an interruption (258B). The three-dimensional
protrusion 251A of the non-interrupted topsheet 24 may coincide
with and fit together with the three-dimensional protrusion 251B of
the interrupted acquisition layer, as shown in FIG. 18D. In other
words, the topsheet 24 is not pushed through the acquisition layer
52 such that the topsheet 24 does not interpenetrate through the
acquisition layer 52.
[0228] Alternatively, the three-dimensional protrusion 251A of the
non-interrupted topsheet 24 may partially fit together with the
three-dimensional protrusion 251B of the interrupted acquisition
layer, as shown in FIG. 18E.
[0229] Likewise, the topsheet 24 may be interrupted in the area of
the three-dimensional protrusion 250 of the topsheet/acquisition
layer laminate 245.
[0230] Generally, the topsheet 24 may have a lower extensibility
than the acquisition layer 52. In such cases, the topsheet 24 may
start to rupture and form an interruption, i.e. the fibers
composing the topsheet 24 may be less extensible and/or mobile than
the fibers composing the acquisition layer 52.
[0231] In another alternative, the topsheet 24 and acquisition
layer 52 may be interrupted in the area of the three-dimensional
protrusions 250 of the topsheet/acquisition layer laminate 245 and
the three-dimensional protrusions of the topsheet 251A coincide
with and fit together with the three-dimensional protrusions 251B
of the acquisition layer. The interruptions 258A in the topsheet 24
in the area of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 will not coincide with the
interruptions 258B in the acquisition layer 52 in the area of the
three-dimensional protrusions 250 of the topsheet/acquisition layer
laminate 245, as shown in FIG. 18F. In this case, the interruptions
(258A, 258B) in the topsheet 24 and acquisition layer 52 are in
different locations in the three-dimensional protrusions 250.
[0232] The majority of the three-dimensional protrusions 250 may
protrude towards the body of the wearer when the absorbent article
20 is in use (see also FIG. 3). When the three-dimensional
protrusions 250 protrude towards the body of the wearer when the
absorbent article 20 is in use, the area of contact between the
topsheet 24 of the topsheet/acquisition layer laminate 245 and the
wearer's skin can be reduced in order to lead to an enhanced
dryness feeling and comfort. Hence, the topsheet/acquisition layer
laminate 245 provides cushioning to the wearer and an improved
sensation of comfort.
[0233] FIG. 19A-FIG. 19E shows alternatives how a plurality of
three-dimensional protrusions 250, e.g. bulbous-shaped protrusions,
may protrude from the acquisition layer 52 to the topsheet 24 of
the topsheet/acquisition layer laminate 245. In those alternatives,
a three-dimensional protrusion 250 may comprise an inner and outer
three-dimensional protrusion 251A and 251B. The inner
three-dimensional protrusion 251A of the acquisition layer 52 is
nested in the outer three-dimensional protrusion 251B of the
topsheet 24. The inner three-dimensional protrusion 251A may
comprise a plurality of looped fibers 254B of the acquisition layer
52. The outer three-dimensional protrusion 251B in which the inner
three-dimensional protrusion 251A is nested, may comprise a
plurality of looped fibers 254A of the topsheet 24.
[0234] An area of 10 cm.sup.2 of the topsheet/acquisition layer
laminate 245 may comprise from 5 to 100 three-dimensional
protrusions 250 from 10 to 50 three-dimensional protrusions 250 or
from 20 to 40 three-dimensional protrusions 250.
Fiber Concentration
[0235] The topsheet 24 may comprise a generally planar first region
of the topsheet 24. The acquisition layer 52 may comprise a
generally planar first region of the acquisition layer 52. The
three-dimensional protrusions of the respective topsheet 24 and the
acquisition layer 52 may comprise a plurality of discrete integral
second regions. The term "generally planar" is not meant to imply
any particular flatness, smoothness, or dimensionality. Thus, the
first region of the topsheet 24 can include other features that
provide the first region of the topsheet 24 with a topography. The
first region of the acquisition layer 52 can include other features
that provide the first region of the acquisition layer 52 with a
topography. Such other features can include, but are not limited to
small protrusions, raised network regions around the base 256
forming an opening, and other types of features. Thus, the first
region of the topsheet 24 and/or the first region of the
acquisition layer 52 can be generally planar when considered
relative to the respective second regions. The first region of the
topsheet 24 and/or the first region of the acquisition layer 52 can
have any suitable plan view configuration. In some cases, the first
region of the topsheet 24 and/or the first region of the
acquisition layer 52 can be in the form of a continuous
inter-connected network which comprises portions that surround each
of the three-dimensional protrusions 250.
[0236] The side walls 259 and the area around the base 256 of the
majority of the three-dimensional protrusions 250 may have a
visibly significantly lower concentration of fibers per given area
(which may be evidence of a lower basis weight or lower opacity)
than the portions of the topsheet 24 and/or the acquisition layer
52 in the unformed first region of the respective topsheet 24 and
the acquisition layer 52. The majority of the three-dimensional
protrusions 250 may also have thinned fibers in the side walls 259.
Thus, the fibers may have a first cross-sectional area when they
are in the undeformed topsheet 24 and the acquisition layer 52, and
a second cross-sectional area in the side walls 259 of the majority
of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245, wherein the first
cross-sectional area is greater than the second cross-sectional
area. The side walls 259 may also comprise some broken fibers as
well. The side walls 259 may comprise greater than or equal to
about 30%, alternatively greater than or equal to about 50% broken
fibers.
[0237] As used herein, the term "fiber concentration" has a similar
meaning as basis weight, but fiber concentration refers to the
number of fibers/given area, rather than g/area as in basis
weight.
[0238] The topsheet/acquisition layer laminate 245 may comprise the
majority of the three-dimensional protrusions 250 which are
oriented with the base 256 facing upward in which the concentration
of fibers at the distal end 259 of each respective topsheet 24 and
the acquisition layer 52 differs between the topsheet 24 and the
acquisition layer 52.
[0239] The concentration of fibers in the first region of the
acquisition layer 52 and in the distal ends 259 of the majority of
the three dimensional protrusions 250 may be greater than the
concentration of fibers in the side walls 255 of the majority of
the three dimensional protrusions 250 in the acquisition layer
52
[0240] The concentration of fibers in the first region of the
topsheet 24 and in the distal ends 259 of the majority of the three
dimensional protrusions 250 may be greater than the concentration
of fibers in the side walls 255 of the majority of the three
dimensional protrusions 250 in the topsheet 24.
[0241] Alternatively, the concentration of fibers in the first
region of the acquisition layer 52 may be greater than the
concentration of fibers in the side walls 255 of the majority of
the three-dimensional protrusions 250 in the acquisition layer 52,
and the concentration of fibers in the side walls 255 of the
majority of the three-dimensional protrusions 250 in the
acquisition layer 52 may be greater than the concentration of
fibers forming the distal ends 259 of the majority of the
three-dimensional protrusions 250 in the acquisition layer 52.
[0242] The concentration of fibers in the first region of the
acquisition layer 52 may be greater than the concentration of
fibers in the distal ends 259 of the majority of the three
dimensional protrusions 250 in the acquisition layer 52, and the
concentration of fibers in the first region of the topsheet 24 and
the distal ends 259 of the majority of the three dimensional
protrusions 250 may be greater than the concentration of fibers in
the side walls 255 of the majority of the three dimensional
protrusions 250 in the topsheet 24.
[0243] A portion of the fibers that form the first region fibers in
the acquisition layer 52 and/or the topsheet 24 may comprise
thermal point bonds, and the portion of the fibers in the
acquisition layer 52 and/or the topsheet 24 forming the side walls
255 and distal ends 259 of the majority of the three-dimensional
protrusions 250 may be substantially free of thermal point bonds.
In at least some of the three-dimensional protrusions, at least
some of the fibers in the acquisition layer 52 and/or the topsheet
24 may form a nest or circle around the perimeter of the
three-dimensional protrusion 250 at the transition between the side
wall 255 and the base 256 of the three-dimensional protrusion
250.
[0244] In some cases, the topsheet 24 or the acquisition layer 52
may have a plurality of bonds (such as thermal point bonds) therein
to hold the fibers together. Any such bonds are typically present
in the precursor materials from which the respective topsheet 24 or
the acquisition layer 52 are formed.
[0245] Forming three-dimensional protrusions 250 in the
topsheet/acquisition layer laminate 245 may also affect the bonds
(thermal point bonds) within the topsheet 24 and/or the acquisition
layer 52.
[0246] The bonds within the distal end 259 of the three-dimensional
protrusions 250 may remain intact (not be disrupted) by the
mechanical deformation process that formed the three-dimensional
protrusions 250. In the side walls 255 of the three-dimensional
protrusions 250, however, the bonds originally present in the
precursor topsheet 24 and/or the acquisition layer 52 may be
disrupted. When it is said that the bonds may be disrupted, this
can take several forms. The bonds can be broken and leave remnants
of a bond. In other cases, such as where the precursor materials of
the respective topsheet 24 or the acquisition layer 52 is
underbonded, the fibers can disentangle from a lightly formed bond
site (similar to untying a bow), and the bond site will essentially
disappear. In some cases, after the mechanical deformation process,
the side walls 255 of the majority of the three-dimensional
protrusions 250 may be substantially free (or completely free) of
thermal point bonds.
[0247] The bonds within the first region of the topsheet 24 and the
distal end 259 of the three-dimensional protrusions 250 may remain
intact. In the side walls 255 of the three-dimensional protrusions
250, however, the bonds originally present in the precursor
topsheet 24 may be disrupted such that the side walls 255 are
substantially free of thermal point bonds. Such a topsheet 24 could
be combined with an acquisition layer 52 in which the concentration
of fibers within the topsheet 24 in the first region and the distal
end 259 of the three-dimensional protrusions 250 is also greater
than the concentration of fibers in the side walls 255 of the
three-dimensional protrusions 250.
[0248] The acquisition layer 52 may have thermal point bonds within
the first region of the acquisition layer 52 and the distal end 259
of the three-dimensional protrusions 250 that remain intact. In the
side walls 255 of the three-dimensional protrusions 250, however,
the bonds originally present in the precursor acquisition layer 52
comprising the acquisition layer 52 may be disrupted such that the
side walls 255 of the acquisition layer 52 are substantially free
of thermal point bonds. In other cases, the thermal point bonds in
the acquisition layer 52 at the distal end 259 of the
three-dimensional protrusions 250 may also be disrupted so that the
distal end 259 of at least some of the three-dimensional
protrusions 250 are substantially or completely free of thermal
point bonds.
Indicia
[0249] The topsheet 24, the acquisition layer 52, and/or the
carrier layer 17 may comprise one or more indicia. In other
instances, more than one of these layers may comprise an
indicia.
[0250] The term "indicia", as used herein, may comprise one or more
inks with pigments, adhesives with pigments, words, designs,
trademarks, graphics, patterns, and/or pigmented areas, for
example. The term "indicia" does not include a fully tinted or
colored layer. The indicia may typically be a different color than:
(1) the layer that it is printed on, positioned on, or applied to;
or (2) a different color than other layers of an absorbent article
20.
[0251] The phrase a "different color" means a different shade of
the same color (e.g., dark blue and light blue) or may be
completely different color (e.g., blue and gray). The phrase
"different color" may also mean two colors having Delta E values
that are at least 1 apart, at least 1.5 apart, at least 2 apart, at
least 3 apart, or at least 1 to 15 apart.
[0252] The indicia should be at least partially visible from either
a wearer facing surface, a garment facing surface, or both of an
absorbent article 20, although the indicia may not be printed on,
positioned or, on applied to the wearer or garment facing surfaces
of the absorbent articles 20.
[0253] The indicia may be printed on, positioned on, or applied to
three-dimensional protrusions areas and non three-dimensional
protrusions areas, three-dimensional protrusion areas only, or non
three-dimensional protrusions areas only, for example. A
three-dimensional protrusion area may comprise a portion or all of
the majority of the three-dimensional protrusions 250.
[0254] The indicia may comprise a light activatable material, a
liquid activatable material, a pH activatable material, a
temperature activatable material, a menses activatable material, a
urine activatable material, or BM activatable material, or an
otherwise activatable material. These activatable materials may
typically undergo a chemical reaction, or other reaction, to change
the indicia from one color to a different color, from one color to
a different shade of the same color, from a color that is not
visually distinguishable in an absorbent article 20 to a color that
is visually distinguishable in an absorbent article 20, or from a
color that is visually distinguishable in an absorbent article 20
to a color that is not visually distinguishable in an absorbent
article 20.
[0255] In an instance, the indicia may grow or shrink or display a
graphic/not display a graphic after the indicia undergoes the
reaction. In other instances, the indicia may be activated by a
stress or a strain during manufacture or wear.
[0256] The indicia may be white or non-white. If the indicia is
white in color, at least one layer may be non-white so that the
indicia is visible from a wearer and/or garment facing surface of
the absorbent articles 20, for example.
[0257] The indicia may comprise embossments, fusion bonds, or other
mechanical deformations. In other instances the indicia may at
least partially overlap embossments, fusion bonds, or other
mechanical deformations.
[0258] In some instances, the indicia may be formed within either a
sheath or a core of bicomponent fibers. For example, a core may be
white, while a sheath may be blue, or vice versa.
[0259] The indicia may be on, positioned on, formed on, formed
with, printed on, or applied to all of, or part of, a certain
layer. The indicia may also be on, positioned on, formed on, formed
with, printed on, or applied to one or more layers, or on all
suitable layers of an absorbent article 20. The indicia may be on,
positioned on, formed on, formed with, printed on, or applied to
either side, or both sides, of the one or more layers of an
absorbent article 20. In some instances, suitable layers for
indicia placement comprise one or more of a topsheet 24, a
secondary topsheet, an acquisition layer 52, a distribution layer
54, a carrier layer 17, a core wrap 160, a bottom side 16' of the
core wrap 160, a top side 16 of the core wrap 160, and/or an
additional layer positioned at least partially intermediate the
topsheet 24 and the top side 16 of the core wrap 160 (hereafter
sometimes referred to as "materials suitable for indicia
placement").
[0260] Either in addition to or separate from the indicia described
above, any one or more of the suitable layers for indicia
placement, or a portion thereof, may have a color different than
any one or more of the remaining layers for indicia placement, or a
portion thereof. The definition of the phrase "different color"
above also applies to this part of the disclosure. In some
instances, the indicia may be a different color than any one or
more of the suitable layers for indicia placement.
[0261] Alternatively, an indicia may be on one of the suitable
layers for indicia placement while another one of the remaining
suitable layers for indicia placement may be a different color than
the indicia. One example may be a blue indicia on a white carrier
layer 17 with the acquisition layer 52 or topsheet 24 being
teal.
[0262] In another example, a blue indicia may be on a white carrier
layer 17 with the acquisition layer 52 and topsheet 24 also being
white. As such, the blue indicia may be viewable from a
wearer-facing surface.
[0263] In another example, a blue indicia may be on an acquisition
layer 52, wherein the topsheet 24 and the acquisition layer 52 are
simultaneously mechanically deformed and combined together,
preferably nested together to provide a topsheet/acquisition layer
laminate 245 having three-dimensional protrusions 250.
[0264] In an instance where the topsheet and the acquisition layer
are simultaneously mechanically deformed and combined together,
preferably nested together to provide a topsheet/acquisition layer
laminate 245 having three-dimensional protrusions 250, the indicia
may be applied to the acquisition layer 52 or the topsheet 24
before or after such mechanical deformation (or preferably namely
nesting).
[0265] In an example, two different indicia may be positioned on
the same or different layers for indicia placement. The two
different indicia may be different in color, pattern, and/or
graphic, for example. If the two different indicia are on different
layers for indicia placement, the two layers may be the same color
or different colors, or have portions that are the same color or
different colors.
[0266] In some instances, a visible color of a portion of, or all
of, the interior (wearer-facing surface) of an absorbent article 20
may be coordinated with and/or compliment a visible color of a
portion of, or all of, the exterior (garment-facing surface) of the
absorbent article 20, as described in further detail in U.S. Pat.
No. 8,936,584. The indicia visible from the interior may also be
coordinated with and/or compliment the indicia visible from the
exterior of the absorbent article 20. In such an instance, the
backsheet 25 of the absorbent article 20 may comprise an outer
cover nonwoven and a backsheet film. The indicia visible from the
exterior of the absorbent article 20 may be on the outer cover
nonwoven or the backsheet film.
[0267] In still other instances, the visible indicia and/or color
from the interior may also be coordinated with or compliment the
indicia and/or color visible from the exterior of the absorbent
article 20.
[0268] In addition to that described above, a first portion of one
of the suitable layers for indicia placement may be a first color
and a second portion of the same of the suitable layers for indicia
placement may be a second color. The first and second colors may be
a different color. In other instances, a first portion of one of
the suitable layers for indicia placement may be a first color and
a second portion of a different one of the suitable layers for
indicia placement may be a second color. The first and second
colors may be a different color.
[0269] In an instance, in an absorbent article 20, one of a
topsheet 24, an acquisition layer 52, a portion of a core wrap 160,
or an additional layer (e.g., a carrier layer 170) may be a
different color than a different one of the topsheet 24, the
acquisition layer 52, the portion of the core wrap 160, or the
additional layer.
[0270] In another instance, in an absorbent article 20, one of a
portion of a topsheet 24, a portion of an acquisition layer 52, a
portion of a core wrap 160, or a portion of an additional layer may
be a different color than a different one of the portion of the
topsheet 24, the portion of the acquisition layer 52, the portion
of the core wrap 160, or the portion of the additional layer.
[0271] In another instance, in an absorbent article 20, a first
portion of one of a topsheet 24, an acquisition layer 52, a portion
of a core wrap 160, or an additional layer may be a different color
as a second portion of the same one of the topsheet 24, the
acquisition layer 52, the core wrap 160, or the additional
layer.
[0272] The process of the present disclosure may comprise applying
the indicia to or positioning or printing the indicia on the
topsheet 24, the acquisition layer 52, the carrier layer 17, a
portion of the core wrap 160, and/or an additional layer positioned
at least partially intermediate the topsheet 24 and the backsheet
25. The indicia may be positioned or printed on or applied to
either side of the topsheet 24, the acquisition layer 52, the
carrier layer 17, the portion of the core wrap 160, and/or the
additional layer positioned at least partially intermediate the
topsheet 24 and the backsheet 25. If the indicia is applied to or
positioned or printed on the topsheet 24 or the acquisition layer
52, this step may be done before or after the topsheet 24 and the
acquisition layer 52 are simultaneously mechanically deformed and
combined together to provide the topsheet/acquisition layer
laminate 245.
[0273] In some forms, the indicia may be positioned or printed on
or applied to a carrier layer 17 that comprises pulp fibers. In
other forms, the indicia may be positioned or printed on or applied
to a garment-facing surface or a wearer-facing surface of the
acquisition layer 52. In some instances, the materials suitable for
indicia placement may be purchased with indicia thereon or the
indicia may be applied to or printed or positioned on before or
during feeding these materials into an absorbent article
manufacturing line.
Precursor Materials for the Topsheet and the Acquisition Layer
[0274] The topsheet/acquisition layer laminate 245 of the present
invention can be made of any suitable nonwoven materials
("precursor materials"). In some cases, the topsheet/acquisition
layer laminate 245 may also be free of cellulose materials. The
precursor materials for the topsheet/acquisition layer laminate 245
may have suitable properties in order to be deformed. The suitable
properties of the precursor materials may include: apparent
elongation of the fibers, fiber mobility, ability to deform and
stretch in the area where the three-dimensional protrusions 250 of
the topsheet/acquisition layer laminate 245 are formed. Hence, the
precursor materials are capable of undergoing mechanical
deformation to ensure that the three-dimensional protrusion 250
will not tend to recover or return to the prior configuration of a
flat topsheet 24 laminated on a flat acquisition layer 52.
[0275] Several examples of nonwoven materials suitable for use as a
topsheet 24 for the topsheet/acquisition layer laminate 245 may
include, but are not limited to: spunbonded nonwovens; carded
nonwovens; and nonwovens with relatively specific properties to be
able to be readily deformed.
[0276] One suitable nonwoven material as a topsheet 24 for the
topsheet/acquisition layer laminate 245 may be an extensible
polypropylene/polyethylene spunbonded nonwoven. One suitable
nonwoven material as a topsheet 24 for the topsheet/acquisition
layer laminate 245 may be a spunbonded nonwoven comprising
polypropylene and polyethylene. The fibers may comprise a blend of
polypropylene and polyethylene. Alternatively, the fibers may
comprise bicomponent fibers, such as a sheath-core fiber with
polyethylene on the sheath and polypropylene in the core of the
fiber.
[0277] The topsheet 24 of the topsheet/acquisition layer laminate
245 may have a basis weight from 8 to 40 gsm or from 8 to 30 gsm or
from 8 to 20 gsm.
[0278] Suitable nonwoven materials for the acquisition layer 52 of
the topsheet/acquisition layer laminate 245 may include, but are
not limited to: spunbonded nonwovens, through-air bonded ("TAB")
carded high loft nonwoven materials, spunlace nonwovens,
hydroentangled nonwovens, and resin bonded carded nonwoven
materials. Spunbonded PET may be denser than carded nonwovens,
providing more uniformity and opacity. Since PET fibers are not
very extensible, the nonwoven can be bonded such that at least some
of the fibers can be separated easily from the bond sites to allow
the fibers to pull out of the bond sites and rearrange when the
material is strained. This type of bonding, e.g. pressure bonding
can help increasing the level of mobility of the fibers. Indeed,
the fibers tend to pull out from the bond sites under tension.
[0279] The acquisition layer exhibits a basis weight from 10 to 120
gsm or from 10 to 100 gsm or from 10 to 80 gsm.
[0280] The topsheet 24 and/or acquisition layer 52 may have a
density from 0.01 to 0.4 g/cm.sup.3 or from 0.01 to 0.25 g/cm.sup.3
or from 0.04 to 0.15 g/cm.sup.3.
[0281] The topsheet 24 and acquisition layer 52 may be joined
together prior or during the mechanical deformation. If desired an
adhesive, chemical bonding, resin or powder bonding, or thermal
bonding between the topsheet 24 and acquisition layer 52 may be
selectively utilized to bond certain regions or all of the topsheet
24 and acquisition layer 52 together. In addition, the topsheet 24
and acquisition layer 52 may be bonded during processing, for
example, by carding the topsheet 24 of onto the acquisition layer
52 and thermal point bonding the combined layers.
[0282] Prior to any mechanical deformation, the topsheet 24 may be
attached to the acquisition layer 52. For instance, the topsheet 24
may be attached to the acquisition layer 52 where the topsheet 24
and the acquisition layer 52 overlaps. The attachment of the
topsheet 24 to the acquisition layer 52 may include a uniform
continuous layer of adhesive, a discontinuous patterned application
of adhesive or an array of separate lines, spirals, or spots of
adhesive. The basis weight of the adhesive in the
topsheet/acquisition layer laminate 245 may be from 0.5 to 30 gsm
or from 1 to 10 gsm or from 2 to 5 gsm.
Example
[0283] The topsheet and the acquisition layer were attached to each
other with a hot melt adhesive applied in form of spirals with a
basis weight of 5 gsm. The acquisition layer was centered onto the
topsheet with respect to the topsheet and placed 50 mm from the
front MD edge of the topsheet. The topsheet and acquisition layer
attached together form a composite web.
[0284] The topsheet and acquisition layer attached together have
been simultaneously mechanically deformed by passing them between a
pair of intermeshing male and female rolls. The topsheet of the
topsheet/acquisition layer laminate was in contact with the male
roll. The acquisition layer of the topsheet/acquisition layer
laminate was in contact with the female roll. The teeth on the male
roll have a rounded diamond shape like that shown in FIG. 14A, with
vertical sidewalls and a radiused or rounded edge at the transition
between the top and the sidewalls of the tooth. The teeth are 0.186
inch (4.72 mm) long and 0.125 inch (3.18 mm) wide with a CD spacing
of 0.150 inch (3.81 mm) and an MD spacing of 0.346 inch (8.79 mm)
The recesses in the mating female roll also have a rounded diamond
shape, similar to that of the male roll, with a clearance between
the rolls of 0.032-0.063 inch (0.813-1.6 mm) The process speed was
800 fpm and the depth of engagement (DOE) was 0.155 inch (3.94 mm),
with the topsheet being in contact with the male roll and the
acquisition layer being in contact with the female roll.
[0285] The topsheet of the topsheet/acquisition layer laminate was
a hydrophilic coated mono component high elongation spunbond
polypropylene (HES PP) nonwoven material with a density of 0.11
g/cm.sup.3. The mono component HES PP nonwoven material for the
topsheet has an overall basis weight of 20 gsm. The mono component
HES PP nonwoven material was first coated with a finish made of a
fatty acid polyethylene glycol ester for the production of a
permanent hydrophilic mono component HES PP nonwoven material. The
topsheet of the topsheet/acquisition layer laminate had a width of
168 mm and a length of 488 mm.
[0286] The acquisition layer of the topsheet/acquisition layer
laminate was a spunbond nonwoven with a basis weight of 60 gsm with
a density of 0.13 g/cm.sup.3. The acquisition layer comprises 7
denier PET/coPET (polyethylene terephthalate) trilobal bicomponent
fibers with a 70/30 ratio of PET/coPET which has been treated with
a surfactant. The acquisition layer of the topsheet/acquisition
layer laminate had a width of 90 mm and a length of 338 mm.
Prototype Diapers for the Example
[0287] Diaper prototypes for the above example were produced using
Pampers Active Fit S4 (size 4) diaper commercially available in
Germany in November 2014. Pampers Active Fit S4 (size 4) diaper
comprises a topsheet, an acquisition layer beneath the topsheet, a
distribution layer beneath the acquisition layer, an absorbent core
between the distribution and a backsheet beneath the absorbent
core. Diaper prototypes for the above example were produced using
Pampers Active Fit S4 (size 4) diaper.
[0288] The topsheet and acquisition layer attached together for the
above example were placed on top of a Pampers Active Fit diaper
commercially available in Germany in November 2014 from where the
commercial topsheet and acquisition layer were removed while
keeping the distribution layer in place. For each diaper prototype
based on the above example, the topsheet/acquisition layer laminate
were placed on top of the distribution layer with the
three-dimensional protrusions protruding towards the backsheet.
[0289] The acquisition layer front edge is placed 10 mm from the
distribution layer front edge. The topsheet/acquisition layer
laminate was attached onto the distribution layer and the absorbent
core with a hot melt adhesive applied all over the side of the
topsheet/acquisition layer laminate facing the distribution layer.
The hot melt adhesive was applied in form of spirals with a basis
weight of 5 gsm.
[0290] The three-dimensional protrusions of the
topsheet/acquisition layer laminate were protruding towards the
backsheet because the topsheet of the topsheet/acquisition layer
laminate was in contact with the male roll, as set out above.
[0291] Each prototype diaper was compacted in a bag at an In Bag
Stack Height, i.e. the total caliper of 10 bi-folded diapers, of 90
mm for 1 week. Then the bag was opened and the diapers out of the
bag were conditioned at least 24 hours prior to any testing at
23.degree. C.+/-2.degree. C. and 50%+/-10% Relative Humidity
(RH).
[0292] The measured protrusion height and protrusion base width of
the three-dimensional protrusions of the topsheet/acquisition layer
laminate have been measured according to the respective Protrusion
Height and Protrusion Base Width Test Methods (Table 1).
TABLE-US-00001 TABLE 1 Average measurements of the height and width
of the protrusions Example Standard average deviation Measured
Protrusion Base Width, mm 2.60 0.20 Measured Protrusion Height, mm
1.30 0.20
Test Methods
Wet Burst Test Method
[0293] The Wet Burst Strength as used herein is a measure of the
ability of a fibrous structure to absorb energy, when wet and
subjected to deformation with regard to the plane of the fibrous
structure.
[0294] The wet burst strength of a fibrous structure (referred to
as "sample" within this test method) is determined using an
electronic burst tester and specified test conditions. The results
obtained are averaged out of 4 experiments and the wet burst
strength is reported for a fibrous structure 55 consisting of one
single layer of wet-laid fibers.
Equipment
[0295] Apparatus: Burst Tester--Thwing-Albert Vantage Burst Tester
or equivalent ball burst instrument where the ball moves downward
during testing. Refer to manufacturer's operation and set-up
instructions. The ball diameter is 1.59 cm and the clamp opening
diameter is 8.9 cm. [0296] Calibration Weights--Refer to
manufacturer's Calibration instructions [0297] Conditioned Room
Temperature and Humidity controlled within the following limits for
Laboratory Testing: [0298] Temperature: 23.degree..+-.1.degree. C.
[0299] Relative humidity: 50%.+-.2% [0300] Paper Cutter--Cutting
board, 600 mm size [0301] Scissors--100 mm, or larger [0302]
Pan--Approximate Width/Length/Depth: 240.times.300.times.50 mm, or
equivalent [0303] Distilled water at the temperature of the
conditioned room used
Sample Preparation
[0304] The fibrous structure 55 may be unwound from the roll.
[0305] The samples to be tested are conditioned in the conditioned
room for 24 hours immediately before testing. All testing occurs
within the conditioned room.
[0306] Cut the samples so that they are approximately 228 mm in
length and width of approximately 140 mm in width.
Operation
[0307] Set-up and calibrate the Burst Tester instrument according
to the manufacturer's instructions for the instrument being
used.
[0308] Holding the sample by the narrow edges, the center of the
sample is dipped into a pan filled approximately 25 mm from the top
with distilled water. The sample is left in the water for 4
(.+-.0.5) seconds.
[0309] The excess water is drained from the sample for 3 (.+-.0.5)
seconds holding the sample in a vertical position.
[0310] The test should proceed immediately after the drain step.
The sample should have no perforations, tears or imperfections in
the area of the sample to be tested. If it does, start the test
over.
[0311] The sample is placed between the upper and lower rings of
the Burst Tester instrument. The sample is positioned centered and
flat on the lower ring of the sample holding device in a manner
such that no slack in the sample is present.
[0312] The upper ring of the pneumatic holding device is lowered to
secure the sample.
[0313] The test is started. The test is over at sample failure
(rupture) i.e., when the load falls 20 g from the peak force. The
maximum force value is recorded.
[0314] The plunger will automatically reverse and return to its
original starting position.
[0315] The upper ring is raised in order to remove and discard the
tested sample.
[0316] The procedure is repeated until all replicates have been
tested.
Calculation
[0317] Wet Burst Strength=sum of peak load readings/number of
replicates tested
[0318] Report the Wet Burst results to the nearest gram.
Accelerated Compression Method
[0319] 1. Cut 10 samples of the topsheet/acquisition layer laminate
245 (called herein specimen) to be tested and 11 samples of paper
towel into a 3 inch.times.3 inch (7.6 cm.times.7.6 cm) square.
[0320] 2. Measure the caliper of each of the 10 specimens at 2.1
kPa and a dwell time of 2 seconds using a Thwing-Albert ProGage
Thickness Tester or equivalent with a 50-60 millimeter diameter
circular foot. Record the pre-compression caliper to the nearest
0.01 mm. [0321] 3. Alternate the layers of the specimens to be
tested with the paper towels, starting and ending with the paper
towels. The choice of paper towel does not matter and is present to
prevent "nesting" of the protrusions in the deformed samples. The
samples should be oriented so the edges of each of the specimens
and each of the paper towels are relatively aligned, and the
protrusions in the specimens are all oriented the same direction.
[0322] 4. Place the stack of samples into a 40.degree. C. oven and
place a weight on top of the stack. The weight must be larger than
the foot of the thickness tester. To simulate high pressures or low
in-bag stack heights, apply 35 kPa (e.g. 17.5 kg weight over a
70.times.70 mm area). To simulate low pressures or high in-bag
stack heights, apply 7 kPa (e.g. 3.5 kg weight over a 70.times.70
mm area). [0323] 5. Leave the samples in the oven for 15 hours.
After the time period has elapsed, remove the weight from the
samples and remove the samples from the oven. [0324] 6. Within 30
minutes of removing the samples from the oven, measure the
post-compression caliper as directed in step 2 above, making sure
to maintain the same order in which the pre-compression caliper was
recorded. Record the post-compression caliper of each of the 10
specimens to the nearest 0.01 mm. [0325] 7. Let the samples rest at
23.+-.2.degree. C. and at 50.+-.2% relative humidity for 24 hours
without any weight on them. [0326] 8. After 24 hours, measure the
post-recovery caliper of each of the 10 specimens as directed in
step 2 above, making sure to maintain the same order in which the
pre-compression and post-compression calipers were recorded. Record
the post-recovery caliper of each of the 10 specimens to the
nearest 0.01 mm. Calculate the amount of caliper recovery by
subtracting the post-compression caliper from the post-recovery
caliper and record to the nearest 0.01 mm. [0327] 9. If desired, an
average of the 10 specimens can be calculated for the
pre-compression, post-compression and post-recovery calipers.
Protrusion Base Width and Protrusion Height Test Methods
[0328] 1) General Information
[0329] The Measured Protrusion Base Width and Measured Protrusion
Height of the three-dimensional protrusions of the
topsheet/acquisition layer laminate of an absorbent article are
measured using a GFM Primos Optical Profiler instrument
commercially available from GFMesstechnik GmbH, WarthestraBe 21,
D14513 Teltow/Berlin, Germany. Alternative suitable non-touching
surface topology profilers having similar principles of measurement
and analysis, can also be used, here GFM Primos is exemplified.
[0330] The GFM Primos Optical Profiler instrument includes a
compact optical measuring sensor based on a digital micro mirror
projection, consisting of the following main components: [0331] a)
DMD projector with 800.times.600 direct digital controlled
micro-mirrors [0332] b) CCD camera with high resolution
(640.times.480 pixels) [0333] c) Projection optics adapted to a
measuring area of at least 30.times.40 mm [0334] d) Recording
optics adapted to a measuring area of at least 30.times.40 mm
[0335] e) A table tripod based on a small hard stone plate [0336]
f) A cold light source (an appropriate unit is the KL 1500 LCD,
Schott North America, Inc., Southbridge, Mass.) [0337] g) A
measuring, control, and evaluation computer running ODSCAD 6.3
software
[0338] Turn on the cold-light source. The settings on the
cold-light source are set to provide a color temperature of at
least 2800K.
[0339] Turn on the computer, monitor, and open the image
acquisition/analysis software. In the Primos Optical Profiler
instrument, select "Start Measurement" icon from the ODSCAD 6.3
task bar and then click the "Live Image button".
[0340] The instrument is calibrated according to manufacturer's
specifications using calibration plates for lateral (X-Y) and
vertical (Z). Such Calibration is performed using a rigid solid
plate of any non-shiny material having a length of 11 cm, a width
of 8 cm and a height of 1 cm. This plate has a groove or machined
channel having a rectangular cross-section, a length of 11 cm, a
width of 6.000 mm and an exact depth of 2.940 mm. This groove is
parallel to the plate length direction. After calibration, the
instrument must be able to measure the width and depth dimensions
of the groove to within .+-.0.004 mm.
[0341] All testing is performed in a conditioned room maintained at
23.+-.2.degree. C. and 50+/-10% relative humidity. The surface to
be measured may be lightly sprayed with a very fine white powder
spray. Preferably, the spray is NORD-TEST Developer U 89, available
from Helling GmbH, Heidgraben, Germany.
[0342] 2) Protrusion Base Width Test Method
[0343] The topsheet/acquisition layer laminate is extracted from
the absorbent article by attaching the absorbent article to a flat
surface in a taut planar (i.e. stretched planar) configuration with
the topsheet of the topsheet/acquisition layer laminate facing up.
Any leg or cuff elastics are severed in order to allow the
absorbent article to lie flat. Using scissors, two longitudinal
cuts are made through all layers above the absorbent core (i.e. the
core wrap) along the edges of the topsheet/acquisition layer
laminate. Two transversal cuts are made through the same layers
following the front and back waist edges of the absorbent
article.
[0344] The topsheet/acquisition layer laminate and any other layers
above the absorbent core are then removed without perturbing the
topsheet/acquisition layer laminate. Freeze spray (e.g. CRC Freeze
Spray manufactured by CRC Industries, Inc. 885 Louis Drive,
Warminster, Pa. 18974, USA), or equivalent aid may be used to
facilitate removal of the uppermost layers from the absorbent
article. The topsheet/acquisition layer laminate is then separated
from any other layers, including any carrier layer (e.g. a nonwoven
carrier layer, a tissue layer), using freeze spray if necessary. If
a distribution layer, e.g. a pulp containing layer is attached to
the topsheet/acquisition layer laminate, any residual cellulose
fibers are carefully removed with tweezers without modifying the
acquisition layer.
[0345] The topsheet/acquisition layer laminate with
three-dimensional protrusions (conditioned at a temperature of
23.degree. C..+-.2.degree. C. and a relative humidity of 50%.+-.10%
for at least 24 hours) namely "the specimen" is laid down on a hard
flat horizontal surface with the body-facing side upward, i.e. the
topsheet of the topsheet/acquisition layer laminate being upward.
Ensure that the specimen is lying in planar configuration, without
being stretched, with the specimen uncovered.
[0346] A nominal external pressure of 1.86 kPa (0.27 psi) is then
applied to the specimen. Such nominal external pressure is applied
without interfering with the topology profile measurement. Such an
external pressure is applied using a transparent, non-shining flat
Plexiglas.RTM. plate 200 mm by 70 mm and appropriate thickness
(approximately 5 mm) to achieve a weight of 83 g. The plate is
gently placed on top of the specimen, such that the center point of
the Plexiglas.RTM. plate is at least 40 mm away from any folds,
with the entire plate resting on the specimen. A fold corresponds
to a part of the absorbent article (e.g. the topsheet/acquisition
layer laminate) where the absorbent article has been folded for
packaging purposes.
[0347] Two 50 mm.times.70 mm metal weights each having a mass of
1200 g (approximate thickness of 43 mm) are gently placed on the
Plexiglas.RTM. plate such that a 70 mm edge of each metal weight is
aligned with the 70 mm edges of the Plexiglas.RTM. plate. A metal
frame having external dimensions of 70 mm.times.80 mm and interior
dimensions of 42 mm.times.61 mm, and a total weight of 142 g
(approximate thickness 6 mm), is positioned in the center of the
Plexiglas.RTM. plate between the two end weights with the longest
sides of the frame aligned with the longest sides of the plate.
[0348] If the specimen is smaller than 70.times.200 mm, or if a
large enough area without a fold is not present, or if an area of
interest is close to the edges of the specimen and can't be
analyzed with the Plexiglas and weights settings described above,
then the X-Y dimensions of the Plexiglas.RTM. plate and the added
metal weights may be adjusted to reach a nominal external pressure
of 1.86 kPa (0.27 psi) while maintaining a minimum 30.times.40 mm
field of view. At least 10 complete three-dimensional protrusions
of the specimen should be captured in the field of view of 30
mm.times.40 mm.
[0349] Position the projection head to be normal to the specimen
surface (i.e. to the topsheet of the topsheet/acquisition layer
laminate).
[0350] Adjust the distance between the specimen and the projection
head for best focus.
[0351] In the Primos Optical Profiler instrument, turn on the
button "Pattern" to make a red cross appear on the screen ross and
a black cross appears on the specimen.
[0352] Adjust the focus control until the black cross is aligned
with the red cross on the screen.
[0353] Adjust image brightness then capture a digitized image.
[0354] In the Primos Optical Profiler instrument, change the
aperture on the lens through the hole in the side of the projector
head and/or altering the camera "gain" setting on the screen.
[0355] When the illumination is optimum, the red circle at the
bottom of the screen labeled "I.O." will turn green.
[0356] Click on the "Measure" button.
[0357] The topology of the upper surface of the
topsheet/acquisition layer laminate specimen is measured through
the Plexiglas plate over the entire field of view 30 mm.times.40
mm. It is important to keep the specimen still stationary during
this time in order to avoid blurring of the captured image. The
image should be captured within the 30 seconds following the
placement of the Plexiglas plate, metal weights and frame on top of
the specimen.
[0358] After the image has been captured, the X-Y-Z coordinates of
every pixel of the 40 mm.times.30 mm field of view area are
recorded. The X direction is the direction parallel to the longest
edge of the rectangular field of view, the Y direction is the
direction parallel to the shortest edge of the rectangular field of
view. The Z direction is the direction perpendicular to the X-Y
plane. The X-Y plane is horizontal while the Z direction is
vertical, i.e. orthogonal to the X-Y plane.
[0359] These data are smoothed and filtered using a polynomial
filter (n=6), a median filter 11 pixels by 11 pixels, and a
structure filter 81 pixels by 81 pixels. The polynomial filter
(n=6) approximates the X-Y-Z coordinate surface with a polynomial
of order 6 and returns the difference to the approximated
polynomial. The median filter 11 pixels by 11 pixels divides the
field of view (40 mm.times.30 mm) in X-Y squares of 11 pixels by 11
pixels. The Z coordinate of the pixel located at the center of a
given 11 pixels by 11 pixels square will be replaced by the mean Z
value of all the pixels of this given square. The structure filter
81 pixels by 81 pixels, removes the waviness of the structure and
translates all the Z peak values belonging to the bottom surface of
the Plexiglas plate to a top X-Y plane.
[0360] A Reference Plane is then defined as the X-Y plane
intercepting the surface topology profile of the entire field of
view (i.e. 30 mm.times.40 mm), 100 microns below this top X-Y
plane. In the Primos Optical Profiler instrument, to measure the
Material Area of the Reference Plane (Z=-0.1 mm), click on the
button "Evaluate". Then, apply a pre-filtering routine including a
polynomial filter (n=6), a median filter 11 by 11 and a structure
filter (n=81) using the function "Filter". Save the image to a
computer file with ".omc" extension.
[0361] The same above procedure is then executed on the
topsheet/acquisition layer laminate with the garment-facing side
upward (i.e. the acquisition layer of the topsheet/acquisition
layer laminate being upward), the 40 mm.times.30 mm field of view
being located at the exact same X-Y position of the
topsheet/acquisition layer laminate.
[0362] The Empty Area of the reference plane can be defined as the
area of the Reference Plane that is above the surface profile. The
Empty Areas having boundaries strictly located inside the field of
view area (i.e. 30 mm.times.40 mm) without crossing or overlapping
with the boundaries of the field of view area (i.e. 40 mm.times.30
mm) are defined as Isolated Empty Area(s). The Measured Protrusion
Base Width is defined for an Isolated Empty Area as the diameter of
the biggest circle that can be inscribed inside a given Isolated
Empty Area. This circle should only overlap with the Isolated Empty
Area.
[0363] In the Primos Optical Profiler instrument, this can be done
by clicking on "Draw circle" and drawing the biggest inscribed
circle possible in a chosen Isolated Empty Area. Click on "Show
sectional picture", the circle diameter can be measure via clicking
on the extremity of the sectional picture profile and then clicking
on "Horizontal distance" to obtain the Protrusion Base Width.
[0364] For both of the acquired and digitized images, the
Protrusion Base Width of all the Isolated Empty Areas is
determined. Then, the Measured Protrusion Base Width is calculated
as the arithmetic average of the 6 biggest Protrusion Base
Widths.
[0365] 3) Protrusion Height Test Method
[0366] The topsheet/acquisition layer laminate is extracted from
the absorbent article as described above in the Protrusion Base
Width Test Method.
[0367] The topsheet/acquisition layer laminate specimen comprising
three-dimensional protrusions is then conditioned and scanned under
a pressure of 1.86 kPa (0.27 psi) with the body-facing side upward,
i.e. the topsheet of the topsheet/acquisition layer laminate being
upward as described above in the Protrusion Base Width Test
Method.
[0368] After the image has been captured, the X-Y-Z coordinates of
every pixel of the 40 mm.times.30 mm field of view area are
recorded and smoothed/filtered as described above in the Protrusion
Base Width Test Method. A reference plane is also defined as
described above in the Protrusion Base Width Test Method.
[0369] In the Primos Optical Profiler instrument, to measure the
Material Area of the Reference Plane (Z=-0.1 mm), click on the
button "Evaluate". Then apply a pre-filtering routine including a
polynomial filter (n=6), a median filter 11 by 11 and a structure
filter (n=81) using the function "Filter". Save the image to a
computer file with ".omc" extension.
[0370] The same above procedure set out in the Protrusion Base
Width Test Method is then executed on the topsheet/acquisition
layer laminate with the garment-facing side upward (i.e. the
acquisition layer of the topsheet/acquisition layer laminate being
upward), the 40 mm.times.30 mm field of view being located at the
exact same X-Y position of the topsheet/acquisition layer
laminate.
[0371] The Empty Area of the reference plane can be defined as the
area of the Reference Plane that is above the surface profile. The
Empty Area having boundaries strictly located inside the field of
view area (i.e. 30 mm.times.40 mm) without crossing or overlapping
with the boundaries of the field of view area (i.e. 40 mm.times.30
mm) are defined as Isolated Empty Area(s). The Protrusion Height is
defined for an Isolated Empty Area as the distance between the
minimum Z value of the points of the topsheet/acquisition layer
laminate surface profile having X-Y coordinates located in this
Isolated Empty Area, and the Z value of the top X-Y plane.
[0372] Click on "Draw N parallel lines" and draw a first segment
parallel to the X axis of the field of view (direction of the
longest dimension of the field of view) passing through the center
of the Isolated Empty Area and extending outside the Isolated Empty
Area boundaries. The center of the Isolated Empty Area corresponds
to the middle of the segment parallel to the Y axis of the field of
view and joining the biggest and smallest Y value of the Isolated
Empty Area. Then input the "number" of lines to be drawn and set
the "distance" between lines to 0.05 mm. Enough lines need to be
drawn such to cover the entire Isolated Empty Area. Leave the
averaging parameter to 0 then click "Ok". Then click on "Show
sectional picture". Click on the point of the sectional picture
profile having the minimum Z value and click on "Vertical distance"
to obtain the Protrusion Height.
[0373] For both of the acquired and digitized images, the
Protrusion Height of all the Isolated Empty Areas is determined.
Then, the Measured Protrusion Height is calculated as the
arithmetic average of the 6 biggest Protrusion Heights.
[0374] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0375] Every document cited herein, including any cross referenced
or related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0376] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *