U.S. patent application number 14/844026 was filed with the patent office on 2016-03-17 for absorbent articles.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Adrien GRENIER, James T. KNAPMEYER, Jill M. ORR, Rodrigo ROSATI, John B. STRUBE, Paul T. WEISMAN.
Application Number | 20160074257 14/844026 |
Document ID | / |
Family ID | 54140723 |
Filed Date | 2016-03-17 |
United States Patent
Application |
20160074257 |
Kind Code |
A1 |
ORR; Jill M. ; et
al. |
March 17, 2016 |
Absorbent Articles
Abstract
Absorbent articles having airfelt-free cores or substantially
airfelt-free cores in combination with high loft, three-dimensional
nonwoven materials are disclosed herein. Packaging comprising the
absorbent articles are also disclosed.
Inventors: |
ORR; Jill M.; (Liberty
Township, OH) ; STRUBE; John B.; (Okeana, OH)
; KNAPMEYER; James T.; (Cincinnati, OH) ; ROSATI;
Rodrigo; (Frankfurt Am Main, DE) ; GRENIER;
Adrien; (Frankfurt Am Main, DE) ; WEISMAN; Paul
T.; (Cincinnati, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
54140723 |
Appl. No.: |
14/844026 |
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: |
604/366 |
Current CPC
Class: |
A61F 2013/51147
20130101; A61F 2013/51009 20130101; A61F 13/55115 20130101; A61F
13/51108 20130101; A61F 2013/51002 20130101; A61F 2013/8497
20130101; A61F 2013/15715 20130101; A61F 13/15707 20130101; A61F
13/55145 20130101; A61F 2013/51007 20130101; A61F 2013/530489
20130101; A61F 2013/51355 20130101; A61F 13/15699 20130101; A61F
2013/427 20130101; A61F 2013/15284 20130101; A61F 13/51104
20130101; A61F 13/55105 20130101; A61F 13/535 20130101; A61F
2013/4568 20130101; A61F 2013/530715 20130101; A61F 2013/5386
20130101; A61F 13/513 20130101; A61F 2013/4587 20130101; A61F
2013/51026 20130101; A61F 2013/5307 20130101; A61F 13/45 20130101;
A61F 13/511 20130101; A61F 2013/530131 20130101; A61F 2013/421
20130101; A61F 2013/15365 20130101; A61F 2013/530481 20130101; A61F
13/536 20130101; A61F 2013/51023 20130101; A61F 13/15723 20130101;
A61F 2013/51092 20130101; A61F 13/15203 20130101; A61F 2013/51377
20130101; A61F 2013/530175 20130101; A61F 2013/530664 20130101;
A61F 13/5116 20130101; A61F 13/5121 20130101; A61F 13/537 20130101;
A61F 2013/5395 20130101; A61F 13/51 20130101; A61F 13/51394
20130101; A61F 2013/530007 20130101; A61F 2013/53472 20130101; A61F
2013/53908 20130101; A61F 13/53 20130101; A61F 13/551 20130101;
A61F 2013/15463 20130101; A61F 13/534 20130101 |
International
Class: |
A61F 13/53 20060101
A61F013/53; A61F 13/511 20060101 A61F013/511; A61F 13/551 20060101
A61F013/551; A61F 13/51 20060101 A61F013/51 |
Claims
1. An absorbent article comprising: a liquid pervious nonwoven
material having a first surface and a second surface, the nonwoven
material comprising a plurality of fibers, wherein the nonwoven
material comprises a generally planar first region and a plurality
of discrete integral second regions that comprise deformations
forming protrusions extending outward from the first surface of the
nonwoven material and openings in the second surface of the
nonwoven material, the protrusions being formed from the fibers,
wherein at least some of the protrusions have an exterior width,
and two ends that define a length of the protrusion therebetween,
and the at least some of the protrusions comprise a base proximate
the first surface of the nonwoven material, an opposed distal end
extending outward in the Z-direction from the base, side walls
between the base and the distal end of the protrusion, and a cap
comprising at least a portion of the side walls and the distal end
of the protrusion, wherein the side walls have interior surfaces,
and wherein the exterior width of the protrusion varies along the
length of the protrusion when the nonwoven material is viewed from
the Z-direction; a liquid impermeable material; and an absorbent
core positioned intermediate the nonwoven material and the liquid
impermeable material, wherein the absorbent core comprises an
absorbent material, and wherein the absorbent material comprises at
least 90% superabsorbent polymers by weight of the absorbent
material and a hotmelt adhesive.
2. The absorbent article of claim 1, wherein the interior surfaces
of the side walls define a base opening at the base of the
protrusion, wherein the cap has a portion with a maximum interior
width, wherein the base opening has a width, and wherein the
maximum interior width of the cap of the protrusion is greater than
the width of the base opening.
3. The absorbent article of claim 1, wherein a channel is formed in
the absorbent material.
4. The absorbent article of claim 3, wherein a second channel is
formed in the absorbent material.
5. The absorbent article of claim 1, wherein the absorbent material
comprises at least 99% superabsorbent polymers by weight of the
absorbent material.
6. The absorbent article of claim 1, wherein the absorbent material
is substantially free of cellulosic, natural, or synthetic
fibers.
7. The absorbent article of claim 1, wherein the at least some
protrusions of the nonwoven material have a middle between their
ends, and wherein the at least some protrusions are wider in the
middle than the ends.
8. The absorbent article of claim 1, wherein the at least some of
the protrusions of the nonwoven material have a non-circular plan
view configuration.
9. The absorbent article of claim 1, wherein multiple fibers of the
nonwoven material extend from the base of protrusion to the distal
end of the protrusion, and contribute to form a portion of the
sides and the cap of the protrusion, and wherein the fibers at
least substantially surround the sides of the protrusion.
10. The absorbent article of claim 1, wherein the base opening has
a minimum width measured at the center of the base opening, and
wherein the minimum width is at least about 0.5 mm.
11. The absorbent article of claim 1, wherein the nonwoven material
comprises two or more layers of nonwoven material.
12. The absorbent article of claim 11, wherein the first layer
comprises a liquid pervious topsheet, and wherein the second layer
comprises an acquisition layer.
13. The absorbent article of claim 1, wherein the two or more
layers are nested within at least one of the protrusions.
14. The absorbent article of claim 1, wherein the nonwoven material
comprises a single layer, and wherein the single layer comprises a
liquid permeable topsheet.
15. The absorbent article of claim 13, wherein the absorbent
material comprises at least 95% superabsorbent polymers by weight
of the absorbent material, and wherein the absorbent material is
substantially free of cellulosic, natural or synthetic fibers.
16. The absorbent article of claim 12, comprising a carrier layer
for supporting a distribution material, wherein the carrier layer
is in a facing relationship with the acquisition layer.
17. A package comprising a plurality of the absorbent articles of
claim 1, wherein the package has an in-bag stack height of less
than about 85 mm, according to the In-Back Stack Height Test
herein.
18. An absorbent article comprising: a liquid pervious nonwoven
material having a first surface and a second surface, the nonwoven
material comprising a plurality of fibers, wherein the nonwoven
material comprises a generally planar first region and a plurality
of discrete integral second regions that comprise deformations
forming protrusions extending outward from the first surface of the
nonwoven material and openings in the second surface of the
nonwoven material, the protrusions being formed from the fibers,
wherein at least some of the protrusions have an exterior width,
and two ends that define a length of the protrusion therebetween,
and the at least some protrusions comprise a base proximate the
first surface of the nonwoven material, an opposed distal end
extending outward in the Z-direction from the base, side walls
between the base and the distal end of the protrusion, and a cap
comprising at least a portion of the side walls and the distal end
of the protrusion, wherein the side walls have interior surfaces,
wherein the interior surfaces of the side walls define a base
opening at the base of the protrusion, wherein the cap has a
portion with a maximum interior width, wherein the base opening has
a width, and wherein the maximum interior width of the cap of the
protrusion is greater than the width of the base opening; a liquid
impermeable material; and an absorbent core positioned intermediate
the nonwoven material and the liquid impermeable material, wherein
the absorbent core comprises an absorbent material, and wherein the
absorbent material comprises at least 85% superabsorbent polymers
by weight of the absorbent material and a hotmelt adhesive.
19. The absorbent article of claim 18, wherein the exterior width
of the protrusion varies along the length of the protrusion when
the nonwoven material is viewed from the z-direction.
20. The absorbent article of claim 18, wherein the absorbent
material comprises at least 99% superabsorbent polymers by weight
of the absorbent material, and wherein the absorbent material is
substantially free of cellulosic, natural or synthetic fibers.
21. The absorbent article of claim 18, wherein the nonwoven
material comprises a plurality of layers, and wherein at least two
of the plurality of layers are nested within the protrusion, and
wherein the protrusion is substantially hollow and forms a bulbous
shape.
22. The absorbent article of claim 21, wherein a first layer
comprises a liquid permeable topsheet, and wherein a second layer
comprises a liquid permeable acquisition material.
23. The absorbent article of claim 22, comprising a carrier layer
and a distribution layer applied to the carrier layer, wherein the
carrier layer is in a facing relationship with the liquid permeable
acquisition material.
24. A package comprising a plurality of the absorbent articles of
claim 18, wherein the package has an in-bag stack height of less
than about 90 mm, according to the In-Back Stack Height Test
herein.
25. A package comprising: a plurality of absorbent articles,
wherein at least some of the absorbent articles comprise: a liquid
pervious nonwoven material having a first surface and a second
surface, the nonwoven material comprising a plurality of fibers,
wherein the nonwoven material comprises a generally planar first
region and a plurality of discrete integral second regions that
comprise deformations forming protrusions extending outward from
the first surface of the nonwoven material and openings in the
second surface of the nonwoven material, the protrusions being
formed from the fibers, wherein at least some of the protrusions
have an exterior width, and two ends that define a length of the
protrusion therebetween, and the at least some protrusions comprise
a base proximate the first surface of the nonwoven material, an
opposed distal end extending outward in the Z-direction from the
base, side walls between the base and the distal end of the
protrusion, and a cap comprising at least a portion of the side
walls and the distal end of the protrusion, wherein the side walls
have interior surfaces, wherein the interior surfaces of the side
walls define a base opening at the base of the protrusion, wherein
the cap has a portion with a maximum interior width, wherein the
base opening has a width, and wherein the maximum interior width of
the cap of the protrusion is greater than the width of the base
opening; a liquid impermeable material; and an absorbent core
positioned intermediate the liquid permeable nonwoven material and
the liquid impermeable material, wherein the absorbent core
comprises an absorbent material, wherein the absorbent material
comprises at least 85% superabsorbent polymers by weight of the
absorbent material and a hotmelt adhesive; wherein the package has
an in-bag stack height of less than about 100 mm, but greater than
about 70 mm, according to the In-Back Stack Height Test herein.
26. The package of claim 25, wherein the nonwoven material
comprises a topsheet and an acquisition layer.
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&G13972PQ),
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
[0002] The present disclosure relates to absorbent articles, and
more particularly relates to absorbent articles having
substantially airfelt-free cores or airfelt-free cores in
combination with three-dimensional nonwoven materials.
BACKGROUND
[0003] Absorbent articles are used to absorb and contain bodily
exudates (e.g., urine, menses, BM). The absorbent articles are
often configured as diapers, pants, adult incontinence articles, or
sanitary napkins, for example. Conventional absorbent articles have
absorbent cores comprising superabsorbent polymers and cellulosic
fibers (for example, sometimes 50% or more cellulosic fibers by
weight). These conventional absorbent cores provide absorbent
articles with thickness and bulk characteristics typical of an
absorbent comprising an assembly of defibered cellulosic fibers.
The thickness and bulk of the absorbent articles provides consumer
perceptions of absorbency and performance, while also providing the
absorbent articles with sufficient capillary void volume to manage
large single bodily exudate insults or multiple insults. These
absorbent articles typically have a flat or planar topsheet.
[0004] In recent years, one or more absorbent article manufacturers
have produced absorbent articles comprising absorbent cores with
little or no cellulosic fibers. These cores are known as
"airfelt-free" cores and typically comprise superabsorbent polymers
and optionally one or more hotmelt adhesives to hold the
superabsorbent polymers in position within the absorbent core. Some
airfelt-free cores rely upon other mechanisms than hotmelt
adhesives, for example mechanical entrapment in pockets, to hold
the superabsorbent polymers in position within the absorbent core
during use. Airfelt-free cores are much thinner than traditional
absorbent cores in that cellulosic fibers are either not present or
are present at a very low level by weight within the absorbent
cores. These thin airfelt-free cores are generally combined with
flat or planar topsheets and flat or planer acquisition layers in
absorbent articles. As a result, the overall absorbent articles
having an airfelt-free core are much thinner than conventional
absorbent articles. The thinness of these absorbent articles can
lead to the consumer perceptions of lack of absorbency and
inadequate performance, although this is not technically accurate,
since the superabsorbent polymers have sufficient absorbency and
performance attributes. Another issue with the thinness of the
absorbent articles comprising airfelt-free cores is the reduction
in capillary void volume within the absorbent articles because of
the removal of all of, or most of, the cellulosic fibers within the
absorbent core. When capillary void volume in an absorbent article
is reduced, the absorbent article may be challenged in handling
large bodily exudates insults or multiple bodily exudates insults
within a short period of time. Typically, addition of capillary
void volume absorbent materials to an absorbent article increases
the thickness of the articles which is a negative for consumers
seeking thin, high performance absorbent articles packaged with low
bulk packages. What is needed are absorbent articles comprising
airfelt-free cores that overcome the above-stated problems.
SUMMARY
[0005] The present disclosure solves the problems associated with
absorbent articles comprising airfelt-free cores and planar
topsheets by providing absorbent articles comprising airfelt-free
cores and high loft, three-dimensional nonwoven materials. The
nonwoven materials may be used as topsheets or as
topsheet/acquisition layer laminates. Unexpectedly, the
three-dimensional nonwoven materials of the present disclosure
increase the capillary void volume within the absorbent articles
comprising airfelt-free cores while still preserving the ability to
ship the absorbent articles with a low stack height so as to have
low distribution costs for the consumer and the manufacturer. This
increase in capillary void volume provides the absorbent articles
comprising airfelt-free cores with better ability to receive
multiple bodily exudate insults or large single insults and,
thereby, makes the absorbent articles less prone to leakage. In
addition, the three-dimensional nonwoven materials of the present
disclosure, when used as at least part of a topsheet of an
absorbent article, provide the consumer with an aesthetically
pleasing absorbent article with an appearance communicating
thickness and absorbency and thus consumer perception of absorbency
and performance. The technical performance improvements of the
absorbent articles of the present disclosure and the consumer
perception improvement accompanying the absorbent articles are
unexpectedly realized in combination with the ability to package
the absorbent articles at stack heights where the consumer and the
manufacturer also realize distribution conveniences and lower
costs.
[0006] In a form, the present disclosure is directed, in part, to
an absorbent article comprises a liquid permeable nonwoven material
comprising a first surface and a second surface. The nonwoven
material comprises a plurality of fibers and comprises a generally
planar first region and a plurality of discrete integral second
regions that comprise deformations forming protrusions extending
outward from the first surface of the nonwoven material and
openings in the second surface of the nonwoven material. The
protrusions are formed from the fibers. At least some of the
protrusions comprise a base proximate to the first surface of the
nonwoven material, an opposed distal end extending outward in the
Z-direction from the base, side walls between the base and the
distal end of the protrusion, and a cap comprising at least a
portion of the side walls and the distal end of the protrusion. The
side walls have interior surfaces. Multiple fibers extend from the
base of the protrusion to the distal end of the protrusion, and
contribute to form a portion of the sides and cap of the
protrusion. The fibers at least substantially surround the sides of
the protrusion. The absorbent article further comprises a liquid
impermeable material and an absorbent core positioned intermediate
the liquid permeable nonwoven material and the liquid impermeable
material. The absorbent core comprises an absorbent material. The
absorbent material comprises at least 85% superabsorbent polymers
by weight of the absorbent material.
[0007] In a form, the present disclosure is directed, in part, to
an absorbent article comprises a liquid permeable nonwoven material
comprising a first surface and a second surface. The nonwoven
material comprises a plurality of fibers, a generally planar first
region and a plurality of discrete integral second regions that
comprise deformations forming protrusions extending outward from
the first surface of the nonwoven material and openings in the
second surface of the nonwoven material. The protrusions are formed
from the fibers. At least some of the protrusions comprise a base
proximate the first surface of the nonwoven material, an opposed
distal end extending outward in the Z-direction from the base, side
walls between the base and the distal end of the protrusion, and a
cap comprising at least a portion of the side walls and the distal
end of the protrusion, wherein the side walls have interior
surfaces. Multiple fibers extend from the base of the protrusion to
the distal end of the protrusion, and contribute to form a portion
of the sides and cap of a protrusion. The interior surfaces of the
side walls define a base opening at the base of the protrusion. The
cap has a portion with a maximum interior width. The base opening
has a width. The maximum interior width of the cap of the
protrusion is greater than the width of the base opening. The
absorbent article further comprising a liquid impermeable material
and an absorbent core positioned intermediate the nonwoven material
and the liquid impermeable material. The absorbent core comprises
an absorbent material. The absorbent material comprises at least
85% superabsorbent polymers by weight of the absorbent material and
a channel.
[0008] In a form, the present disclosure is directed, in part, to a
package comprises a plurality of absorbent articles. At least some
of the absorbent articles comprise a liquid permeable nonwoven
material comprising a first surface and a second surface. The
nonwoven material comprises a plurality of fibers. The nonwoven
material comprises a generally planar first region and a plurality
of discrete integral second regions that comprise deformations
forming protrusions extending outward from the first surface of the
nonwoven material and openings in the second surface of the
nonwoven material. The protrusions are formed from the fibers. At
least some of the protrusions comprise a base proximate the first
surface of the nonwoven material, an opposed distal end extending
outward in the Z-direction from the base, side walls between the
base and the distal end of the protrusion, and a cap comprising at
least a portion of the side walls and the distal end of the
protrusion. The side walls have interior surfaces. Multiple fibers
extend from the base of the protrusion to the distal end of the
protrusion, and contribute to form a portion of the sides and cap
of a protrusion. The interior surfaces of the side walls define a
base opening at the base of the protrusion. The cap has a portion
with a maximum interior width. The base opening has a width. The
maximum interior width of the cap of the protrusion is greater than
the width of the base opening. The at least some absorbent articles
further comprise a liquid impermeable material and an absorbent
core positioned intermediate the liquid permeable nonwoven material
and the liquid impermeable material. The absorbent core comprises
an absorbent material. The absorbent material comprises at least
85% superabsorbent polymers by weight of the absorbent material.
The package has an in-bag stack height of less than about 80 mm,
according to the In-Back Stack Height Test herein.
[0009] In a form, the present disclosure is directed, in part, to
an absorbent article comprises a liquid pervious nonwoven material
having a first surface and a second surface. The nonwoven material
comprises a plurality of fibers. The nonwoven material comprises a
generally planar first region and a plurality of discrete integral
second regions that comprise deformations forming protrusions
extending outward from the first surface of the nonwoven material
and openings in the second surface of the nonwoven material. The
protrusions are formed from the fibers. At least some of the
protrusions have an exterior width, and two ends that define a
length of the protrusion therebetween. The at least some of the
protrusions comprise a base proximate the first surface of the
nonwoven material, an opposed distal end extending outward in the
Z-direction from the base, side walls between the base and the
distal end of the protrusion, and a cap comprising at least a
portion of the side walls and the distal end of the protrusion. The
side walls have interior surfaces. The exterior width of the
protrusion varies along the length of the protrusion when the
nonwoven material is viewed from the z-direction. The absorbent
article further comprises a liquid impermeable material and an
absorbent core positioned intermediate the nonwoven material and
the liquid impermeable material. The absorbent core comprises an
absorbent material. The absorbent material comprises at least 90%
superabsorbent polymers by weight of the absorbent material and a
hotmelt adhesive.
[0010] In a form, the present disclosure is directed, in part, to
an absorbent article comprises a liquid pervious nonwoven material
having a first surface and a second surface. The nonwoven material
comprises a plurality of fibers. The nonwoven material comprises a
generally planar first region and a plurality of discrete integral
second regions that comprise deformations forming protrusions
extending outward from the first surface of the nonwoven material
and openings in the second surface of the nonwoven material. The
protrusions are formed from the fibers. At least some of the
protrusions have an exterior width, and two ends that define a
length of the protrusion therebetween, and the at least some
protrusions comprise a base proximate the first surface of the
nonwoven material, an opposed distal end extending outward in the
Z-direction from the base, side walls between the base and the
distal end of the protrusion, and a cap comprising at least a
portion of the side walls and the distal end of the protrusion. The
side walls have interior surfaces. The interior surfaces of the
side walls define a base opening at the base of the protrusion. The
cap has a portion with a maximum interior width. The base opening
has a width. The maximum interior width of the cap of the
protrusion is greater than the width of the base opening. The
absorbent article comprises a liquid impermeable material and an
absorbent core positioned intermediate the nonwoven material and
the liquid impermeable material. The absorbent core comprises an
absorbent material. The absorbent material comprises at least 85%
superabsorbent polymers by weight of the absorbent material and a
hotmelt adhesive.
[0011] In a form, the present disclosure is directed, in part, to a
package comprises a plurality of absorbent articles. At least some
of the absorbent articles comprise a liquid pervious nonwoven
material having a first surface and a second surface. The nonwoven
material comprises a plurality of fibers. The nonwoven material
comprises a generally planar first region and a plurality of
discrete integral second regions that comprise deformations forming
protrusions extending outward from the first surface of the
nonwoven material and openings in the second surface of the
nonwoven material. The protrusions are formed from the fibers. At
least some of the protrusions have an exterior width, and two ends
that define a length of the protrusion therebetween. The at least
some protrusions comprise a base proximate the first surface of the
nonwoven material, an opposed distal end extending outward in the
Z-direction from the base, side walls between the base and the
distal end of the protrusion, and a cap comprising at least a
portion of the side walls and the distal end of the protrusion. The
side walls have interior surfaces. The interior surfaces of the
side walls define a base opening at the base of the protrusion. The
cap has a portion with a maximum interior width. The base opening
has a width. The maximum interior width of the cap of the
protrusion is greater than the width of the base opening. The at
least some absorbent articles further comprising a liquid
impermeable material and an absorbent core positioned intermediate
the liquid permeable nonwoven material and the liquid impermeable
material. The absorbent core comprises an absorbent material. The
absorbent material comprises at least 85% superabsorbent polymers
by weight of the absorbent material and a hotmelt adhesive. The
package has an in-bag stack height of less than about 80 mm,
according to the In-Back Stack Height Test herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above-mentioned and other features and advantages of the
present disclosure, and the manner of attaining them, will become
more apparent and the disclosure itself will be better understood
by reference to the following description of non-limiting
embodiments of the disclosure taken in conjunction with the
accompanying drawings, wherein:
[0013] FIG. 1 is a photomicrograph showing the end view of a prior
art tuff;
[0014] FIG. 2 is a schematic end view of a prior art tuft after it
has been subjected to compression;
[0015] FIG. 3 is a photomicrograph of the end of a prior art
nonwoven web showing a plurality of collapsed tufts;
[0016] FIG. 4 is a schematic side view of a prior art
conical-shaped structure before and after it has been subjected to
compression;
[0017] FIG. 5 is a plan view photomicrograph showing one side of a
nonwoven material having three-dimensional deformations formed
therein, with the protrusions oriented upward in accordance with
the present disclosure;
[0018] FIG. 6 is a plan view photomicrograph showing the other side
of a nonwoven material similar to that shown in FIG. 5, with the
openings in the nonwoven facing upward in accordance with the
present disclosure;
[0019] FIG. 7 is a Micro CT scan image showing a perspective view
of a protrusion in a single layer nonwoven material in accordance
with the present disclosure;
[0020] FIG. 8 is a Micro CT scan image showing a side of a
protrusion in a single layer nonwoven material in accordance with
the present disclosure;
[0021] FIG. 9 is a Micro CT scan image showing a perspective view
of a deformation with the opening facing upward in a single layer
nonwoven material in accordance with the present disclosure;
[0022] FIG. 10 is a perspective view of a deformation in a two
layer nonwoven material with the opening facing upward in
accordance with the present disclosure;
[0023] FIG. 11 is a photomicrograph of a cross-section taken along
the transverse axis of a deformation showing one example of a
multi-layer nonwoven material having a three-dimensional
deformation in the form of a protrusion on one side of the material
that provides a wide opening on the other side of the material,
with the opening facing upward in accordance with the present
disclosure;
[0024] FIG. 12 is a schematic view of the protrusion shown in FIG.
11 in accordance with the present disclosure;
[0025] FIG. 13 is a plan view photomicrograph from the protrusion
side of a material after it has been subjected to compression
showing the high fiber concentration region around the perimeter of
the protrusion in accordance with the present disclosure;
[0026] FIG. 14 is a photomicrograph of the cross-section of a
protrusion taken along the transverse axis of the protrusion
showing the protrusion after it has been subjected to compression
in accordance with the present disclosure;
[0027] FIG. 15A is a cross-sectional view taken along the
transverse axis of a deformation of one embodiment of a multi-layer
nonwoven web shown with the base opening facing upward in
accordance with the present disclosure;
[0028] FIG. 15B is a cross-sectional view taken along the
transverse axis of a deformation of an alternative embodiment of a
multi-layer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0029] FIG. 15C is a cross-sectional view taken along the
transverse axis of a deformation of an alternative embodiment of a
multi-layer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0030] FIG. 15D is a cross-sectional view taken along the
transverse axis of a deformation of an alternative embodiment of a
multi-layer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0031] FIG. 15E is a cross-sectional view taken along the
transverse axis of a deformation of an alternative embodiment of a
multi-layer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0032] FIG. 15F is a cross-sectional view taken along the
transverse axis of a deformation of an alternative embodiment of a
multi-layer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0033] FIG. 16 is a plan view photomicrograph of a nonwoven web
with the protrusions oriented upward showing the concentration of
fibers in one layer in of a two layer structure in accordance with
the present disclosure;
[0034] FIG. 17 is a perspective view photomicrograph showing the
reduced fiber concentration in the side walls of the protrusions in
a layer similar to that shown in FIG. 16 in accordance with the
present disclosure;
[0035] FIG. 18 is a plan view photomicrograph of a nonwoven web
with the protrusions oriented upward showing the reduced
concentration of fibers in the cap of a protrusion in the other
layer of a two layer structure in accordance with the present
disclosure;
[0036] FIG. 19 is a perspective view photomicrograph showing the
increased fiber concentration in the side walls of the protrusions
in a layer similar to that shown in FIG. 18 in accordance with the
present disclosure;
[0037] FIG. 20 is a perspective view photomicrograph of one layer
of a multiple layer nonwoven material on the surface of a forming
roll showing the "hanging chads" that can be formed in one of the
layers when some nonwoven precursor web materials are used in
accordance with the present disclosure;
[0038] FIG. 21 is a perspective view of one example of an apparatus
for forming the nonwoven materials described herein in accordance
with the present disclosure;
[0039] FIG. 22 is an enlarged perspective view of a portion of the
male roll shown in FIG. 21 in accordance with the present
disclosure;
[0040] FIG. 23 is an enlarged perspective view showing the nip
between the rolls shown in FIG. 21 in accordance with the present
disclosure;
[0041] FIG. 24 is a schematic perspective view of one version of a
method of making nonwoven materials having deformations therein
where two precursor materials are used, one of which is a
continuous web and the other of which is in the form of discrete
pieces in accordance with the present disclosure;
[0042] FIG. 25 is an absorbent article in the form of a diaper
comprising an exemplary topsheet/acquisition layer composite
structure wherein the length of the acquisition layer is less that
the length of the topsheet with some layers partially removed in
accordance with the present disclosure;
[0043] FIG. 26 is one transverse cross-section of the diaper of
FIG. 25 taken along line 26-26 in accordance with the present
disclosure;
[0044] FIG. 27 is an alternative transverse cross-section of the
diaper of FIG. 25 in accordance with the present disclosure;
[0045] FIG. 28 is a top view of an example absorbent article,
wearer-facing surface facing the viewer, with some layers partially
removed in accordance with the present disclosure;
[0046] FIG. 29 is a cross-sectional view of the absorbent article
taken about line 29-29 of FIG. 28 in accordance with the present
disclosure;
[0047] FIG. 30 is a cross-sectional view of the absorbent article
taken about line 29-29 of FIG. 28 where the absorbent article has
been loaded with fluid in accordance with the present
disclosure;
[0048] FIG. 31 is a top view of another absorbent article,
wearer-facing surface facing the viewer, with some layers partially
removed in accordance with the present disclosure;
[0049] FIG. 32 is a cross-sectional view of the absorbent article
taken about line 32-32 of FIG. 31 in accordance with the present
disclosure;
[0050] FIG. 33 is a top view of an example absorbent core of the
absorbent article of FIG. 31 with some layers partially removed in
accordance the present disclosure;
[0051] FIG. 34 is a cross-sectional view of the absorbent core
taken about line 34-34 of FIG. 33 in accordance with the present
disclosure;
[0052] FIG. 35 is a cross-sectional view of the absorbent core
taken about line 35-35 of FIG. 33 in accordance with the present
disclosure;
[0053] FIG. 36 is a top view of another example absorbent article,
wearer-facing surface facing the viewer, that is a sanitary napkin
with some of the layers cut away in accordance with the present
disclosure; and
[0054] FIG. 37 is a side view of a package of absorbent articles
showing the package width in accordance with the present
disclosure. The outer surface is illustrated as transparent for
purposes of clarity.
DETAILED DESCRIPTION
[0055] Various non-limiting embodiments of the present disclosure
will now be described to provide an overall understanding of the
principles of the structure, function, manufacture, and use of the
absorbent articles disclosed herein. One or more examples of these
non-limiting embodiments are illustrated in the accompanying
drawings. Those of ordinary skill in the art will understand that
the absorbent articles described herein and illustrated in the
accompanying drawings are non-limiting example embodiments and that
the scope of the various non-limiting embodiments of the present
disclosure are defined solely by the claims. The features
illustrated or described in connection with one non-limiting
embodiment may be combined with the features of other non-limiting
embodiments. Such modifications and variations are intended to be
included within the scope of the present disclosure.
DEFINITIONS
[0056] The term "absorbent article" includes disposable articles
such as sanitary napkins, panty liners, tampons, interlabial
devices, wound dressings, diapers, adult incontinence articles,
wipes, and the like. At least some of such absorbent articles are
intended for the absorption of body liquids, such as menses or
blood, vaginal discharges, urine, and feces. Wipes may be used to
absorb body liquids, or may be used for other purposes, such as for
cleaning surfaces. Various absorbent articles described above will
typically comprise a liquid pervious topsheet, a liquid impervious
backsheet joined to the topsheet, and an absorbent core between the
topsheet and backsheet. The nonwoven material described herein can
comprise at least part of other articles such as scouring pads, wet
or dry-mop pads (such as SWIFFER.RTM. pads), and the like.
[0057] The term "absorbent core", as used herein, refers to the
component of the absorbent article that is primarily responsible
for storing liquids. As such, the absorbent core typically does not
include the topsheet or backsheet of the absorbent article.
[0058] The term "aperture", as used herein, refers to a regular or
substantially regularly-shaped hole that is intentionally formed
and extends completely through a web or structure (that is, a
through hole). The apertures can either be punched cleanly through
the web so that the material surrounding the aperture lies in the
same plane as the web prior to the formation of the aperture (a
"two dimensional" aperture), or the holes can be formed such that
at least some of the material surrounding the opening is pushed out
of the plane of the web. In the latter case, the apertures may
resemble a depression with an aperture therein, and may be referred
to herein as a "three dimensional" aperture, a subset of
apertures.
[0059] The term "component" of an absorbent article, as used
herein, refers to an individual constituent of an absorbent
article, such as a topsheet, acquisition layer, liquid handling
layer, absorbent core or layers of absorbent cores, backsheets, and
barriers such as barrier layers and barrier cuffs.
[0060] The term "cross-machine direction" or "CD" means the path
that is perpendicular to the machine direction in the plane of the
web.
[0061] The term "deformable material", as used herein, is a
material which is capable of changing its shape or density in
response to applied stresses or strains.
[0062] The term "discrete", as used herein, means distinct or
unconnected. When the term "discrete" is used relative to forming
elements on a forming member, it is meant that the distal (or
radially outwardmost) ends of the forming elements are distinct or
unconnected in all directions, including in the machine and
cross-machine directions (even though bases of the forming elements
may be formed into the same surface of a roll, for example).
[0063] The term "disposable" is used herein to describe absorbent
articles and other products which are not intended to be laundered
or otherwise restored or reused as an absorbent article or product
(i.e., they are intended to be discarded after use and, preferably,
to be recycled, composted or otherwise disposed of in an
environmentally compatible manner).
[0064] The term "forming elements", as used herein, refers to any
elements on the surface of a forming member that are capable of
deforming a web.
[0065] The term "integral", as used herein as in "integral
extension" when used to describe the protrusions, refers to fibers
of the protrusions having originated from the fibers of the
precursor web(s). Thus, as used herein, "integral" is to be
distinguished from fibers introduced to or added to a separate
precursor web for the purpose of making the protrusions.
[0066] The term "joined to" encompasses configurations in which an
element is directly secured to another element by affixing the
element directly to the other element; 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; and configurations in which one element is integral
with another element, i.e., one element is essentially part of 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.
[0067] The term "machine direction" or "MD" means the path that
material, such as a web, follows through a manufacturing
process.
[0068] The term "macroscopic", as used herein, refers to structural
features or elements that are readily visible and distinctly
discernable to a human having 20/20 vision when the perpendicular
distance between the viewer's eye and the web is about 12 inches
(30 cm). Conversely, the term "microscopic" refers to such features
that are not readily visible and distinctly discernable under such
conditions.
[0069] The term "mechanically deforming", as used herein, refers to
processes in which a mechanical force is exerted upon a material in
order to permanently deform the material.
[0070] The term "permanently deformed", as used herein, refers to
the state of a deformable material whose shape or density has been
permanently altered in response to applied stresses or strains.
[0071] The terms "SELF" and "SELF'ing", refer to Procter &
Gamble technology in which SELF stands for Structural Elastic Like
Film. While the process was originally developed for deforming
polymer film to have beneficial structural characteristics, it has
been found that the SELF'ing process can be used to produce
beneficial structures in other materials. Processes, apparatuses,
and patterns produced via SELF are illustrated and described in
U.S. Pat. Nos. 5,518,801; 5,691,035; 5,723,087; 5,891,544;
5,916,663; 6,027,483; and 7,527,615 B2.
[0072] The term "tuft", as used herein, refers to a particular type
of feature that may be formed from fibers in a nonwoven web. Tufts
may have a tunnel-like configuration which may be open at both of
their ends.
[0073] The term "web" is used herein to refer to a material whose
primary dimension is X-Y, i.e., along its length (or longitudinal
direction) and width (or transverse direction). It should be
understood that the term "web" is not necessarily limited to single
layers or sheets of material. Thus the web can comprise laminates
or combinations of several sheets of the requisite type of
materials.
[0074] The term "Z-dimension" refers to the dimension orthogonal to
the length and width of the web or article. The Z-dimension usually
corresponds to the thickness of the web or material. As used
herein, the term "X-Y dimension" refers to the plane orthogonal to
the thickness of the web or material. The X-Y dimension usually
corresponds to the length and width, respectively, of the web or
material.
Nonwoven Materials
[0075] The present disclosure is directed, in part, to high-loft
nonwoven materials having discrete three-dimensional deformations,
which deformations provide protrusions on one side of the material,
and openings on the other side of the nonwoven materials. Methods
of making the nonwoven materials are also disclosed. The nonwoven
materials can be used in absorbent articles and other articles, as
will be described in further detail below.
[0076] As used herein, the term "nonwoven" refers to a web or
material having a structure of individual fibers or threads which
are interlaid, but not in a repeating pattern as in a woven or
knitted fabric, which latter types of fabrics do not typically have
randomly oriented or substantially randomly-oriented fibers.
Nonwoven webs will have a machine direction (MD) and a cross
machine direction (CD) as is commonly known in the art of web
manufacture. By "substantially randomly oriented" is meant that,
due to processing conditions of the precursor web, there may be a
higher amount of fibers oriented in the MD than the CD, or vice
versa. For example, in spunbonding and meltblowing processes
continuous strands of fibers are deposited on a support moving in
the MD. Despite attempts to make the orientation of the fibers of
the spunbond or meltblown nonwoven web truly "random," usually a
slightly higher percentage of fibers are oriented in the MD as
opposed to the CD.
[0077] Nonwoven webs and materials are often incorporated into
products, such as absorbent articles, at high manufacturing line
speeds. Such manufacturing processes can apply compressive and
shear forces on the nonwoven webs that may damage certain types of
three-dimensional features that have been purposefully formed in
such webs. In addition, in the event that the nonwoven material is
incorporated into a product (such as a disposable diaper) that is
made or packaged under compression, it becomes difficult to
preserve the three-dimensional character of some types of prior
three-dimensional features after the material is subjected to such
compressive forces.
[0078] For instance, FIGS. 1 and 2 show an example of a prior art
nonwoven material 10 with a tufted structure. The nonwoven material
comprises tufts 12 formed from looped fibers 14 that form a
tunnel-like structure having two ends 16. The tufts 12 extend
outward from the plane of the nonwoven material in the Z-direction.
The tunnel-like structure has a width that is substantially the
same from one end of the tuft to the opposing end. Often, such
tufted structures will have holes or openings 18 at both ends and
an opening 20 at their base. Typically, the openings 18 at the ends
of the tufts are at the machine direction (MD) ends of the tufts.
The openings 18 at the ends of the tufts can be a result of the
process used to form the tufts. If the tufts 12 are formed by
forming elements in the form of teeth with a relatively small tip
and vertical leading and trailing edges that form a sharp point,
these leading and/or trailing edges may punch through the nonwoven
web at least one of the ends of the tufts. As a result, openings 18
may be formed at one or both ends of the tufts 12.
[0079] While such a nonwoven material 10 provides well-defined
tufts 12, the opening 20 at the base of the tuft structure can be
relatively narrow and difficult to see with the naked eye. In
addition, as shown in FIG. 2, the material of the tuft 12
surrounding this narrow base opening 20 may tend to form a hinge
22, or pivot point if forces are exerted on the tuft. If the
nonwoven is compressed (such as in the Z-direction), in many cases,
the tufts 12 can collapse to one side and close off the opening 20.
Typically, a majority of the tufts in such a tufted material will
collapse and close off the openings 20. FIG. 2 schematically shows
an example of a tuft 12 after it has collapsed. In FIG. 2, the tuft
12 has folded over to the left side. FIG. 3 is an image showing a
nonwoven material with several upwardly-oriented tufts, all of
which have folded over to the side. However, not all of the tufts
12 will collapse and fold over to the same side. Often, some tufts
12 will fold to one side, and some tufts will fold to the other
side. As a result of the collapse of the tufts 12, the openings 20
at the base of the tufts can close up, become slit-like, and
virtually disappear.
[0080] Prior art nonwoven materials with certain other types of
three dimensional deformations, such as conical structures, can
also be subject to collapse when compressed. As shown in FIG. 4,
conical structures 24 will not necessarily fold over as will
certain tufted structures when subjected to compressive forces F.
However, conical structures 24 can be subject to collapse in that
their relatively wide base opening 26 and smaller tip 28 causes the
conical structure to push back toward the plane of the nonwoven
material, such as to the configuration designated 24A.
[0081] The nonwoven materials of at least some embodiments of the
present disclosure described herein are intended to better preserve
the structure of discrete three-dimensional features in the
nonwoven materials after compression.
[0082] FIGS. 5-14 show examples of nonwoven materials 30 with
three-dimensional deformations comprising protrusions 32 therein.
The nonwoven materials 30 have a first surface 34, a second surface
36, and a thickness T therebetween (the thickness being shown in
FIG. 12). FIG. 5 shows the first surface 34 of a nonwoven material
30 with the protrusions 32 that extend outward from the first
surface 34 of the nonwoven material oriented upward. FIG. 6 shows
the second surface 36 of a nonwoven material 30 such as that shown
in FIG. 5, having three-dimensional deformations formed therein,
with the protrusions oriented downward and the base openings 44
oriented upward. FIG. 7 is a Micro CT scan image showing a
perspective view of a protrusion 32. FIG. 8 is a Micro CT scan
image showing a side view of a protrusion 32 (of one of the longer
sides of the protrusion). FIG. 9 is a Micro CT scan image showing a
perspective view of a deformation with the opening 44 facing
upward. The nonwoven materials 30 comprise a plurality of fibers 38
(shown in FIGS. 7-11 and 14). As shown in FIGS. 7 and 9, the
nonwoven material 30 may have a plurality of bonds 46 therein to
hold the fibers 38 together. Any such bonds are typically present
in the precursor material.
[0083] The protrusions 32 may, in some cases, be formed from looped
fibers (which may be continuous) 38 that are pushed outward so that
they extend out of the plane of the nonwoven web in the
Z-direction. The protrusions 32 will typically comprise more than
one looped fiber. In some cases, the protrusions 32 may be formed
from looped fibers and at least some broken fibers. In addition, in
the case of some types of nonwoven materials (such as carded
materials, which are comprised of shorter fibers), the protrusions
32 may be formed from loops comprising multiple discontinuous
fibers. Multiple discontinuous fibers in the form of a loop are
shown as layer 30A in FIGS. 15A-15F. The looped fibers may either
be aligned (that is, oriented in substantially the same direction),
or not be aligned within the protrusions 32. Typically, if
male/female forming elements are used to form the protrusions, and
the female forming elements substantially surround the male forming
elements, the fibers in the protrusions 32 may remain substantially
randomly oriented (rather than aligned), similar to their
orientation in the precursor web(s) from which the nonwoven
materials 30 are formed.
[0084] The nonwoven material 30 may comprise a generally planar
first region 40 and the three-dimensional deformations may comprise
a plurality of discrete integral second regions 42. The term
"generally planar" is not meant to imply any particular flatness,
smoothness, or dimensionality. Thus, the first region 40 can
include other features that provide the first region 40 with a
topography. Such other features can include, but are not limited to
small projections, raised network regions around the base openings
44, and other types of features. Thus, the first region 40 is
generally planar when considered relative to the second regions
42.
[0085] The term "deformation", as used herein, includes both the
protrusions 32 formed on one side of the nonwoven material and the
base openings 44 formed in the opposing side of the material. The
base openings 44 are most often not in the form of an aperture or a
through-hole. The base openings 44 may instead appear as
depressions. The base openings 44 can be analogized to the opening
of a bag. A bag has an opening that typically does not pass
completely through the bag. In the case of the present nonwoven
materials 30, as shown in FIG. 10, the base openings 44 open into
the interior of the protrusions 32.
[0086] FIG. 11 shows one example of a multi-layer nonwoven material
30 having a three-dimensional deformation in the form of a
protrusion 32 on one side of the material that provides a wide base
opening 44 on the other side of the material. The dimensions of
"wide" base openings are described in further detail below. In this
case, the base opening 44 is oriented upward in the figure. When
there is more than one nonwoven layer, the individual layers can be
designated 30A, 30B, etc. The individual layers 30A and 30B each
have first and second surfaces, which can be designated similarly
to the first and second surfaces 34 and 36 of the nonwoven material
(e.g., 34A and 36A for the first and second surfaces of the first
layer 30A; and, 34B and 36B for the first and second surfaces of
the second layer 30B).
[0087] As shown in FIGS. 11 and 12, the protrusions 32 comprise: a
base 50 proximate the first surface 34 of the nonwoven material; an
opposed enlarged distal portion or cap portion, or "cap" 52, that
extends to a distal end 54; side walls (or "sides") 56; an interior
58; and a pair of ends 60 (the latter being shown in FIG. 5). The
"base" 50 of the protrusions 32 comprises the narrowest portion of
the protrusion when viewed from one of the ends of the protrusion.
The term "cap" does not imply any particular shape, other than it
comprises the wider portion of the protrusion 32 that includes and
is adjacent to the distal end 54 of the protrusion 32. The side
walls 56 have an inside surface 56A and an outside surface 56B. As
shown in FIGS. 11 and 12, the side walls 56 transition into, and
may comprise part of the cap 52. Therefore, it is not necessary to
precisely define where the side walls 56 end and the cap 52 begins.
The cap 52 will have a maximum interior width, W.sub.I, between the
inside surfaces 56A of the opposing side walls 56. The cap 52 will
also have a maximum exterior width W between the outside surfaces
56B of the opposing side walls 56. The ends 60 of the protrusions
32 are the portions of the protrusions that are spaced furthest
apart along the longitudinal axis, L, of the protrusions.
[0088] As shown in FIGS. 11 and 12, the narrowest portion of the
protrusion 32 defines the base opening 44. The base opening 44 has
a width W.sub.O. The base opening 44 may be located (in the
z-direction) between the plane defined by the second surface 36 of
the material and the distal end 54 of the protrusion. As shown in
FIGS. 11 and 12, the nonwoven material 30 may have an opening in
the second surface 36 (the "second surface opening" 64) that
transitions into the base opening 44 (and vice versa), and is the
same size as, or larger than the base opening 44. The base opening
44 will, however, generally be discussed more frequently herein
since its size will often be more visually apparent to the consumer
in those embodiments where the nonwoven material 30 is placed in an
article with the base openings 44 visible to the consumer. It
should be understood that in certain embodiments, such as in
embodiments in which the base openings 44 face outward (for
example, toward a consumer and away from the absorbent core in an
absorbent article), it may be desirable for the base openings 44
not to be covered and/or closed off by another web.
[0089] As shown in FIG. 12, the protrusions 32 have a depth D
measured from the second surface 36 of the nonwoven web to the
interior of the protrusion at the distal end 54 of the protrusions.
The protrusions 32 have a height H measured from the second surface
36 of the nonwoven web to the distal end 54 of the protrusions. In
most cases the height H of the protrusions 32 will be greater than
the thickness T of the first region 40. The relationship between
the various portions of the deformations may be such that as shown
in FIG. 11, when viewed from the end, the maximum interior width
W.sub.I of the cap 52 of the protrusions is wider than the width,
W.sub.O, of the base opening 44.
[0090] The protrusions 32 may be of any suitable shape. Since the
protrusions 32 are three-dimensional, describing their shape
depends on the angle from which they are viewed. When viewed from
above (that is, perpendicular to the plane of the web, or plan
view) such as in FIG. 5, suitable shapes include, but are not
limited to: circular, diamond-shaped, rounded diamond-shaped, U.S.
football-shaped, oval-shaped, clover-shaped, triangle-shaped,
tear-drop shaped, and elliptical-shaped. (The base openings 44 will
typically have a shape similar to the plan view shape of the
protrusions 32.) In other cases, the protrusions 32 (and base
openings 44) may be non-circular. The protrusions 32 may have
similar plan view dimensions in all directions, or the protrusions
may be longer in one dimension than another. That is, the
protrusions 32 may have different length and width dimensions. If
the protrusions 32 have a different length than width, the longer
dimension will be referred to as the length of the protrusions. The
protrusions 32 may, thus, have a ratio of length to width, or an
aspect ratio. The aspect ratios can range from about 1:1 to about
10:1.
[0091] As shown in FIG. 5, the protrusions 32 may have a width, W,
that varies from one end 60 to the opposing end 60 when the
protrusions are viewed in plan view. The width W may vary with the
widest portion of the protrusions in the middle of the protrusions,
and the width of the protrusions decreasing at the ends 60 of the
protrusions. In other cases, the protrusions 32 could be wider at
one or both ends 60 than in the middle of the protrusions. If the
width of the protrusions 32 varies along the length of the
protrusions, the portion of the protrusion where the width is the
greatest is used in determining the aspect ratio of the
protrusions.
[0092] When the protrusions 32 have a length L that is greater than
their width W, the length of the protrusions may be oriented in any
suitable direction relative to the nonwoven material 30. For
example, the length of the protrusions 32 (that is, the
longitudinal axis, LA, of the protrusions) may be oriented in the
machine direction, the cross-machine direction, or any desired
orientation between the machine direction and the cross-machine
direction. The protrusions 32 also have a transverse axis TA
generally orthogonal to the longitudinal axis LA in the MD-CD
plane. In the embodiment shown in FIGS. 5 and 6, the longitudinal
axis LA is parallel to the MD. In some embodiments, all the spaced
apart protrusions 32 may have generally parallel longitudinal axes
LA.
[0093] The protrusions 32 may have any suitable shape when viewed
from the side. Suitable shapes include those in which there is a
distal portion or "cap" with an enlarged dimension and a narrower
portion at the base when viewed from at least one side. The term
"cap" is analogous to the cap portion of a mushroom. (The cap does
not need to resemble that of any particular type of mushroom. In
addition, the protrusions 32 may, but need not, have a
mushroom-like stem portion.) In some cases, the protrusions 32 may
be referred to as having a bulbous shape when viewed from the end
60, such as in FIG. 11. The term "bulbous", as used herein, is
intended to refer to the configuration of the protrusions 32 as
having a cap 52 with an enlarged dimension and a narrower portion
at the base when viewed from at least one side (particularly when
viewing from one of the shorter ends 60) of the protrusion 32. The
term "bulbous" is not limited to protrusions that have a circular
or round plan view configuration that is joined to a columnar
portion. The bulbous shape, in the embodiment shown (where the
longitudinal axis LA of the deformations 32 is oriented in the
machine direction), may be most apparent if a section is taken
along the transverse axis TA of the deformation (that is, in the
cross-machine direction). The bulbous shape may be less apparent if
the deformation is viewed along the length (or longitudinal axis
LA) of the deformation such as in FIG. 8.
[0094] The protrusions 32 may comprise fibers 38 that at least
substantially surround the sides of the protrusions. This means
that there are multiple fibers that extend (e.g., in the
Z-direction) from the base 50 of the protrusions 32 to the distal
end 54 of the protrusions, and contribute to form a portion of the
sides 56 and cap 52 of a protrusion. The phrase "substantially
surround" does not require that each individual fiber be wrapped in
the X-Y plane substantially or completely around the sides of the
protrusions. If the fibers 38 are located completely around the
sides of the protrusions, this would mean that the fibers are
located 360.degree. around the protrusions. The protrusions 32 may
be free of large openings at their ends 60, such as those openings
18 at the leading end and trailing end of the tufts shown in FIG.
1. The protrusions 32 also differ from embossed structures such as
shown in FIG. 4. Embossed structures typically do not have distal
portions that are spaced perpendicularly away (that is, in the
Z-direction) from their base that are wider than portions that are
adjacent to their base, as in the case of the cap 52 on the present
protrusions 32.
[0095] The protrusions 32 may have certain additional
characteristics. As shown in FIGS. 11 and 12, the protrusions 32
may be substantially hollow. As used herein, the term
"substantially hollow" refers to structures which the protrusions
32 are substantially free of fibers in interior of protrusions. The
term "substantially hollow", does not, however, require that the
interior of the protrusions must be completely free of fibers.
Thus, there can be some fibers inside the protrusions.
"Substantially hollow" protrusions are distinguishable from filled
three-dimensional structures, such as those made by laying down
fibers, such as by airlaying or carding fibers onto a forming
structure with recesses therein.
[0096] The side walls 56 of the protrusions 32 can have any
suitable configuration. The configuration of the side walls 56,
when viewed from the end of the protrusion such as in FIG. 11, can
be linear or curvilinear, or the side walls can be formed by a
combination of linear and curvilinear portions. The curvilinear
portions can be concave, convex, or combinations of both. For
example, the side walls 56 in the embodiment show in FIG. 11,
comprise portions that are curvilinear concave inwardly near the
base of the protrusions and convex outwardly near the cap of the
protrusions. The sidewalls 56 and the area around the base opening
44 of the protrusions may, under 20.times. magnification, 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 nonwoven in the unformed first region 40.
The protrusions 32 may also have thinned fibers in the sidewalls
56. The fiber thinning, if present, will be apparent in the form of
necked regions in the fibers 38 as seen in scanning electron
microscope (SEM) images taken at 200.times. magnification. Thus,
the fibers may have a first cross-sectional area when they are in
the undeformed nonwoven precursor web, and a second cross-sectional
area in the side walls 56 of the protrusions 32 of the deformed
nonwoven web, wherein the first cross-sectional area is greater
than the second cross-sectional area. The side walls 56 may also
comprise some broken fibers as well.
[0097] In some embodiments, the distal end 54 of the protrusions 32
may be comprised of original basis weight, non-thinned, and
non-broken fibers. If the base opening 44 faces upward, the distal
end 54 will be at the bottom of the depression that is formed by
the protrusion. The distal end 54 will be free from apertures
formed completely through the distal end. Thus, the nonwoven
materials may be nonapertured. The term "apertures", as used
herein, refers to holes formed in the nonwovens after the formation
of the nonwovens, and does not include the pores typically present
in nonwovens. The term "apertures" also does not refer to irregular
breaks (or interruptions) in the nonwoven material(s) such as shown
in FIGS. 15D-15F and FIG. 20 resulting from localized tearing of
the material(s) during the process of forming deformations therein,
which breaks may be due to variability in the precursor
material(s). The distal end 54 may have relatively greater fiber
concentration or density in comparison to the remaining portions of
the structure that forms the protrusions. As described in greater
detail below, however, if the nonwoven web is comprised of more
than one layer, the concentration of fibers in the different
portions of the protrusions may vary between the different
layers.
[0098] The protrusions 32 may be of any suitable size. The size of
the protrusions 32 can be described in terms of protrusion length,
width, caliper, height, depth, cap size, and opening size. (Unless
otherwise stated, the length L and width W of the protrusions are
the exterior length and width of the cap 52 of the protrusions.)
The dimensions of the protrusions and openings can be measured
before and after compression (under either a pressure of 7 kPa or
35 KPa, whichever is specified) in accordance with the Accelerated
Compression Method described in the Test Methods section. The
protrusions have a caliper that is measured between the same points
as the height H, but under a 2 KPa load, in accordance with the
Accelerated Compression Method. All dimensions of the protrusions
and openings other than caliper (that is, length, width, height,
depth, cap size, and opening size) are measured without pressure
applied at the time of making the measurement using a microscope at
20.times. magnification.
[0099] In some embodiments, the length of the cap 52 may be in a
range from about 1.5 mm to about 10 mm. In some embodiments, the
width of the cap (measured where the width is the greatest) may be
in a range from about 1.5 mm to about 5 mm. The cap portion of the
protrusions may have a plan view surface area of at least about 3
mm.sup.2. In some embodiments, the protrusions may have a
pre-compression height H that is in a range from about 1 mm to
about 10 mm, alternatively from about 1 mm to about 6 mm. In some
embodiments, the protrusions may have a post-compression height H
that is in a range from about 0.5 mm to about 6 mm, alternatively
from about 0.5 mm to about 1.5 mm. In some embodiments, the
protrusions may have a depth D, in an uncompressed state that is in
a range from about 0.5 mm to about 9 mm, alternatively from about
0.5 mm to about 5 mm. In some embodiments, the protrusions may have
a depth D, after compression that is in a range from about 0.25 mm
to about 5 mm, alternatively from about 0.25 mm to about 1 mm.
[0100] The nonwoven material 30 can comprise a composite of two or
more nonwoven materials that are joined together. In such a case,
the fibers and properties of the first layer will be designated
accordingly (e.g., the first layer is comprised of a first
plurality of fibers), and the fibers and properties of the second
and subsequent layers will be designated accordingly (e.g., the
second layer is comprised of a second plurality of fibers). In a
two or more layer structure, there are a number of possible
configurations the layers may take following the formation of the
deformations therein. These will often depend on the extensibility
of the nonwoven materials used for the layers. It is desirable that
at least one of the layers have deformations which form protrusions
32 as described herein in which, along at least one cross-section,
the width of the cap 52 of the protrusions is greater than the
width of the base opening 44 of the deformations. For example, in a
two layer structure where one of the layers will serve as the
topsheet of an absorbent article and the other layer will serve as
an underlying layer (such as an acquisition layer), the layer that
has protrusions therein may comprise the topsheet layer. The layer
that most typically has a bulbous shape will be the one which is in
contact with the male forming member during the process of
deforming the web. FIG. 15A-FIG. 15E show different alternative
embodiments of three-dimensional protrusions 32 in multiple layer
materials.
[0101] In certain embodiments, such as shown in FIGS. 11, 12, and
15A, similar-shaped looped fibers may be formed in each layer of
multiple layer nonwoven materials, including in the layer 30A that
is spaced furthest from the discrete male forming elements during
the process of forming the protrusions therein, and in the layer
30B that is closest to the male forming elements during the
process. One layer such as 30B fits within the other layer, such as
30A. These layers may be referred to as a "nested" structure.
Formation of a nested structure may require the use of two (or
more) highly extensible nonwoven precursor webs. In the case of two
layer materials, nested structures may form two complete loops, or
(as shown in some of the following drawing figures) two incomplete
loops of fibers.
[0102] As shown in FIG. 15A, a three-dimensional protrusion 32
comprises protrusions 32A formed in the first layer 30A and
protrusions 32B formed in the second layer 30B. In one embodiment,
the first layer 30A may be incorporated into an absorbent article
as an acquisition layer, and the second layer 30B may be a
topsheet, and the protrusions formed by the two layers may fit
together (that is, are nested). In this embodiment, the protrusions
32A and 32B formed by the first and second layers 30A and 30B fit
closely together. The three-dimensional protrusion 32A comprises a
plurality of fibers 38A and the three-dimensional protrusion 32B
comprises a plurality of fibers 38B. The three-dimensional
protrusion 32B is nested into the three-dimensional protrusion 32A.
In the embodiment shown, the fibers 38A in the first layer 30A are
shorter in length than the fibers 38B in the second layer 30B. In
other embodiments, the relative length of fibers in the layers may
be the same, or in the opposite relationship wherein the fibers in
the first layer are longer than those in the second layer. In
addition, in this embodiment, and any of the other embodiments
described herein, the nonwoven layers can be inverted when
incorporated into an absorbent article, or other article, so that
the protrusions 32 face upward (or outward). In such a case, the
material suitable for the topsheet will be used in layer 30A, and
material suitable for the underlying layer will be used in layer
30B.
[0103] FIG. 15B shows that the nonwoven layers need not be in a
contacting relationship within the entirety of the protrusion 32.
Thus, the protrusions 32A and 32B formed by the first and second
layers 30A and 30B may have different heights and/or widths. The
two materials may have substantially the same shape in the
protrusion 32 as shown in FIG. 15B (where one of the materials has
the same the curvature as the other). In other embodiments,
however, the layers may have different shapes. It should be
understood that FIG. 15B shows only one possible arrangement of
layers, and that many other variations are possible, but that as in
the case of all the figures, it is not possible to provide a
drawing of every possible variation.
[0104] As shown in FIG. 15C, one of the layers, such as first layer
30A (e.g., an acquisition layer) may be ruptured in the area of the
three-dimensional protrusion 32. As shown in FIG. 15C, the
protrusions 32 are only formed in the second layer 30B (e.g., the
topsheet) and extend through openings in the first layer 30A. That
is, the three-dimensional protrusion 32B in the second layer 30B
interpenetrates the ruptured first layer 30A. Such a structure may
place the topsheet in direct contact an underlying distribution
layer or absorbent core, which may lead to improved dryness. In
such an embodiment, the layers are not considered to be "nested" in
the area of the protrusion. (In the other embodiments shown in
FIGS. 15D-15F, the layers would still be considered to be
"nested".) Such a structure may be formed if the material of the
second layer 30B is much more extensible than the material of the
first layer 30A. In such a case, the openings can be formed by
locally rupturing first precursor web by the process described in
detail below. The ruptured layer may have any suitable
configuration in the area of the protrusion 32. Rupture may involve
a simple splitting open of first precursor web, such that the
opening in the first layer 30A remains a simple two-dimensional
aperture. However, for some materials, portions of the first layer
30A can be deflected or urged out-of-plane (i.e., out of the plane
of the first layer 30A) to form flaps 70. The form and structure of
any flaps is highly dependent upon the material properties of the
first layer 30A. Flaps can have the general structure shown in FIG.
15C. In other embodiments, the flaps 70 can have a more
volcano-like structure, as if the protrusion 32B is erupting from
the flaps.
[0105] Alternatively, as shown in FIGS. 15D-15F, one or both of the
first layer 30A and the second layer 30B may be interrupted (or
have a break therein) in the area of the three-dimensional
protrusion 32. FIGS. 15D and 15E show that the three-dimensional
protrusion 32A of the first layer 30A may have an interruption 72A
therein. The three-dimensional protrusion 32B of the
non-interrupted second layer 30B may coincide with and fit together
with the three-dimensional protrusion 32A of the interrupted first
layer 30A. Alternatively, FIG. 15F shows an embodiment in which
both the first and second layers 30A and 30B have interruptions, or
breaks, therein (72A and 72B, respectively). In this case, the
interruptions in the layers 30A and 30B are in different locations
in the protrusion 32. FIGS. 15D-15F show unintentional random or
inconsistent breaks in the materials typically formed by random
fiber breakage, which are generally misaligned and can be in the
first or second layer, but are not typically aligned and completely
through both layers. Thus, there typically will not be an aperture
formed completely through all of the layers at the distal end 54 of
the protrusions 32.
[0106] For dual layer and other multiple layer structures, the
basis weight distribution (concentration of fibers) within the
deformed material 30 can be different between the layers. As shown
in FIG. 16, the nonwoven layer in contact with the male forming
element (e.g., 30B) may have a large portion at the distal end 54B
of the protrusion 32B with a similar basis weight to the original
nonwoven. As shown in FIG. 17, the basis weight in the sidewalls
56B of the protrusion 32B and near the base opening 44 may be lower
than the basis weight of the original material and the distal end
54 of the protrusion 32B. As shown in FIG. 18, the nonwoven layer
in contact with the female forming element (e.g., 30A) may,
however, have significantly less basis weight in the cap 52A of the
protrusion 32A than in the original nonwoven. As shown in FIG. 19,
the sidewalls 56A of the protrusion 32A may have less basis weight
than the original nonwoven, but more basis weight than the distal
end 54A of the protrusion 32A.
[0107] The base openings 44 can be of any suitable shape and size.
The shape of the base opening 44 will typically be similar to, or
the same as, the plan view shape of the corresponding protrusions
32. The base opening 44 may have a width that is greater than about
any of the following dimensions before (and after compression): 0.5
mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, or any 0.1 mm increment above 1
mm. The width of the base opening 44 may be in a range that is from
any of the foregoing amounts up to about 4 mm, or more. The base
openings 44 may have a length that ranges from about 1.5 mm or less
to about 10 mm, or more. The base openings 44 may have an aspect
ratio that ranges from about 1:1 to 20:1, alternatively from about
1:1 to 10:1. Measurements of the dimensions of the base opening can
be made on a photomicrograph. When the size of the width of the
base opening 44 is specified herein, it will be appreciated that if
the openings are not of uniform width in a particular direction,
the width, W.sub.O, is measured at the widest portion as shown in
FIG. 6. The nonwoven materials of the present disclosure and the
method of making the same may create deformations with a wider
opening than certain prior structures which have a narrow base.
This allows the base openings 44 to be more visible to the naked
eye. The width of the base opening 44 is of interest because, being
the narrowest portion of the opening, it will be most restrictive
of the size of the opening. The deformations retain their wide base
openings 44 after compression perpendicular to the plane of the
first region 40.
[0108] The deformations may compress under load. In some cases, it
may be desirable that the load is low enough so that, if the
nonwoven is worn against a wearer's body, with the deformations in
contact with the wearer's body, the deformations will be soft and
will not imprint the skin. This applies in cases where either the
protrusions 32 or the base openings 44 are oriented so that they
are in contact with the wearer's body. For example, it may be
desirable for the deformations to compress under pressures of 2 kPa
or less. In other cases, it will not matter if the deformations
imprint the wearer's skin. It may be desirable for at least one of
the protrusions 32 in the nonwoven material 30 to collapse or
buckle in the controlled manner described below under the 7 KPa
load when tested in accordance with the Accelerated Compression
Method in the Test Methods section below. Alternatively, at least
some, or in other cases, a majority of the protrusions 32 may
collapse in the controlled manner described herein. Alternatively,
substantially all of the protrusions 32 may collapse in the
controlled manner described herein. The ability of the protrusions
32 to collapse may also be measured under a load of 35 kPa. The 7
kPa and 35 kPa loads simulate manufacturing and compression
packaging conditions. Wear conditions can range from no or limited
pressure (if the wearer is not sitting on the absorbent article) up
to 2 kPa, 7 kPa, or more.
[0109] The protrusions 32 may collapse in a controlled manner after
compression to maintain the wide opening 44 at the base. FIG. 13
shows the first surface 34 of a nonwoven material 30 according to
the present disclosure after it has been subjected to compression.
FIG. 14 is a side view of a single downwardly-oriented protrusion
32 after it has been subjected to compression. As shown in FIG. 13,
when the protrusions 32 have been compressed, there appears to be a
higher concentration of fibers in the form of a ring of increased
opacity 80 around the base opening 44. When a compressive force is
applied to the nonwoven materials, the side walls 56 of the
protrusions 32 may collapse in a more desirable/controlled manner
such that the side walls 56 become concave and fold into regions of
overlapping layers (such as into an s-shape/accordion-shape). The
ring of increased opacity 80 represents folded layers of material.
In other words, the protrusions 32 may have a degree of dimensional
stability in the X-Y plane when a Z-direction force is applied to
the protrusions. It is not necessary that the collapsed
configuration of the protrusions 32 be symmetrical, only that the
collapsed configuration prevent the protrusions 32 from flopping
over or pushing back into the original plane of the nonwoven, and
significantly reducing the size of the base opening. For example,
as shown in FIG. 14, the left side of the protrusion 32 can form a
z-folded structure, and the right side of the protrusion does not,
but still appears, when viewed from above, to have higher opacity
due to a degree of overlapping of the material in the folded
portion. Without wishing to be bound to any particular theory, it
is believed that the wide base opening 44 and large cap 52 (greater
than the width of the base opening 44), combined with the lack of a
pivot point, causes the protrusions 32 to collapse in a controlled
manner (prevents the protrusion 32 from flopping over). Thus, the
protrusions 32 are free of a hinge structure that would otherwise
permit them to fold to the side when compressed. The large cap 52
also prevents the protrusion 32 from pushing back into the original
plane of the nonwoven.
[0110] The deformations can be disposed in any suitable density
across the surface of the nonwoven material 30. The deformations
may, for example, be present in a density of: from about 5 to about
100 deformations; alternatively from about 10 to about 50
deformations; alternatively from about 20 to about 40 deformations,
in an area of 10 cm.sup.2.
[0111] The deformations can be disposed in any suitable arrangement
across the plane of the nonwoven material. Suitable arrangements
include, but are not limited to: staggered arrangements, and zones.
In some cases, the nonwoven material 30 may comprise both
deformations and other features known in the art such as
embossments and apertures. The deformations 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 deformations and then subsequently passing the nonwoven
web 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 deformations and other
features to be combined so they are disposed in different locations
on the nonwoven material or they can cause at least some of the
deformations and at least some of the other features to be disposed
in the same location on the nonwoven material.
[0112] The nonwoven webs 30 described herein can comprise any
suitable component or components of an absorbent article. For
example, the nonwoven webs can comprise the topsheet of an
absorbent article, or as shown in FIG. 25, if the nonwoven web 30
comprises more than one layer, the nonwoven web can comprise a
combined topsheet 84 and acquisition layer 86 of an absorbent
article, such as diaper 82. The diaper 82 shown in FIGS. 25-27 also
comprises an absorbent core 88, a backsheet 94, and a distribution
layer 96. The nonwoven materials of the present disclosure may also
form an outer cover of an absorbent article, such as backsheet 94.
The nonwoven webs 30 can be placed in an absorbent article with the
deformations 31 in any suitable orientation. For example, the
protrusions 32 can be oriented up or down. In other words, the
protrusions 32 may be oriented toward the absorbent core 88 as
shown in FIG. 26. Thus, for example, it may be desirable for the
protrusions 32 to point inward toward the absorbent core 88 in a
diaper (that is, away from the body-facing side and toward the
garment-facing side), or other absorbent article. Alternatively,
the protrusions 32 may be oriented so that they extend away from
the absorbent core of the absorbent article as shown in FIG. 27. In
still other embodiments, the nonwoven webs 30 can be made so that
they have some protrusions 32 that are oriented upward, and some
that are oriented downward. Without wishing to be bound to any
particular theory, it is believed that such a structure may be
useful in that the protrusions that are oriented upward can be more
effective for cleaning the body from exudates, while the
protrusions that are oriented downward can be more effective for
absorption of exudates into the absorbent core. Therefore, without
being bound to theory, a combination of these two protrusion
orientations will offer advantage that the same product can fulfill
the two functions.
[0113] A two or more layer nonwoven structure may provide fluid
handling benefits. If the layers are integrated together, and the
protrusions 32 are oriented toward the absorbent core, they may
also provide a dryness benefit. It may be desirable, on the other
hand, for the protrusions 32 to point outward, away from the
absorbent core in a pad for a wet or dry mop to provide a cleaning
benefit. In some embodiments, when the nonwoven web 30 is
incorporated into an absorbent article, the underlying layers can
be either substantially, or completely free, of tow fibers.
Suitable underlying layers that are free of tow fibers may, for
example, comprise a layer or patch of cross-linked cellulose
fibers. In some cases, it may be desirable that the nonwoven
material 30 is not entangled with (that is, is free from
entanglement with) another web.
[0114] The layers of the nonwoven structure (e.g., a topsheet
and/or acquisition layer) may be colored. Color may be imparted to
the webs by color pigmentation. The term "color pigmentation"
encompasses any pigments suitable for imparting a non-white color
to a web. 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. 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 webs may be of from 0.3%-2.5%. Alternatively, color
may be imparted to the webs 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 fiber or filament
formation.
[0115] Precursor Materials.
[0116] The nonwoven materials of the present disclosure can be made
of any suitable nonwoven materials ("precursor materials"). The
nonwoven webs can be made from a single layer, or multiple layers
(e.g., two or more layers). If multiple layers are used, they can
be comprised of the same type of nonwoven material, or different
types of nonwoven materials. In some cases, the precursor materials
may be free of any film layers.
[0117] The fibers of the nonwoven precursor material(s) can be made
of any suitable materials including, but not limited to natural
materials, synthetic materials, and combinations thereof. Suitable
natural materials include, but are not limited to cellulose, cotton
linters, bagasse, wool fibers, silk fibers, etc. Cellulose fibers
can be provided in any suitable form, including but not limited to
individual fibers, fluff pulp, drylap, liner board, etc. Suitable
synthetic materials include, but are not limited to nylon, rayon
and polymeric materials. Suitable polymeric materials include, but
are not limited to: polyethylene (PE), polyester, polyethylene
terephthalate (PET), polypropylene (PP), and co-polyester. In some
embodiments, however, the nonwoven precursor materials can be
either substantially, or completely free, of one or more of these
materials. For example, in some embodiments, the precursor
materials may be substantially free of cellulose, and/or exclude
paper materials. In some embodiments, one or more precursor
materials can comprise up to 100% thermoplastic fibers. The fibers
in some cases may, therefore, be substantially non-absorbent. In
some embodiments, the nonwoven precursor materials can be either
substantially, or completely free, of tow fibers.
[0118] The precursor nonwoven materials can comprise any suitable
types of fibers. Suitable types of fibers include, but are not
limited to: monocomponent, bicomponent, and/or biconstituent,
non-round (e.g., shaped fibers (including but not limited to fibers
having a trilobal cross-section) and capillary channel fibers). The
fibers can be of any suitable size. The fibers may, for example,
have major cross-sectional dimensions (e.g., diameter for round
fibers) ranging from 0.1-500 microns. Fiber size can also be
expressed in denier, which is a unit of weight per length of fiber.
The constituent fibers may, for example, range from about 0.1
denier to about 100 denier. The constituent fibers of the nonwoven
precursor web(s) may also be a mixture of different fiber types,
differing in such features as chemistry (e.g., PE and PP),
components (mono- and bi-), shape (i.e. capillary channel and
round) and the like.
[0119] The nonwoven precursor webs can be formed from many
processes, such as, for example, air laying processes, wetlaid
processes, meltblowing processes, spunbonding processes, and
carding processes. The fibers in the webs can then be bonded via
spunlacing processes, hydroentangling, calendar bonding,
through-air bonding and resin bonding. Some of such individual
nonwoven webs may have bond sites where the fibers are bonded
together.
[0120] The basis weight of nonwoven materials is usually expressed
in grams per square meter (gsm). The basis weight of a single layer
nonwoven material can range from about 8 gsm to about 100 gsm,
depending on the ultimate use of the material 30. For example, the
topsheet of a topsheet/acquisition layer laminate or composite may
have a basis weight from about 8 to about 40 gsm or from about 8 to
about 30 gsm, or from about 8 to about 20 gsm. The acquisition
layer may have a basis weight from about 10 to about 120 gsm or
from about 10 to about 100 gsm, or from about 10 to about 80 gsm.
The basis weight of a multi-layer material is the combined basis
weight of the constituent layers and any other added components.
The basis weight of multi-layer materials of interest herein can
range from about 20 gsm to about 150 gsm, depending on the ultimate
use of the material 30. The nonwoven precursor webs may have a
density that is between about 0.01 and about 0.4 g/cm.sup.3
measured at 0.3 psi (2 KPa).
[0121] The precursor nonwoven webs may have certain desired
characteristics. The precursor nonwoven web(s) each have a first
surface, a second surface, and a thickness. The first and second
surfaces of the precursor nonwoven web(s) may be generally planar.
It is typically desirable for the precursor nonwoven web materials
to have extensibility to enable the fibers to stretch and/or
rearrange into the form of the protrusions. If the nonwoven webs
are comprised of two or more layers, it is desirable for all of the
layers to be as extensible as possible. Extensibility is desirable
in order to maintain at least some non-broken fibers in the
sidewalls around the perimeter of the protrusions. It may be
desirable for individual precursor webs, or at least one of the
nonwovens within a multi-layer structure, to be capable of
undergoing an elongation of greater than or equal to about one of
the following amounts: 100% (that is double its unstretched
length), 110%, 120%, or 130% up to about 200%, or more, at or
before reaching the peak tensile force. It is also desirable for
the precursor nonwoven webs to be capable of undergoing plastic
deformation to ensure that the structure of the deformations is
"set" in place so that the nonwoven web will not tend to recover or
return to its prior configuration.
[0122] Materials that are not extensible enough (e.g., inextensible
PP) may form broken fibers around much of the perimeter of the
deformation, and create more of a "hanging chad" 90 (i.e., the cap
52 of the protrusions 32 may be at least partially broken from and
separated from the rest of the protrusion (as shown in FIG. 20).
The area on the sides of the protrusion where the fibers are broken
is designated with reference number 92. Materials such as that
shown in FIG. 20 will not be suitable for a single layer structure,
and, if used, will typically be part of a composite multi-layer
structure in which another layer has protrusions 32 as described
herein.
[0123] When the fibers of a nonwoven web are not very extensible,
it may be desirable for the nonwoven to be underbonded as opposed
to optimally bonded. A thermally bonded nonwoven web's tensile
properties can be modified by changing the bonding temperature. A
web can be optimally or ideally bonded, underbonded or overbonded.
Optimally or ideally bonded webs are characterized by the highest
peak tensile strength and elongation at tensile peak with a rapid
decay in strength after tensile peak. Under strain, bond sites fail
and a small amount of fibers pull out of the bond site. Thus, in an
optimally bonded nonwoven, the fibers 38 will stretch and break
around the bond sites 46 when the nonwoven web is strained beyond a
certain point. Often there is a small reduction in fiber diameter
in the area surrounding the thermal point bond sites. Underbonded
webs have a lower peak tensile strength and elongation at tensile
peak when compared to optimally bonded webs, with a slow decay in
strength after tensile peak. Under strain, some fibers will pull
out from the thermal point bond sites. Thus, in an underbonded
nonwoven, at least some of the fibers 38 can be separated easily
from the bond sites 46 to allow the fibers 38 to pull out of the
bond sites and rearrange when the material is strained. Overbonded
webs also have a lowered peak tensile strength and elongation at
tensile peak when compared to optimally bonded webs, with a rapid
decay in strength after tensile peak. The bond sites look like
films and result in complete bond site failure under strain.
[0124] When the nonwoven web comprises two or more layers, the
different layers can have the same properties, or any suitable
differences in properties relative to each other. In one
embodiment, the nonwoven web 30 can comprise a two layer structure
that is used in an absorbent article. For convenience, the
precursor webs and the material into which they are formed are
referred to herein by the same reference numbers. One of the
layers, a second layer 30B, can serve as the topsheet of the
absorbent article, and the first layer 30A can be an underlying
layer (or sub-layer) and serve as an acquisition layer. The
acquisition layer 30A receives liquids that pass through the
topsheet and distributes them to underlying absorbent layers. In
such a case, the topsheet 30B may be less hydrophilic than
sub-layer(s) 30A, which may lead to better dewatering of the
topsheet. In other embodiments, the topsheet can be more
hydrophilic than the sub-layer(s). In some cases, the pore size of
the acquisition layer may be reduced, for example via using fibers
with smaller denier or via increasing the density of the
acquisition layer material, to better dewater the pores of the
topsheet.
[0125] The second nonwoven layer 30B that may serve as the topsheet
can have any suitable properties. Properties of interest for the
second nonwoven layer, when it serves as a topsheet, in addition to
sufficient extensibility and plastic deformation may include
uniformity and opacity. As used herein, "uniformity" refers to the
macroscopic variability in basis weight of a nonwoven web. As used,
herein, "opacity" of nonwoven webs is a measure of the
impenetrability of visual light, and is used as visual
determination of the relative fiber density on a macroscopic scale.
As used herein, "opacity" of the different regions of a single
nonwoven deformation is determined by taking a photomicrograph at
20.times. magnification of the portion of the nonwoven containing
the deformation against a black background. Darker areas indicate
relatively lower opacity (as well as lower basis weight and lower
density) than white areas.
[0126] Several examples of nonwoven materials suitable for use as
the second nonwoven layer 30B include, but are not limited to:
spunbonded nonwovens; carded nonwovens; and other nonwovens with
high extensibility (strain at peak tensile strength in the ranges
set forth above) and sufficient plastic deformation to ensure the
structure is set and does not have significant recovery. One
suitable nonwoven material as a topsheet for a topsheet/acquisition
layer composite structure may be an extensible spunbonded nonwoven
comprising polypropylene and polyethylene. The fibers can comprise
a blend of polypropylene and polyethylene, or they can be
bi-component fibers, such as a sheath-core fiber with polyethylene
on the sheath and polypropylene in the core of the fiber. Another
suitable material is a bi-component fiber spunbonded nonwoven
comprising fibers with a polyethylene sheath and a
polyethylene/polypropylene blend core.
[0127] The first nonwoven layer 30A that may, for example, serve as
the acquisition layer can have any suitable properties. Properties
of interest for the first nonwoven layer, in addition to sufficient
extensibility and plastic deformation may include uniformity and
opacity. If the first nonwoven layer 30A serves as an acquisition
layer, its fluid handling properties must also be appropriate for
this purpose. Such properties may include: permeability, porosity,
capillary pressure, caliper, as well as mechanical properties such
as sufficient resistance to compression and resiliency to maintain
void volume. Suitable nonwoven materials for the first nonwoven
layer when it serves as an acquisition layer include, but are not
limited to: spunbonded nonwovens; through-air bonded ("TAB") carded
nonwoven materials; spunlace nonwovens; hydroentangled nonwovens;
and, resin bonded carded nonwoven materials. Of course, the
composite structure may be inverted and incorporated into an
article in which the first layer 30A serves as the topsheet and the
second layer 30B serves as an acquisition layer. In such cases, the
properties and exemplary methods of the first and second layers
described herein may be interchanged.
[0128] The layers of a two or more layered nonwoven web structure
can be combined together in any suitable manner. In some cases, the
layers can be unbonded to each other and held together autogenously
(that is, by virtue of the formation of deformations therein). For
example, both precursor webs 30A and 30B contribute fibers to
deformations in a "nested" relationship that "locks" the two
precursor webs together, forming a multi-layer web without the use
or need for adhesives or thermal bonding between the layers. In
other embodiments, the layers can be joined together by other
mechanisms. If desired an adhesive between the layers, ultrasonic
bonding, chemical bonding, resin or powder bonding, thermal
bonding, or bonding at discrete sites using a combination of heat
and pressure can be selectively utilized to bond certain regions or
all of the precursor webs. If adhesives are used, they can be
applied in any suitable manner or pattern including, but not
limited to: slots, spirals, spray, and curtain coating. Adhesives
can be applied in any suitable amount or basis weight including,
but not limited to between about 0.5 and about 30 gsm,
alternatively between about 2 and about 5 gsm. In addition, the
multiple layers may be bonded during processing, for example, by
carding one layer of nonwoven onto a spunbond nonwoven and thermal
point bonding the combined layers. In some cases, certain types of
bonding between layers may be excluded. For example, the layers of
the present structure may be non-hydroentangled together.
[0129] When the precursor nonwoven web comprises two or more
layers, it may be desirable for at least one of the layers to be
continuous, such as in the form of a web that is unwound from a
roll. In some embodiments, each of the layers can be continuous. In
alternative embodiments, such as shown in FIG. 24, one or more of
the layers can be continuous, and one or more of the layers can
have a discrete length. The layers may also have different widths.
For example, in making a combined topsheet and acquisition layer
for an absorbent article, the nonwoven layer that will serve as the
topsheet may be a continuous web, and the nonwoven layer that will
serve as the acquisition layer may be fed into the manufacturing
line in the form of discrete length (for example, rectangular, or
other shaped) pieces that are placed on top of the continuous web.
Such an acquisition layer may, for example, have a lesser width
than the topsheet layer. The layers may be combined together as
described above.
Methods of Making the Nonwoven Materials
[0130] The nonwoven materials are made by a method comprising the
steps of: a) providing at least one precursor nonwoven web; b)
providing an apparatus comprising a pair of forming members
comprising a first forming member and a second forming member; and
c) placing the precursor nonwoven web(s) between the forming
members and mechanically deforming the precursor nonwoven web(s)
with the forming members. The forming members have a machine
direction (MD) orientation and a cross-machine direction (CD)
orientation.
[0131] The first and second forming members can be plates, rolls,
belts, or any other suitable types of forming members. In some
embodiments, it may be desirable to modify the apparatus for
incrementally stretching a web described in U.S. Pat. No.
8,021,591, Curro, et al. entitled "Method and Apparatus for
Incrementally Stretching a Web" by providing the activation members
described therein with the forming elements of the type described
herein. In the embodiment of the apparatus 100 shown in FIG. 21,
the first and second forming members 102 and 104 are in the form of
non-deformable, meshing, counter-rotating rolls that form a nip 106
therebetween. The precursor web(s) is/are fed into the nip 106
between the rolls 102 and 104. Although the space between the rolls
102 and 104 is described herein as a nip, as discussed in greater
detail below, in some cases, it may be desirable to avoid
compressing the precursor web(s) to the extent possible.
[0132] First Forming Member.
[0133] The first forming member 102 has a surface comprising a
plurality of first forming elements which comprise discrete, spaced
apart male forming elements 112. The male forming elements are
spaced apart in the machine direction and in the cross-machine
direction. The term "discrete" does not include continuous or
non-discrete forming elements such as the ridges and grooves on
corrugated rolls (or "ring rolls") which have ridges that may be
spaced apart in one, but not both, of the machine direction and in
the cross-machine direction.
[0134] As shown in FIG. 22, the male forming elements 112 have a
base 116 that is joined to (in this case is integral with) the
first forming member 102, a top 118 that is spaced away from the
base, and sides 120 that extend between the base and the top of the
male forming elements. The male elements 112 also have a plan view
periphery, and a height H.sub.1 (the latter being measured from the
base 116 to the top 118). The discrete elements on the male roll
have a top 118 with a relatively large surface area (e.g., from
about 1 mm to about 10 mm in width, and from about 1 mm to about 20
mm in length) for creating a wide deformation. The male elements
112 may have any suitable configuration. In one embodiment, the
male elements 112 have a flat top 118, vertical sidewalls 120, a
radiused edge forming the transition 122 between the flat top 118
and vertical sidewalls 120 (by vertical side walls, it is meant
that the side walls 120 have zero degree side wall angles relative
to the perpendicular from the base of the side wall). The top 118
of the male elements 112 may have any suitable plan view
configuration, including but not limited to: a rounded diamond
configuration as shown in FIGS. 21 and 22, and an American
football-like shape, triangle, clover, teardrop, oval,
elliptical.
[0135] Numerous other embodiments of the male forming elements 112
are possible. In other embodiments, the top 118 of the male forming
elements 112 can be rounded. In other embodiments, the side walls
120 can be tapered inwardly toward the center of the male forming
elements 112 so that the side walls form an angle greater than
zero. In other embodiments, the top 118 of the male elements 112
can be of different shapes from those shown in the drawings. In
other embodiments, the male forming elements 112 can be disposed in
other orientations on the first forming member 102 rather than
having their length oriented in the machine direction (including
CD-orientations, and orientations between the MD and CD).
[0136] Second Forming Member.
[0137] As shown in FIG. 21, the second forming member 104 has a
surface 124 having a plurality of cavities or recesses 114 therein.
The recesses 114 are aligned and configured to receive the male
forming elements 112 therein. Thus, the male forming elements 112
mate with the recesses 114 so that a single male forming element
112 fits within the periphery of a single recess 114, and at least
partially within the recess 114 in the z-direction. The recesses
114 have a plan view periphery 126 that is larger than the plan
view periphery of the male elements 112. As a result, the recess
114 on the female roll completely encompasses the discrete male
element 112 when the rolls 102 and 104 are intermeshed. The
recesses 114 have a depth D.sub.1 shown in FIG. 23. In some cases,
the depth D.sub.1 of the recesses may be greater than the height
H.sub.1 of the male forming elements 112.
[0138] The recesses 114 may have a similar plan view configuration
as the male elements 112, side walls 128, and an edge 130 around
the bottom 132 of the recesses where the side walls 128 meet the
bottom 132 of the recesses. The side walls 128 of the recesses 114
may be vertical. The edge 130 of the recesses may be sharp or
rounded.
[0139] As discussed above, the recesses 114 may be deeper than the
height H.sub.1 of the male elements 112 so the nonwoven material is
not nipped (or squeezed) between the male and female rolls 102 and
104 to the extent possible. However, it is understood that passing
the precursor web(s) between two rolls with a relatively small
space therebetween will likely apply some shear and compressive
forces to the web(s). The present method, however, differs from
some embossing processes in which the top of the male elements
compress the material to be embossed against the bottom of the
female elements, thereby increasing the density of the region in
which the material is compressed.
[0140] The depth of engagement (DOE) is a measure of the level of
intermeshing of the forming members. As shown in FIG. 23, the DOE
is measured from the top 118 of the male elements 112 to the
outermost surface 124 of the female forming member 114 (e.g., the
roll with recesses). The DOE should be sufficiently high, when
combined with extensible nonwoven materials, to create protrusions
32 having a distal portion or cap 52 with a maximum width that is
greater than the width of the base opening 44. The DOE may, for
example, range from at least about 1.5 mm, or less, to about 5 mm,
or more. In certain embodiments, the DOE may be between about 2.5
mm to about 5 mm, alternatively between about 3 mm and about 4 mm.
The formation of protrusions 32 having a distal portion with a
maximum width that is greater than the width of the base opening 44
is believed to differ from most embossing processes in which the
embossments typically take the configuration of the embossing
elements, which have a base opening that is wider than the
remainder of the embossments. As shown in FIG. 23, there is a
clearance, C, between the sides 120 of the male elements 112 and
the sides (or side walls) 128 of the recesses 114. The clearance,
C, between the male and female roll may be the same, or it may vary
slightly around the perimeter of the male element. Clearances can
range from about 0.005 inches (0.13 mm) to about 0.05 inches (1.3
mm). The clearances and the DOE's are related such that larger
clearances can permit higher DOE's to be used.
[0141] The precursor nonwoven web is placed between the forming
members 102 and 104. The precursor nonwoven web can be placed
between the forming members with either side of the precursor web
(first surface 34 or second surface 36) facing the first forming
member, male forming member 102. For convenience of description,
the second surface 36 of the precursor nonwoven web will be
described herein as being placed in contact with the first forming
member 102. (Of course, in other embodiments, the second surface 36
of the precursor nonwoven web can be placed in contact with the
second forming member 104.) The precursor material is mechanically
deformed with the forming members 102 and 104 when a force is
applied on the nonwoven web with the forming members 102 and 104.
The force can be applied in any suitable manner. If the forming
members 102 and 104 are in the form of plates, the force will be
applied when the plates are brought together. If the forming
members 102 and 104 are in the form of counter-rotating rolls (or
belts, or any combination of rolls and belts), the force will be
applied when the precursor nonwoven web passes through the nip
between the counter-rotating elements. The force applied by the
forming members impacts the precursor web and mechanically deforms
the precursor nonwoven web.
[0142] When deforming multiple webs that are laminated together
with an adhesive, it may be desirable to chill the forming members
in order to avoid glue sticking to and fouling the forming members.
The forming members can be chilled using processes know in the art.
One such process could be an industrial chiller that utilizes a
coolant, such as propylene glycol. In some cases, it may be
desirable to operate the process in a humid environment such that a
layer of condensate forms on the forming members.
[0143] The precursor nonwoven web forms nonwoven web comprising a
generally planar first region and a plurality of discrete integral
second regions that comprise deformations comprising protrusions
extending outward from the first surface 34 of the nonwoven web and
openings in the second surface of the nonwoven web. (Of course, if
the second surface 36 of the precursor nonwoven web is placed in
contact with the second forming member 104, the protrusions will
extend outward from the second surface of the nonwoven web and the
openings will be formed in the first surface of the nonwoven web.)
Without wishing to be bound by any particular theory, it is
believed that the extensibility of the precursor web (or at least
one of the layers of the same) when pushed by the male forming
elements 112 into the recesses 114 with depth of engagement DOE
being less than the depth D.sub.1 of the recesses, stretches a
portion of the nonwoven web to form a deformation comprising a
protrusion with the enlarged cap and wide base opening described
above. (This can be analogized to sticking one's finger into an
uninflated balloon to stretch and permanently deform the material
of the balloon.)
[0144] In cases in which the precursor nonwoven material 30
comprises more than one layer, and one of the layers is in the form
of discrete pieces of nonwoven material, as shown in FIG. 24, it
may be desirable for the deformations to be formed so that the base
openings are in the continuous layer (such as 30B) and the
protrusions 32 extend toward the discrete layer (such as 30A). Of
course, in other embodiments, the deformations in such a structure
can be in the opposite orientation. The deformations can be
distributed in any suitable manner over the surfaces of such
continuous and discrete layers. For example, the deformations can:
be distributed over the full length and/or width of the continuous
layer; be distributed in an area narrower than the width of the
continuous layer; or be limited to the area of the discrete
layer.
[0145] The method of making the nonwoven materials described herein
may exclude (or be distinguishable from) the following processes:
hydroforming (hydroentangling); hydromolding; use of air jets;
rigid-to-resilient (e.g., steel/rubber) embossing; and the use of a
patterned surface against a flat anvil surface. The method may also
exclude (or be distinguishable from) The Procter & Gamble
Company's processes for making Structural Elastic-Like Films
("SELF" processes). The forming members used herein differ from the
forming members used in SELFing processes to form corrugated
structures (and tufted structures) in that the SELF teeth typically
have a comparatively small diameter tip, and the ridges of the
mating ring roll only border the SELF teeth on the sides, and not
the front and back of the teeth.
Absorbent Articles
[0146] Three-dimensional nonwoven materials and the method of their
manufacture of the present disclosure have been discussed above.
The use of those three-dimensional nonwoven materials is now
explained in further detail in the context of example absorbent
articles.
General Description of an Absorbent Article
[0147] An example absorbent article in the form of a diaper 220 is
represented in FIGS. 28-30. FIG. 28 is a plan view of the example
diaper 220, in a flat, laid-out state, with portions of the
structure being cut-away to more clearly show the construction of
the diaper 220. The wearer-facing surface of the diaper 220 of FIG.
28 is facing the viewer. This diaper 220 is shown for illustration
purpose only as the three-dimensional nonwoven materials of the
present disclosure may be used as one or more components of an
absorbent article, such as the topsheet, the acquisition layer, the
topsheet and the acquisition layer individually, or the topsheet
and the acquisition layer as a laminate. In any event the
three-dimensional nonwoven materials of the present disclosure may
be liquid permeable.
[0148] The absorbent article 220 may comprise a liquid permeable
material or topsheet 224, a liquid impermeable material or
backsheet 225, an absorbent core 228 positioned at least partially
intermediate the topsheet 224 and the backsheet 225, and barrier
leg cuffs 234. The absorbent article may also comprise an ADS 250,
which in the example represented comprises a distribution layer 254
and an acquisition layer 252, which will be further discussed
below. The absorbent article 220 may also comprise elasticized
gasketing cuffs 232 comprising elastics 233 joined to a chassis of
the absorbent article, typically via the topsheet and/or backsheet,
and substantially planar with the chassis of the diaper.
[0149] FIGS. 28 and 31 also show typical taped diaper components
such as a fastening system comprising tabs 242 attached towards the
rear edge of the article and cooperating with a landing zone 244 on
the front of the absorbent article. The absorbent article may also
comprise other typical elements, which are not represented, such as
a rear elastic waist feature, a front elastic waist feature,
transverse barrier cuff(s), and/or a lotion application, for
example.
[0150] The absorbent article 220 comprises a front waist edge 210,
a rear waist edge 212 longitudinally opposing the front waist edge
210, a first side edge 203, and a second side edge 204 laterally
opposing the first side edge 203. The front waist edge 210 is the
edge of the article which is intended to be placed towards the
front of the user when worn, and the rear waist edge 212 is the
opposite edge. The absorbent article 220 may have a longitudinal
axis 280 extending from the lateral midpoint of the front waist
edge 210 to a lateral midpoint of the rear waist edge 212 of the
article and dividing the article in two substantially symmetrical
halves relative to the longitudinal axis 280, with the article
placed flat, laid-out and viewed from above as in FIG. 28. The
absorbent article 220 may also have a lateral axis 290 extending
from the longitudinal midpoint of the first side edge 203 to the
longitudinal midpoint of the second side edge 204. The length, L,
of the article may be measured along the longitudinal axis 280 from
the front waist edge 210 to the rear waist edge 212. The width, W,
of the absorbent article may be measured along the lateral axis 290
from the first side edge 203 to the second side edge 204. The
absorbent article may comprise a crotch point C defined herein as
the point placed on the longitudinal axis at a distance of two
fifth ( ) of L starting from the front edge 210 of the article 220.
The article may comprise a front waist region 205, a rear waist
region 206, and a crotch region 207. The front waist region 205,
the rear waist region 206, and the crotch region 207 may each
define 1/3 of the longitudinal length, L, of the absorbent article.
The topsheet 224, the backsheet 225, the absorbent core 228, and
the other article components may be assembled in a variety of
configurations, in particular by gluing or heat embossing, for
example.
[0151] The absorbent core 228 may comprise an absorbent material
comprising at least 80% by weight, at least 85% by weight, at least
90% by weight, at least 95% by weight, or at least 99% by weight of
superabsorbent polymers, and a core wrap enclosing the
superabsorbent polymers. The core wrap may typically comprise two
materials, substrates, or nonwoven materials 216 and 216' for the
top side and the bottom side of the core. These types of cores are
known as airfelt-free cores. The core may comprise one or more
channels, represented in FIG. 28 as the four channels 226, 226' and
227, 227'. The channels 226, 226', 227, and 227' are optional
features. Instead, the core may not have any channels or may have
any number of channels.
[0152] These and other components of the example absorbent articles
will now be discussed in more details.
Topsheet
[0153] In the present disclosure, the topsheet (the portion of the
absorbent article that contacts the wearer's skin and receives the
fluids) may be formed of a portion of, or all of, one or more of
the three-dimensional nonwoven materials described herein and/or
have one or more of the nonwoven materials positioned thereon
and/or joined thereto, so that the nonwoven material(s) contact(s)
the wearer's skin. Other portions of the topsheet (other than the
three-dimensional nonwoven materials) may also contact the wearer's
skin. The three-dimensional nonwoven materials may be positioned as
a strip or a patch on top of the typical topsheet 224.
Alternatively, the three-dimensional nonwoven material may only
form a central CD area of the topsheet. The central CD area may
extend the full MD length of the topsheet or less than the full MD
length of the topsheet.
[0154] The topsheet 224 may be joined to the backsheet 225, the
absorbent core 228 and/or any other layers as is known to those of
skill in the art. Usually, the topsheet 224 and the backsheet 225
are joined directly to each other in some locations (e.g., on or
close to the periphery of the absorbent article) and are indirectly
joined together in other locations by directly joining them to one
or more other elements of the article 220.
[0155] The topsheet 224 may be compliant, soft-feeling, and
non-irritating to the wearer's skin. Further, a portion of, or all
of, the topsheet 224 may be liquid permeable, permitting liquids to
readily penetrate through its thickness. Any portion of the
topsheet 224 may be coated with a lotion and/or a skin care
composition as is generally disclosed in the art. The topsheet 224
may also comprise or be treated with antibacterial agents.
Backsheet
[0156] The backsheet 225 is generally that portion of the absorbent
article 220 positioned adjacent the garment-facing surface of the
absorbent core 228 and which prevents, or at least inhibits, the
fluids and bodily exudates absorbed and contained therein from
soiling articles such as bedsheets and undergarments. The backsheet
225 is typically impermeable, or at least substantially
impermeable, to fluids (e.g., urine). The backsheet may, for
example, be or comprise a thin plastic film such as a thermoplastic
film having a thickness of about 0.012 mm to about 0.051 mm. Other
suitable backsheet materials may include breathable materials which
permit vapors to escape from the absorbent article 220, while still
preventing, or at least inhibiting, fluids from passing through the
backsheet 225.
[0157] The backsheet 225 may be joined to the topsheet 224, the
absorbent core 228, and/or any other element of the absorbent
article 220 by any attachment methods known to those of skill in
the art.
[0158] An outer cover 223 of the absorbent article 220 may cover at
least a portion of, or all of, the backsheet 225 to form a soft
garment-facing surface of the absorbent article. The outer cover
223 may be formed of the high loft, three-dimensional nonwoven
materials described herein. Alternatively, the outer cover 223 may
comprise one or more known outer cover materials. If the outer
cover 223 comprises one of the three-dimensional nonwoven materials
of the present disclosure, the three-dimensional nonwoven material
of the outer cover 223 may or may not match (e.g., same material,
same pattern) a three-dimensional nonwoven material used as the
topsheet or the topsheet and the acquisition layer of the absorbent
article. In other instances, the outer cover may have a printed or
otherwise applied pattern that matches or visually resembles the
pattern of the three-dimensional nonwoven materials used as the
topsheet or the topsheet and the acquisition layer laminate of the
absorbent article. The outer cover 223 is illustrated in dash in
FIG. 29, as an example. The outer cover 223 may be joined to at
least a portion of the backsheet 225 through mechanical bonding,
adhesive bonding, or other suitable methods of attachment.
Absorbent Core
[0159] The absorbent core is the component of the absorbent article
that has the most absorbent capacity and that comprises an
absorbent material and a core wrap or core bag enclosing the
absorbent material. The absorbent core does not include the
acquisition and/or distribution system or any other components of
the absorbent article which are not either integral part of the
core wrap or core bag or placed within the core wrap or core bag.
The absorbent core may comprise, consist essentially of, or consist
of, a core wrap, an absorbent material (e.g., superabsorbent
polymers and little or no cellulose fibers) as discussed, and glue.
In other instances, the absorbent material may comprise a mixture
of superabsorbent polymers and air-felt or cellulose fibers. This
mixture of superabsorbent polymers and air-felt or cellulose fibers
may be positioned within the core bag. The core bag may form a
C-wrap around the mixture or may be otherwise formed. Glue may also
be present within the core bag to at least partially hold the
mixture in place during manufacture and wear.
[0160] The absorbent core 228 may comprise an absorbent material
with a high amount of superabsorbent polymers (herein abbreviated
as "SAP") enclosed within the core wrap. The SAP content may
represent 70%-100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99%,
or 100%, by weight of the absorbent material, contained in the core
wrap. The core wrap is not considered as absorbent material for the
purpose of assessing the percentage of SAP in the absorbent
core.
[0161] By "absorbent material" it is meant a material which has
some absorbency property or liquid retaining properties, such as
SAP, cellulosic fibers as well as synthetic fibers. Typically,
glues used in making absorbent cores have no or little absorbency
properties and are not considered as absorbent material. The SAP
content may be higher than 80%, for example at least 85%, at least
90%, at least 95%, at least 99%, and even up to and including 100%
of the weight of the absorbent material contained within the core
wrap. This airfelt-free core is relatively thin compared to a
conventional core typically comprising between 40-60% SAP by weight
and a high content of cellulose fibers. The absorbent material may
in particular comprises less than 15% weight percent or less than
10% weight percent of natural, cellulosic, or synthetic fibers,
less than 5% weight percent, less than 3% weight percent, less than
2% weight percent, less than 1% weight percent, or may even be
substantially free of natural, cellulosic, and/or synthetic
fibers.
[0162] As referenced above, the airfelt-free cores with very little
or no natural, cellulosic and/or synthetic fibers are quite thin
compared to conventional cores, thereby making the overall
absorbent article thinner than absorbent articles with cores
comprising mixed SAP and cellulosic fibers (e.g., 40-60% cellulose
fibers). This core thinness can lead to consumer perceptions of
reduced absorbency and performance, although technically this is
not the case. Presently, these thin cores have typically been used
with substantially planer or apertured topsheets. Furthermore,
absorbent articles having these thin airfelt-free cores have
reduced capillary void space since there is little or no natural,
cellulosic, or synthetic fibers in the cores. Thus, there may
sometimes not be enough capillary void space in the absorbent
article to fully accept multiple insults of bodily exudates or a
single large insult.
[0163] To solve such problems, the present disclosure provides
absorbent articles with these thin airfelt-free cores in
combination with one of the high-loft, three-dimensional nonwoven
materials described herein as a topsheet, an acquisition layer, or
as a topsheet and acquisition layer laminate. In such an instance,
consumer perception of absorbency and performance, through the
increased thickness of the absorbent article owing to the
additional thickness provided by the high-loft, three-dimensional
nonwoven material, is increased. Furthermore, the three-dimensional
nonwoven materials, when used with these thin airfelt-free cores
and as the topsheet, and the acquisition layer, or the topsheet and
acquisition layer laminate, add capillary void space back into the
absorbent articles, while still allowing for minimal stack heights,
thereby passing cost savings onto consumers and manufactures. As
such, the absorbent articles of the present disclosure may easily
absorb multiple bodily exudate insults or single large insults
owing to this increased capillary void space. Additionally,
absorbent articles that comprise the nonwoven materials as the
topsheet, the acquisition layer, or the topsheet and acquisition
layer laminate provide consumers with an aesthetically pleasing
topsheet relative to a planer topsheet or an apertured topsheet
with an increased thickness and thus the consumer perceptions of
absorbency and performance.
[0164] The example absorbent core 228 of the absorbent article 220
of FIGS. 31-32 is shown in isolation in FIGS. 33-35. The absorbent
core 228 may comprises a front side 480, a rear side 482, and two
longitudinal sides 484, 486 joining the front side 480 and the rear
side 482. The absorbent core 228 may also comprise a generally
planar top side and a generally planar bottom side. The front side
480 of the core is the side of the core intended to be placed
towards the front waist edge 210 of the absorbent article. The core
228 may have a longitudinal axis 280' corresponding substantially
to the longitudinal axis 280 of the absorbent article 220, as seen
from the top in a planar view as in FIG. 28. The absorbent material
may be distributed in higher amount towards the front side 480 than
towards the rear side 482 as more absorbency may be required at the
front in particular absorbent articles. The front and rear sides
480 and 482 of the core may be shorter than the longitudinal sides
484 and 486 of the core. The core wrap may be formed by two
nonwoven materials, substrates, laminates, or other materials, 216,
216' which may be at least partially sealed along the sides 484,
486 of the absorbent core 228. The core wrap may be at least
partially sealed along its front side 480, rear side 482, and two
longitudinal sides 484, 486 so that substantially no absorbent
material leaks out of the absorbent core wrap. The first material,
substrate, or nonwoven 216 may at least partially surround the
second material, substrate, or nonwoven 216' to form the core wrap,
as illustrated in FIG. 34. The first material 216 may surround a
portion of the second material 216' proximate to the first and
second side edges 484 and 486.
[0165] The absorbent core may comprise adhesive, for example, to
help immobilizing the SAP within the core wrap and/or to ensure
integrity of the core wrap, in particular when the core wrap is
made of two or more substrates. The adhesive may be a hot melt
adhesive, supplied, by H. B. Fuller, for example. The core wrap may
extend to a larger area than strictly needed for containing the
absorbent material within.
[0166] The absorbent material may be a continuous layer present
within the core wrap. Alternatively, the absorbent material may be
comprised of individual pockets or stripes of absorbent material
enclosed within the core wrap. In the first case, the absorbent
material may be, for example, obtained by the application of a
single continuous layer of absorbent material. The continuous layer
of absorbent material, in particular of SAP, may also be obtained
by combining two absorbent layers having discontinuous absorbent
material application patterns, wherein the resulting layer is
substantially continuously distributed across the absorbent
particulate polymer material area, as disclosed in U.S. Pat. Appl.
Pub. No. 2008/0312622A1 (Hundorf), for example. The absorbent core
228 may comprise a first absorbent layer and a second absorbent
layer. The first absorbent layer may comprise the first material
216 and a first layer 261 of absorbent material, which may be 100%
or less of SAP. The second absorbent layer may comprise the second
material 216' and a second layer 262 of absorbent material, which
may also be 100% or less of SAP. The absorbent core 228 may also
comprise a fibrous thermoplastic adhesive material 251 at least
partially bonding each layer of absorbent material 261, 262 to its
respective material 216 or 216'. This is illustrated in FIGS.
34-35, as an example, where the first and second SAP layers have
been applied as transversal stripes or "land areas" having the same
width as the desired absorbent material deposition area on their
respective substrate before being combined. The stripes may
comprise different amounts of absorbent material (SAP) to provide a
profiled basis weight along the longitudinal axis of the core 280.
The first material 216 and the second material 216' may form the
core wrap.
[0167] The fibrous thermoplastic adhesive material 251 may be at
least partially in contact with the absorbent material 261, 262 in
the land areas and at least partially in contact with the materials
216 and 216' in the junction areas. This imparts an essentially
three-dimensional structure to the fibrous layer of thermoplastic
adhesive material 251, which in itself is essentially a
two-dimensional structure of relatively small thickness, as
compared to the dimension in length and width directions. Thereby,
the fibrous thermoplastic adhesive material may provide cavities to
cover the absorbent material in the land areas, and thereby
immobilizes this absorbent material, which may be 100% or less of
SAP.
[0168] The thermoplastic adhesive used for the fibrous layer may
have elastomeric properties, such that the web formed by the fibers
on the SAP layer is able to be stretched as the SAP swell.
Superabsorbent Polymer (SAP)
[0169] The SAP useful with the present disclosure may include a
variety of water-insoluble, but water-swellable polymers capable of
absorbing large quantities of fluids.
[0170] The superabsorbent polymer may be in particulate form so as
to be flowable in the dry state. Particulate absorbent polymer
materials may be made of poly(meth)acrylic acid polymers. However,
starch-based particulate absorbent polymer material may also be
used, as well as polyacrylamide copolymer, ethylene maleic
anhydride copolymer, cross-linked carboxymethylcellulose, polyvinyl
alcohol copolymers, cross-linked polyethylene oxide, and starch
grafted copolymer of polyacrylonitrile.
[0171] The SAP may be of numerous shapes. The term "particles"
refers to granules, fibers, flakes, spheres, powders, platelets and
other shapes and forms known to persons skilled in the art of
superabsorbent polymer particles. The SAP particles may be in the
shape of fibers, i.e., elongated, acicular superabsorbent polymer
particles. The fibers may also be in the form of a long filament
that may be woven. SAP may be spherical-like particles. The
absorbent core may comprise one or more types of SAP.
[0172] For most absorbent articles, liquid discharges from a wearer
occur predominately in the front half of the absorbent article, in
particular for a diaper. The front half of the article (as defined
by the region between the front edge and a transversal line placed
at a distance of half L from the front waist edge 210 or rear waist
edge 212 may therefore may comprise most of the absorbent capacity
of the core. Thus, at least 60% of the SAP, or at least 65%, 70%,
75%, 80%, or 85% of the SAP may be present in the front half of the
absorbent article, while the remaining SAP may be disposed in the
rear half of the absorbent article. Alternatively, the SAP
distribution may be uniform through the core or may have other
suitable distributions.
[0173] The total amount of SAP present in the absorbent core may
also vary according to expected user. Diapers for newborns may
require less SAP than infant, child, or adult incontinence diapers.
The amount of SAP in the core may be about 5 to 60 g or from 5 to
50 g. The average SAP basis weight within the (or "at least one",
if several are present) deposition area 8 of the SAP may be at
least 50, 100, 200, 300, 400, 500 or more g/m.sup.2. The areas of
the channels (e.g., 226, 226', 227, 227') present in the absorbent
material deposition area 8 are deduced from the absorbent material
deposition area to calculate this average basis weight.
Core Wrap
[0174] The core wrap may be made of a single substrate, material,
or nonwoven folded around the absorbent material, or may comprise
two (or more) substrates, materials, or nonwovens which are
attached to another. Typical attachments are the so-called C-wrap
and/or sandwich wrap. In a C-wrap, as illustrated, for example, in
FIGS. 29 and 34, the longitudinal and/or transversal edges of one
of the substrates are folded over the other substrate to form
flaps. These flaps are then bonded to the external surface of the
other substrate, typically by gluing.
[0175] The core wrap may be formed by any materials suitable for
receiving and containing the absorbent material. Typical substrate
materials used in the production of conventional cores may be used,
in particular paper, tissues, films, wovens or nonwovens, or
laminates or composites of any of these.
[0176] The substrates may also be air-permeable (in addition to
being liquid or fluid permeable). Films useful herein may therefore
comprise micro-pores.
[0177] The core wrap may be at least partially sealed along all the
sides of the absorbent core so that substantially no absorbent
material leaks out of the core. By "substantially no absorbent
material" it is meant that less than 5%, less than 2%, less than
1%, or about 0% by weight of absorbent material escape the core
wrap. The term "seal" is to be understood in a broad sense. The
seal does not need to be continuous along the whole periphery of
the core wrap but may be discontinuous along part or the whole of
it, such as formed by a series of seal points spaced on a line. A
seal may be formed by gluing and/or thermal bonding.
[0178] If the core wrap is formed by two substrates 216, 216', four
seals may be used to enclose the absorbent material 260 within the
core wrap. For example, a first substrate 216 may be placed on one
side of the core (the top side as represented in FIGS. 33-35) and
extend around the core's longitudinal edges to at least partially
wrap the opposed bottom side of the core. The second substrate 216'
may be present between the wrapped flaps of the first substrate 216
and the absorbent material 260. The flaps of the first substrate
216 may be glued to the second substrate 216' to provide a strong
seal. This so called C-wrap construction may provide benefits such
as improved resistance to bursting in a wet loaded state compared
to a sandwich seal. The front side and rear side of the core wrap
may then also be sealed by gluing the first substrate and second
substrate to another to provide complete encapsulation of the
absorbent material across the whole of the periphery of the core.
For the front side and rear side of the core, the first and second
substrates may extend and may be joined together in a substantially
planar direction, forming for these edges a so-called sandwich
construction. In the so-called sandwich construction, the first and
second substrates may also extend outwardly on all sides of the
core and be sealed flat, or substantially flat, along the whole or
parts of the periphery of the core typically by gluing and/or
heat/pressure bonding. In an example, neither the first nor the
second substrates need to be shaped, so that they may be
rectangularly cut for ease of production but other shapes are also
within the scope of the present disclosure.
[0179] The core wrap may also be formed by a single substrate which
may enclose as in a parcel wrap the absorbent material and be
sealed along the front side and rear side of the core and one
longitudinal seal.
SAP Deposition Area
[0180] The absorbent material deposition area 208 may be defined by
the periphery of the layer formed by the absorbent material 260
within the core wrap, as seen from the top side of the absorbent
core. The absorbent material deposition area 208 may have various
shapes, in particular, 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 material
deposition area 8 may have a relatively narrow width in an area of
the core intended to be placed in the crotch region of the
absorbent article, as illustrated in FIG. 28. This may provide
better wearing comfort. The absorbent material deposition area 8
may also be generally rectangular, for example as shown in FIGS.
31-33, but other deposition areas, such as a rectangular, "T," "Y,"
"sand-hour," or "dog-bone" shapes are also within the scope of the
present disclosure. The absorbent material may be deposited using
any suitable techniques, which may allow relatively precise
deposition of SAP at relatively high speed.
Channels
[0181] The absorbent material deposition area 208 may comprise at
least one channel 226, which is at least partially oriented in the
longitudinal direction of the article 280 (i.e., has a longitudinal
vector component). Other channels may be at least partially
oriented in the lateral direction (i.e., has a lateral vector
component) or in any other direction. In the following, the plural
form "channels" will be used to mean "at least one channel". The
channels may have a length L' projected on the longitudinal axis
280 of the article that is at least 10% of the length L of the
article. The channels may be formed in various ways. For example,
the channels may be formed by zones within the absorbent material
deposition area 208 which may be substantially free of, or free of,
absorbent material, in particular SAP. In addition or
alternatively, the channel(s) may also be formed by continuously or
discontinuously bonding the top side of the core wrap to the bottom
side of the core wrap through the absorbent material deposition
area 208. The channels may be continuous, but it is also envisioned
that the channels may be intermittent. The acquisition-distribution
system or layer 250, or another layer of the article, may also
comprise channels, which may or not correspond to the channels of
the absorbent core.
[0182] In some instances, the channels may be present at least at
the same longitudinal level as the crotch point C or the lateral
axis 260 in the absorbent article, as represented in FIG. 28 with
the two longitudinally extending channels 226, 226'. The channels
may also extend from the crotch region 207 or may be present in the
front waist region 205 and/or in the rear waist region 206 of the
article.
[0183] The absorbent core 228 may also comprise more than two
channels, for example, at least 3, at least 4, at least 5, or at
least 6 or more. Shorter channels may also be present, for example
in the rear waist region 206 or the front waist region 205 of the
core as represented by the pair of channels 227, 227' in FIG. 28
towards the front of the article. The channels may comprise one or
more pairs of channels symmetrically arranged, or otherwise
arranged relative to the longitudinal axis 280.
[0184] The channels may be particularly useful in the absorbent
core when the absorbent material deposition area is rectangular, as
the channels may improve the flexibility of the core to an extent
that there is less advantage in using a non-rectangular (shaped)
core. Of course channels may also be present in a layer of SAP
having a shaped deposition area.
[0185] The channels may be completely oriented longitudinally and
parallel to the longitudinal axis or completely oriented
transversely and parallel to the lateral axis, but also may have at
least portions that are curved.
[0186] In order to reduce the risk of fluid leakages, the
longitudinal main channels may not extend up to any of the edges of
the absorbent material deposition area 208, and may therefore be
fully encompassed within the absorbent material deposition area 208
of the core. The smallest distance between a channel and the
closest edge of the absorbent material deposition area 208 may be
at least 5 mm.
[0187] The channels may have a width We along at least part of
their length which is at least 2 mm, at least 3 mm, at least 4 mm,
up to for example 20 mm, 16 mm, or 12 mm, for example. The width of
the channel(s) may be constant through substantially the whole
length of the channel or may vary along its length. When the
channels are formed by absorbent material-free zone within the
absorbent material deposition area 208, the width of the channels
is considered to be the width of the material free zone,
disregarding the possible presence of the core wrap within the
channels. If the channels are not formed by absorbent material free
zones, for example mainly though bonding of the core wrap through
the absorbent material zone, the width of the channels is the width
of this bonding.
[0188] At least some or all of the channels may be permanent
channels, meaning their integrity is at least partially maintained
both in the dry state and in the wet state. Permanent channels may
be obtained by provision of one or more adhesive materials, for
example, the fibrous layer of adhesive material or construction
glue that helps adhere a substrate with an absorbent material
within the walls of the channel. Permanent channels may also be
formed by bonding the upper side and lower side of the core wrap
(e.g., the first substrate 216 and the second substrate 216')
and/or the topsheet 224 to the backsheet 225 together through the
channels. Typically, an adhesive may be used to bond both sides of
the core wrap or the topsheet and the backsheet through the
channels, but it is possible to bond via other known processes,
such as pressure bonding, ultrasonic bonding, heat bonding, or
combination thereof. The core wrap or the topsheet 224 and the
backsheet 225 may be continuously bonded or intermittently bonded
along the channels. The channels may advantageously remain or
become visible at least through the topsheet and/or backsheet when
the absorbent article is fully loaded with a fluid. This may be
obtained by making the channels substantially free of SAP, so they
will not swell, and sufficiently large so that they will not close
when wet. Furthermore, bonding the core wrap to itself or the
topsheet to the backsheet through the channels may be
advantageous.
Barrier Leg Cuffs
[0189] The absorbent article may comprise a pair of barrier leg
cuffs 34. Each barrier leg cuff may be formed by a piece of
material which is bonded to the absorbent article so it may extend
upwards from a wearer-facing surface of the absorbent article and
provide improved containment of fluids and other body exudates
approximately at the junction of the torso and legs of the wearer.
The barrier leg cuffs are delimited by a proximal edge 64 joined
directly or indirectly to the topsheet 224 and/or the backsheet 225
and a free terminal edge 266, which is intended to contact and form
a seal with the wearer's skin. The barrier leg cuffs 234 extend at
least partially between the front waist edge 210 and the rear waist
edge 212 of the absorbent article on opposite sides of the
longitudinal axis 280 and are at least present at the level of the
crotch point (C) or crotch region. The barrier leg cuffs may be
joined at the proximal edge 264 with the chassis of the article by
a bond 265 which may be made by gluing, fusion bonding, or a
combination of other suitable bonding processes. The bond 265 at
the proximal edge 264 may be continuous or intermittent. The bond
265 closest to the raised section of the leg cuffs delimits the
proximal edge 264 of the standing up section of the leg cuffs.
[0190] The barrier leg cuffs may be integral with the topsheet 224
or the backsheet 225 or may be a separate material joined to the
article's chassis. Each barrier leg cuff 234 may comprise one, two
or more elastic strings 235 close to the free terminal edge 266 to
provide a better seal.
[0191] In addition to the barrier leg cuffs 234, the article may
comprise gasketing cuffs 232, which are joined to the chassis of
the absorbent article, in particular to the topsheet 224 and/or the
backsheet 225 and are placed externally relative to the barrier leg
cuffs. The gasketing cuffs 232 may provide a better seal around the
thighs of the wearer. Each gasketing leg cuff may comprise one or
more elastic strings or elastic elements 233 in the chassis of the
absorbent article between the topsheet 224 and backsheet 225 in the
area of the leg openings. All, or a portion of, the barrier leg
cuffs and/or gasketing cuffs may be treated with a lotion or
another skin care composition.
Acquisition-Distribution System
[0192] The absorbent articles of the present disclosure may
comprise an acquisition-distribution layer or system 250 ("ADS").
One function of the ADS is to quickly acquire one or more of the
fluids and distribute them to the absorbent core in an efficient
manner. The ADS may comprise one, two or more layers, which may
form a unitary layer or may remain as discrete layers which may be
attached to each other. In an example, the ADS may comprise two
layers: a distribution layer 254 and an acquisition layer 252
disposed between the absorbent core and the topsheet, but the
present disclosure is not so limited.
[0193] In one example, the high loft, three-dimensional nonwoven
materials of the present disclosure may comprise the topsheet and
the acquisition layer as a laminate. A distribution layer may also
be provided on the garment-facing side of the topsheet/acquisition
layer laminate.
[0194] In another example, the high loft, three dimensional
nonwoven materials of the present disclosure may comprise an
acquisition layer of an absorbent article and a topsheet of the
absorbent article may be generally planar. The topsheet may have an
opacity such that the acquisition layer, such as a colored
acquisition layer or an acquisition layer with indicia, is visible
through the topsheet from the wearer-facing side of the absorbent
article.
Carrier Layer
[0195] In an instance where the high loft, three-dimensional
nonwoven materials of the present disclosure encompass a topsheet
and acquisition layer laminate, the distribution layer may need to
be supported by a carrier layer (not illustrated) that may comprise
one or more nonwoven materials or other materials. The distribution
layer may be applied to or positioned on the carrier layer. As
such, the carrier layer may be positioned intermediate the
acquisition layer and the distribution layer and be in a facing
relationship with the acquisition layer and the distribution
layer.
Distribution Layer
[0196] The distribution layer of the ADS may 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 is disclosed in U.S. Pat. Publ. No. 2008/0312622
A1 (Hundorf). The cross-linked cellulosic fibers provide higher
resilience and therefore higher resistance to the first absorbent
layer against the compression in the product packaging or in use
conditions, e.g., under wearer weight. This may provide the core
with a higher void volume, permeability, and liquid absorption, and
hence reduced leakage and improved dryness.
[0197] The distribution layer comprising the cross-linked cellulose
fibers of the present disclosure may comprise other fibers, but
this layer may advantageously comprise at least 50%, or 60%, or
70%, or 80%, or 90%, or even up to 100%, by weight of the layer, of
cross-linked cellulose fibers (including the cross-linking
agents).
Acquisition Layer
[0198] If a three-dimensional nonwoven material of the present
disclosure is provided as only the topsheet of an absorbent
article, the ADS 250 may comprise an acquisition layer 252. The
acquisition layer may be disposed between the distribution layer
254 and the topsheet 224. In such an instance, the acquisition
layer 252 may be or may comprise a nonwoven material, such as a
hydrophilic SMS or SMMS material, comprising a spunbonded, a
melt-blown and a further spunbonded layer or alternatively a carded
staple fiber chemical-bonded nonwoven. The nonwoven material may be
latex bonded.
Fastening System
[0199] The absorbent article may comprise a fastening system. The
fastening system may be used to provide lateral tensions about the
circumference of the absorbent article to hold the absorbent
article on the wearer as is typical for taped diapers. This
fastening system may not be necessary for training pant articles
since the waist region of these articles is already bonded. The
fastening system may comprise a fastener such as tape tabs, hook
and loop fastening components, interlocking fasteners such as tabs
& slots, buckles, buttons, snaps, and/or hermaphroditic
fastening components, although any other suitable fastening
mechanisms are also within the scope of the present disclosure. A
landing zone 244 is normally provided on the garment-facing surface
of the front waist region 205 for the fastener to be releasably
attached thereto.
Front and Rear Ears
[0200] The absorbent article may comprise front ears 246 and rear
ears 240. The ears may be an integral part of the chassis, such as
formed from the topsheet 224 and/or backsheet 226 as side panels.
Alternatively, as represented on FIG. 28, the ears may be separate
elements attached by gluing, heat embossing, and/or pressure
bonding. The rear ears 240 may be stretchable to facilitate the
attachment of the tabs 242 to the landing zone 244 and maintain the
taped diapers in place around the wearer's waist. The rear ears 240
may also be elastic or extensible to provide a more comfortable and
contouring fit by initially conformably fitting the absorbent
article to the wearer and sustaining this fit throughout the time
of wear well past when absorbent article has been loaded with
fluids or other bodily exudates since the elasticized ears allow
the sides of the absorbent article to expand and contract.
Elastic Waist Feature
[0201] The absorbent article 220 may also comprise at least one
elastic waist feature (not represented) that helps to provide
improved fit and containment. The elastic waist feature is
generally intended to elastically expand and contract to
dynamically fit the wearer's waist. The elastic waist feature may
extend at least longitudinally outwardly from at least one waist
edge of the absorbent core 228 and generally forms at least a
portion of the end edge of the absorbent article. Disposable
diapers may be constructed so as to have two elastic waist
features, one positioned in the front waist region and one
positioned in the rear waist region.
Sanitary Napkin
[0202] The three-dimensional nonwoven materials of the present
disclosure may form a portion of a sanitary napkin, for instance, a
portion of, or all of, a topsheet, or portion of, or all of, a
topsheet and acquisition layer (or secondary topsheet). In other
instances, the three-dimensional nonwoven materials may form a
strip or patch placed on the topsheet of the sanitary napkin. An
example sanitary napkin 500 is disclosed in FIG. 36. The sanitary
napkin 500 may comprise a liquid permeable topsheet 514, a liquid
impermeable, or substantially liquid impermeable, backsheet 516,
and an absorbent core 508. The absorbent core 508 may have any or
all of the features described herein with respect to the absorbent
cores 228 and, in some forms, may have a secondary topsheet
(acquisition layer or system) instead of the
acquisition-distribution system disclosed above. The sanitary
napkin 500 may also comprise wings 520 extending outwardly with
respect to a longitudinal axis 580 of the sanitary napkin 500. The
sanitary napkin 500 may also comprise a lateral axis 590. The wings
520 may be joined to the topsheet 514, the backsheet 516, and/or
the absorbent core 508. The sanitary napkin 500 may also comprise a
front edge 522, a rear edge 524 longitudinally opposing the front
edge 522, a first side edge 526, and a second side edge 528
longitudinally opposing the first side edge 526. The longitudinal
axis 580 may extend from a midpoint of the front edge 522 to a
midpoint of the rear edge 524. The lateral axis 590 may extend from
a midpoint of the first side edge 526 to a midpoint of the second
side edge 528. The sanitary napkin 500 may also be provided with
additional features commonly found in sanitary napkins as is
generally known in the art, such as a secondary topsheet 519, for
example.
Packages
[0203] Absorbent articles comprising airfelt-free cores and the
high loft, three-dimensional nonwoven materials of the present
disclosure may be placed into packages. The packages may comprise
polymeric films and/or other materials. Graphics and/or indicia
relating to properties of the absorbent articles may be formed on,
printed on, positioned on, and/or placed on outer portions of the
packages. Each package may comprise a plurality of absorbent
articles. The absorbent articles may be packed under compression so
as to reduce the size of the packages, while still providing an
adequate amount of absorbent articles per package. By packaging the
absorbent articles under compression, caregivers can easily handle
and store the packages, while also providing distribution savings
to manufacturers owing to the size of the packages.
[0204] As discussed above, one of the unexpected benefits of the
absorbent articles of the present disclosure having airfelt-free
cores and the nonwoven materials as a topsheet and/or a topsheet
and acquisition layer laminate is cost savings to the consumer and
the manufacturer owing to reduced stack height. Accordingly,
packages of the absorbent articles of the present disclosure may
have an In-Bag Stack Height of less than about 100 mm, less than
about 95 mm, less than about 90 mm, less than about 85 mm, less
than about 85 mm, but greater than about 75 mm, less than about 80
mm, less than about 78 mm, less than about 76 mm, or less than
about 74 mm, specifically reciting all 0.1 mm increments within the
specified ranges and all ranges formed therein or thereby,
according to the In-Bag Stack Height Test described herein.
Alternatively, packages of the absorbent articles of the present
disclosure may have an In-Bag Stack Height of from about 70 mm to
about 100 mm, from about 70 mm to about 95 mm, from about 72 mm to
about 85 mm, from about 72 mm to about 80 mm, or from about 74 mm
to about 78 mm, specifically reciting all 0.1 mm increments within
the specified ranges and all ranges formed therein or thereby,
according to the In-Back Stack Height Test described herein.
[0205] FIG. 37 illustrates an example package 1000 comprising a
plurality of absorbent articles 1004. The package 1000 defines an
interior space 1002 in which the plurality of absorbent articles
1004 are situated. The plurality of absorbent articles 1004 are
arranged in one or more stacks 1006.
EXAMPLES
Comparative Example 1
[0206] In Comparative Example 1, the material is a composite of two
materials glued together using H. B. Fuller of St. Paul, Minn.,
U.S.A. D3166ZP hot melt adhesive applied in a spiral pattern at a 1
gsm add on level. The composite material is processed through a nip
formed by one of The Procter & Gamble Company's SELF rolls and
a ring roll as described in U.S. Pat. No. 7,410,683 B2, Curro, et
al., at 25 feet/minute (fpm) (7.6 meters per minute) and 0.135''
(3.43 mm) DOE. The material layer in contact with the SELF roll is
a 20 gsm spunbond nonwoven produced by Fitesa of Simpsonville,
S.C., U.S.A. Such a material is described in Fitesa's U.S. patent
application Ser. No. 14/206,699 entitled "Extensible Nonwoven
Fabric" and is comprised of 2.5 denier fibers comprising a blend of
PP and PE fibers. The material layer in contact with the ring roll
is a 43 gsm spunbond nonwoven produced by Reicofil of Troisdorf,
Germany, comprised of 7 denier co-PET/PET tipped-trilobal
bicomponent fibers.
Example 1
Single Layer
[0207] In Example 1, the material is a 50 grams/m.sup.2 (gsm) PE/PP
sheath/core bicomponent spunbond nonwoven from Fitesa. It is
processed at 25 fpm (7.6 meters per minute) speed at 0.155 inch
(3.94 mm) depth of engagement (DOE) through male/female tooling
(forming members). The teeth on the male tool have a rounded
diamond shape like that shown in FIG. 21, 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), varying slightly around
the perimeter of the recess.
Example 2
Two layers
[0208] In Example 2, the material is a composite of two materials
glued together using the same hot melt adhesive applied in a spiral
pattern as described in Comparative Example 1. It is processed
through the male/female tooling described in Example 1, at 800 feet
per minute (fpm) (24.4 meters per minute) and 0.155 inch (3.94 mm)
DOE. The material layer in contact with the male roll is the 20 gsm
spunbond nonwoven produced by Fitesa comprised of 2.5 denier fibers
with a blend of PP and PE described in Comparative Example 1. The
material layer in contact with the female roll is a 60 gsm
through-air bonded carded nonwoven produced by Beijing Dayuan
Non-Woven Fabric Co, LTD of Beijing, China, comprised of 5 denier
PE/PET sheath/core bicomponent fibers.
Example 3
Two layers
[0209] In Example 3, the material is a composite of two materials
glued together using the same hot melt adhesive applied in a spiral
pattern as described in Comparative Example 1. It is processed
through the male/female tooling described in Example 1, at 800 fpm
and 0.155 inch (3.94 mm) DOE. The material layer in contact with
the male roll is a 20 gsm spunbond nonwoven produced by Fitesa
comprised of 2.5 denier fibers with a blend of PP and PE described
in Example 2. The material layer in contact with the female roll is
an 86 gsm spunbond nonwoven produced by Reicofil comprised of 7
denier co-PET/PET tipped-trilobal bicomponent fibers.
[0210] The samples are compressed according to the Accelerated
Compression Method, with a 7 kPa weight). The pre-compression
caliper and the post-compression caliper of the samples are
measured following the Accelerated Compression Method. The
dimensions of the protrusions and openings are measured using a
microscope at 20.times. magnification. The exterior dimensions of
the cap are measured from a perspective view with the protrusions
facing up, like that shown in FIG. 5. The protrusion depth and the
interior cap width is measured from the cross-section of the
material like that shown in FIG. 11.
TABLE-US-00001 Ratio of Cap Base Cap width- Measured Opening Base
Width- Cap Cap Interior First Layer Second Layer Before or After
Caliper at Protrusion Width Opening Interior Width- Length- to Base
(Contacts (Contacts Compression 2.1 kPa Depth (W.sub.0) Length
(W.sub.I) Exterior Exterior Opening Example Male Tool) Female Tool)
(7 kPa) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Width Comp. 20 gsm 43
gsm co- Before 1.2 1.1 0.5 4.7 <0.1* 1.5 4.6 -- Ex. 1 Spunbond
PET/PET Compression (Tuft) (Tuft) (Tuft) (Tuft) PE/PP Blend
Spunbond After 0.7 0.3 0* 4.7 0* 0.7 4.0 -- Compression (opening
(opening was was closed) closed) Ex. 1 50 gsm None Before 0.48 1.3
1.5 3.3 1.7 2.4 4.2 1.1 PE/PP Bico Compression Spunbond After 0.39
0.4 1.7 3.0 2.1 2.9 4.3 1.2 Compression Ex. 2 20 gsm 60 gsm PET
Before 1.6 1.9 1.9 3.5 2.4 3.2 4.5 1.3 Spunbond Carded Compression
PE/PP Blend Through-air After 0.88 0.5 1.6 3.3 1.8 2.7 4.4 1.1
Bonded Compression Ex. 3 20 gsm 86 gsm co- Before 2.0 1.9 1.8 3.8
2.2 3.8 4.8 1.2 Spunbond PET/PET Compression PE/PP Blend Spunbond
After 1.3 0.7 1.5 3.6 2.5 3.7 5.2 1.7 Compression *Difficult to
measure because measurement was so small
Test Methods:
[0211] A. Accelerated Compression Method. [0212] 1. Cut 10 samples
of the specimen to be tested and 11 pieces of a paper towel into a
3 inch.times.3 inch (7.6 cm.times.7.6 cm) square. [0213] 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. [0214] 3.
Alternate the layers of the specimens to be tested with the pieces
of paper towel, 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. [0215] 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). [0216]
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. [0217] 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. [0218] 7. Let the samples rest at 23.+-.2.degree. C. and
at 50.+-.2% relative humidity for 24 hours without any weight on
them.
[0219] 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. [0220] 9. If desired, an average of the 10
specimens can be calculated for the pre-compression,
post-compression and post-recovery calipers.
[0221] B. Tensile Method
[0222] The MD and CD tensile properties are measured using method
WSP 110.4 (05) Option B, with a 50 mm sample width, 60 mm gauge
length, and 60 mm/min rate of extension. Note that the gauge
length, rate of extension and resultant strain rate are different
from that specified within the method.
[0223] C. In-Bag Stack Height Test
[0224] The in-bag stack height of a package of absorbent articles
is determined as follows:
Equipment
[0225] A thickness tester with a flat, rigid horizontal sliding
plate is used. The thickness tester is configured so that the
horizontal sliding plate moves freely in a vertical direction with
the horizontal sliding plate always maintained in a horizontal
orientation directly above a flat, rigid horizontal base plate. The
thickness tester includes a suitable device for measuring the gap
between the horizontal sliding plate and the horizontal base plate
to within .+-.0.5 mm. The horizontal sliding plate and the
horizontal base plate are larger than the surface of the absorbent
article package that contacts each plate, i.e. each plate extends
past the contact surface of the absorbent article package in all
directions. The horizontal sliding plate exerts a downward force of
850.+-.1 gram-force (8.34 N) on the absorbent article package,
which may be achieved by placing a suitable weight on the center of
the non-package-contacting top surface of the horizontal sliding
plate so that the total mass of the sliding plate plus added weight
is 850.+-.1 grams.
Test Procedure
[0226] Absorbent article packages are equilibrated at
23.+-.2.degree. C. and 50.+-.5% relative humidity prior to
measurement.
[0227] The horizontal sliding plate is raised and an absorbent
article package is placed centrally under the horizontal sliding
plate in such a way that the absorbent articles within the package
are in a horizontal orientation (see FIG. 37). Any handle or other
packaging feature on the surfaces of the package that would contact
either of the plates is folded flat against the surface of the
package so as to minimize their impact on the measurement. The
horizontal sliding plate is lowered slowly until it contacts the
top surface of the package and then released. The gap between the
horizontal plates is measured to within .+-.0.5 mm ten seconds
after releasing the horizontal sliding plate. Five identical
packages (same size packages and same absorbent articles counts)
are measured and the arithmetic mean is reported as the package
width. The "In-Bag Stack Height"=(package width/absorbent article
count per stack).times.10 is calculated and reported to within
.+-.0.5 mm.
[0228] 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 "90.degree." is intended to mean "about
90.degree.".
[0229] It should be understood that every maximum numerical
limitation given throughout this specification includes every lower
numerical limitation, as if such lower numerical limitations were
expressly written herein. Every minimum numerical limitation given
throughout this specification will include every higher numerical
limitation, as if such higher numerical limitations were expressly
written herein. Every numerical range given throughout this
specification will include every narrower numerical range that
falls within such broader numerical range, as if such narrower
numerical ranges were all expressly written herein.
[0230] All documents cited in the Detailed Description are, in
relevant part, incorporated herein by reference; the citation of
any document is not to be construed as an admission that it is
prior art with respect to the present disclosure. To the extent
that any meaning or definition of a term in this written document
conflicts with any meaning or definition of the term in a document
incorporated by reference, the meaning or definition assigned to
the term in this written document shall govern.
[0231] While particular embodiments of the present disclosure 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.
* * * * *