U.S. patent application number 14/844043 was filed with the patent office on 2016-03-17 for absorbent articles with indicia and/or color.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Aniruddha CHATTERJEE, Adrien GRENIER, John Lee HAMMONS, James T. KNAPMEYER, Jill Marlene ORR, Matthew Steven RITTER, Rodrigo ROSATI, John B. STRUBE, Paul Thomas WEISMAN.
Application Number | 20160074258 14/844043 |
Document ID | / |
Family ID | 54140723 |
Filed Date | 2016-03-17 |
United States Patent
Application |
20160074258 |
Kind Code |
A1 |
ROSATI; Rodrigo ; et
al. |
March 17, 2016 |
ABSORBENT ARTICLES WITH INDICIA AND/OR COLOR
Abstract
An absorbent article comprises a liquid permeable
three-dimensional material, a liquid impermeable backsheet, and an
absorbent core positioned at least partially intermediate the
liquid impermeable backsheet and the three-dimensional material.
The absorbent core comprises an absorbent material having one or
more channels defined therein. The absorbent article may comprise
other layers positioned at least partially intermediate the
absorbent core and the liquid permeable three-dimensional material
that also may comprise one or more channels. Any of the layers of
the absorbent article may comprise indicia and/or color.
Inventors: |
ROSATI; Rodrigo; (Frankfurt
Am Main, DE) ; CHATTERJEE; Aniruddha; (Kelkheim,
DE) ; RITTER; Matthew Steven; (Liberty Township,
OH) ; ORR; Jill Marlene; (Liberty Township, OH)
; STRUBE; John B.; (Okeana, OH) ; GRENIER;
Adrien; (Frankfurt Am Main, DE) ; KNAPMEYER; James
T.; (Cincinnati, OH) ; HAMMONS; John Lee;
(Hamilton, OH) ; WEISMAN; Paul Thomas;
(Cincinnati, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
54140723 |
Appl. No.: |
14/844043 |
Filed: |
September 3, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62049516 |
Sep 12, 2014 |
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62049521 |
Sep 12, 2014 |
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62049408 |
Sep 12, 2014 |
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62049406 |
Sep 12, 2014 |
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62049404 |
Sep 12, 2014 |
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62049403 |
Sep 12, 2014 |
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62049401 |
Sep 12, 2014 |
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62049397 |
Sep 12, 2014 |
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62049392 |
Sep 12, 2014 |
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62210057 |
Aug 26, 2015 |
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62210005 |
Aug 26, 2015 |
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62210020 |
Aug 26, 2015 |
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62210014 |
Aug 26, 2015 |
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Current U.S.
Class: |
206/526 ;
604/378 |
Current CPC
Class: |
A61F 13/15723 20130101;
A61F 13/537 20130101; A61F 13/535 20130101; A61F 13/536 20130101;
A61F 2013/51147 20130101; A61F 13/551 20130101; A61F 2013/15463
20130101; A61F 2013/530715 20130101; A61F 13/51 20130101; A61F
2013/421 20130101; A61F 2013/51007 20130101; A61F 2013/530175
20130101; A61F 2013/53472 20130101; A61F 13/51394 20130101; A61F
2013/51002 20130101; A61F 13/51104 20130101; A61F 13/513 20130101;
A61F 2013/51026 20130101; A61F 2013/51023 20130101; A61F 2013/4568
20130101; A61F 2013/530007 20130101; A61F 13/15707 20130101; A61F
2013/530481 20130101; A61F 2013/53908 20130101; A61F 2013/51355
20130101; A61F 13/53 20130101; A61F 13/15203 20130101; A61F
2013/15715 20130101; A61F 13/51108 20130101; A61F 13/534 20130101;
A61F 2013/15365 20130101; A61F 2013/427 20130101; A61F 2013/51092
20130101; A61F 2013/8497 20130101; A61F 13/15699 20130101; A61F
2013/5386 20130101; A61F 2013/51377 20130101; A61F 13/5116
20130101; A61F 13/5121 20130101; A61F 13/45 20130101; A61F 13/55145
20130101; A61F 2013/4587 20130101; A61F 2013/51009 20130101; A61F
2013/530489 20130101; A61F 13/55115 20130101; A61F 2013/530131
20130101; A61F 2013/530664 20130101; A61F 2013/5307 20130101; A61F
2013/5395 20130101; A61F 13/511 20130101; A61F 2013/15284 20130101;
A61F 13/55105 20130101 |
International
Class: |
A61F 13/535 20060101
A61F013/535; A61F 13/551 20060101 A61F013/551; A61F 13/53 20060101
A61F013/53 |
Claims
1. An absorbent article comprising: a liquid permeable topsheet; an
acquisition material; wherein the liquid permeable topsheet or the
acquisition material forms a three-dimensional material comprising:
a first surface; a second surface; a generally planar first region;
and a plurality of discrete integral second regions that comprise
deformations forming protrusions extending outwardly from the
second surface of the three-dimensional material and openings in
the first surface of the three-dimensional material, wherein at
least some of the protrusions each comprise: a base proximate to
the first surface; an opposed distal end extending outwardly in a
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 measured in the same
direction as the maximum interior 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 backsheet; an
absorbent core positioned at least partially intermediate the
three-dimensional material and the liquid impermeable backsheet,
wherein the absorbent core comprises an absorbent material at least
partially surrounded by a core bag; and wherein one of a portion of
the topsheet, a portion of the acquisition material, a portion of
the core bag, or a portion of an additional layer positioned at
least partially intermediate the topsheet and the core bag is a
different color than a different one of the portion of the
topsheet, the portion of the acquisition material, the portion of
the core bag, or the portion of the additional layer.
2. The absorbent article of claim 1, wherein the liquid permeable
topsheet and the acquisition material together form the
three-dimensional material.
3. The absorbent article of claim 1, comprising an indicia on any
of the topsheet, the acquisition material, the core bag, or the
additional layer, wherein the indicia is visible when viewing a
wearer-facing surface of the absorbent article.
4. The absorbent article of claim 3, wherein the indicia is applied
to any of the topsheet, the acquisition material, the core bag, or
the additional layer.
5. The absorbent article of claim 3, wherein the indicia comprises
a color different than a color of the portion of the topsheet, a
color of the portion of the acquisition layer, a color of the
portion of the core bag, or a color of the portion of the
additional layer.
6. The absorbent article of claim 4, wherein the indicia comprises
an adhesive.
7. The absorbent article of claim 6, wherein the adhesive comprises
a non-white or non-clear pigment.
8. The absorbent article of claim 3, wherein the indicia comprises
an ink.
9. The absorbent article of claim 8, wherein the ink comprises a
pigment.
10. The absorbent article of claim 3, wherein the indicia comprises
a light activatable material.
11. The absorbent article of claim 3, wherein the indicia comprises
a liquid activatable material.
12. The absorbent article of claim 3, wherein the indicia comprises
a pH or temperature activatable material.
13. The absorbent article of claim 3, wherein the indicia is formed
by a sheath or a core of a plurality of bicomponent fibers.
14. The absorbent article of claim 3, wherein the indicia comprises
embossed areas.
15. The absorbent article of claim 3, wherein the indicia comprises
fusion bonds.
16. The absorbent article of claim 1, wherein the absorbent
material comprises a mixture of superabsorbent polymers and
air-felt.
17. The absorbent article of claim 1, wherein the absorbent
material is substantially free of air-felt.
18. The absorbent article of claim 1, wherein the additional layer
comprises a nonwoven material or a material comprising pulp
fibers.
19. The absorbent article of claim 1, wherein at least some of the
protrusions comprise a bulbous shape.
20. A package comprising a plurality of the absorbent articles of
claim 1, wherein the package has an in-bag stack height in the
range of about 70 mm to about 100 mm, according to the In-Bag Stack
Height Test herein.
21. An absorbent article comprising: a liquid permeable topsheet;
an acquisition material; wherein the liquid permeable topsheet or
the acquisition material forms a three-dimensional material
comprising: a first surface; a second surface; a generally planar
first region; and a plurality of discrete integral second regions
that comprise deformations forming bulbous protrusions extending
outwardly from the second surface and openings in the first
surface; a liquid impermeable backsheet; an absorbent core
positioned at least partially intermediate the laminate and the
liquid impermeable material, wherein the absorbent core comprises
an absorbent material at least partially surrounded by a nonwoven
core bag; and wherein one of a portion of the topsheet, a portion
of the acquisition material, a portion of the core bag, or a
portion of an additional layer positioned at least partially
intermediate the topsheet and the core bag is a different color
than a different one of the portion of the topsheet, the portion of
the acquisition material, the portion of the core bag, and the
portion of the additional layer.
22. The absorbent article of claim 21, wherein the additional layer
comprises a material comprising pulp fibers.
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application Ser. Nos.
62/049,516 (P&G 13530P), 62/049,521 (P&G 13531PQ),
62/049,408 (P&G CM4137FPQ), 62/049,406 (P&G CM4136FPQ),
62/049,404 (P&G CM4135FPQ), 62/049,403 (P&G CM4134FPQ),
62/049,401 (P&G CM4133FPQ), 62/049,397 (P&G CM4132FPQ), and
62/049,392 (P&G CM4131FPQ), all of which were filed on Sep. 12,
2014, and to U.S. Provisional Patent Application Ser. Nos.
62/210,005 (P&G 13971PQ), 62/210,014 (P&G 13972PQ),
62/210,020 (P&G 13973PQ), and 62/210,057 (P&G CM 4131P2Q),
all of which were filed on Aug. 26, 2015. The entire disclosures of
all of the above-referenced U.S. Provisional Patent Applications
are fully incorporated herein by reference.
FIELD
[0002] The present disclosure relates to absorbent articles, and
more particularly relates to absorbent articles with channel
configurations in combination with three-dimensional materials.
These absorbent articles may have indicia and/or color in various
layers. The indicia or color may be used in the various layers with
or without the channels configurations.
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. Consumers in some markets desire
three-dimensional materials on wearer-facing surfaces of the
absorbent articles, such as topsheets. These three-dimensional
materials create depth in absorbent articles and thereby provide
consumers with the impression of better absorbency and reduced skin
exposure to bodily exudates. The three-dimensional materials also
provide improved softness or the impression of improved softness
relative to planar materials. The impressions of better absorbency,
reduced bodily exudate exposure to skin, and softness, however, are
not the only attributes that consumers desire. Consumers also
desire the impression that the absorbent article will not only lock
away bodily exudates adequately, reduce skin exposure thereto, and
have improved softness, but also that the absorbent article will
distribute the bodily exudates evenly about the length of the
absorbent article to at least inhibit, for example, crotch sagging.
Further, consumers desire absorbent articles that are visually
appealing and that enhance the impression that the absorbent
articles will lock away bodily exudates, reduce skin exposure
thereto, and provide the impression of depth and improved softness.
What is needed are absorbent articles that provide the impression
of depth, improved softness, and reduced skin exposure to bodily
exudates, but that also provide the impression of uniform fluid
distribution about the length of the absorbent articles. Further,
what is needed are absorbent articles with indicia and/or color
that provide consumer desired absorbent articles that are
aesthetically pleasing and give the desired impressions discussed
above.
SUMMARY
[0004] The absorbent articles of the present disclosure solve the
problems associated with related art absorbent articles by
providing not only the impressions of depth, improved softness, and
reduced exposure to bodily exudates, but also by providing the
impression of uniform fluid distribution about the length of the
absorbent articles. The absorbent articles of the present
disclosure provide all of these benefits by providing a
three-dimensional material in combination with channels in various
layers intermediate wearer and garment facing surfaces of the
absorbent articles. For example, the channels may be present in an
absorbent core and/or in one or more layers of a material
positioned intermediate an absorbent core and a topsheet. In some
instances, the three-dimensional material may create the impression
of channels using one or more designs or one or more elongate
designs that are visible from a wearer-facing surface of the
absorbent articles. The one or more designs or elongate designs may
be positioned so that they at least partially overlap with, fully
overlap with, or are free from overlap with (all in the
Z-direction) other channels in the absorbent articles. The one or
more designs or elongate designs may be formed in the
three-dimensional material through the use of non-three dimensional
areas, different three dimensional areas compared to a remainder of
a three-dimensional material, or may be formed in planar topsheets
or acquisition materials using embossing, printing, and/or
graphics, for example.
[0005] The impressions of depth, improved softness, absorbency, and
reduced exposure to bodily exudates may also be enhanced in the
absorbent articles by providing indicia and/or color on various
layers of the absorbent articles, or portions thereof. The indicia
and/or color may be used in combination with three dimensional
materials and/or channels in various layer of the present
disclosure to achieve all of the consumer desired attributes of
absorbent articles.
[0006] In addition to providing the benefits specified above,
consumers desire their absorbent articles to be packaged in
conveniently sized packages that still have an adequate amount of
absorbent articles. The packages should be compression packed so
that a package of the absorbent articles may be conveniently
stored. Further, there are distribution cost benefits to
compression packaging the absorbent articles, which cost savings is
ultimately passed along to consumers.
[0007] In a form, the present disclosure is directed, in part, to
an absorbent article comprising 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 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 comprises a
liquid impermeable material and an absorbent core positioned at
least partially intermediate the nonwoven material and the liquid
impermeable material. The absorbent core comprises an absorbent
material having one or more channels defined therein. The absorbent
article comprises a material positioned at least partially
intermediate the nonwoven material and the absorbent core. One or
more channels are defined in the material.
[0008] In a form, the present disclosure is directed, in part, to
an absorbent article comprising 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 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 comprises a
liquid impermeable material and an absorbent core positioned at
least partially intermediate the nonwoven material and the liquid
impermeable material. The absorbent core comprises an absorbent
material. A first channel is defined in the absorbent material. The
absorbent article comprises a material positioned at least
partially intermediate the nonwoven material and the absorbent
core. A second channel is defined in the material. The absorbent
article comprises an indicia visible from a wearer-facing surface
on the nonwoven material or another layer intermediate the nonwoven
material and the absorbent core.
[0009] In a form, the present disclosure is directed, in part, to
an absorbent article comprising 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 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 nonwoven material comprises an
elongate visible design. 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. A first channel is
defined in the absorbent material. The absorbent article comprises
a material positioned at least partially intermediate the nonwoven
material and the absorbent core. A second channel is defined in the
material. The elongate visible design, the first channel, and the
second channel all at least partially overlap each other in a
Z-direction.
[0010] In a form, the present disclosure is directed, in part, to a
package comprising a plurality of absorbent articles. At least a
majority 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 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 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. A
first channel is defined in the absorbent material. The absorbent
article comprises a material positioned at least partially
intermediate the nonwoven material and the absorbent core. A second
channel is defined in the material. The first channel at least
partially overlaps the second channel in a Z-direction. The package
has an in-bag stack height in the range of about 70 mm to about 100
mm, in accordance with the In-Bag Stack Height Test herein.
[0011] In a form, the present disclosure is directed, in part, to
an absorbent article comprising a liquid permeable topsheet and an
acquisition material. The liquid permeable topsheet or the
acquisition material forms a three-dimensional material comprising
a first surface, a second surface, a generally planar first region,
and a plurality of discrete integral second regions that comprise
deformations forming protrusions extending outwardly from the
second surface of the three-dimensional material and openings in
the first surface of the three-dimensional material. At least some
protrusions each comprise a base proximate to the first surface, an
opposed distal end extending outwardly in a 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
measured in the same direction as the maximum interior 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 backsheet, an absorbent core positioned at least
partially intermediate the three-dimensional material and the
liquid impermeable backsheet. The absorbent core comprises an
absorbent material at least partially surrounded by a core bag. The
absorbent article comprises one or more indicias on any of the
topsheet, the acquisition material, the core bag, or an additional
layer positioned at least partially intermediate the topsheet and
the core bag. The indicia has a different color than the topsheet,
the acquisition material, the core bag, or the additional layer
that the indicia is on. The indicia is visible when viewing a
wearer-facing surface of the absorbent article.
[0012] In a form, the present disclosure is directed, in part, to
an absorbent article comprising a liquid permeable topsheet and an
acquisition material. The liquid permeable topsheet or the
acquisition material forms a three-dimensional material comprising
a first surface, a second surface, a generally planar first region,
and a plurality of discrete integral second regions that comprise
deformations forming bulbous protrusions extending outwardly from
the second surface of the three-dimensional material and openings
in the first surface of the three-dimensional material. The
absorbent article comprises a liquid impermeable backsheet and an
absorbent core positioned at least partially intermediate the
three-dimensional material and the liquid impermeable backsheet.
The absorbent core comprises an absorbent material at least
partially surrounded by a nonwoven core bag. The absorbent article
comprises one or more indicias on any of the topsheet, the
acquisition material, the core bag, or an additional layer
positioned at least partially intermediate the topsheet and the
core bag. The indicia has a different color than the topsheet, the
acquisition material, the core bag, or the additional layer that
the indicia is on. The indicia is visible when viewing a
wearer-facing surface of the absorbent article.
[0013] In a form, the present disclosure is directed, in part, to
an absorbent article comprising a liquid permeable topsheet and an
acquisition material. The liquid permeable topsheet or the
acquisition material forms a three-dimensional material comprising
a first surface, a second surface, a generally planar first region
and a plurality of discrete integral second regions that comprise
deformations forming protrusions extending outwardly from the
second surface of the three-dimensional material and openings in
the first surface of the three-dimensional material. At least some
of the protrusions each comprise a base proximate to the first
surface, an opposed distal end extending outwardly in a 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
measured in the same direction as the maximum interior 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 backsheet, an absorbent core positioned at least
partially intermediate the three-dimensional material and the
liquid impermeable backsheet. The absorbent core comprises an
absorbent material at least partially surrounded by a core bag. One
of a portion of the topsheet, a portion of the acquisition
material, a portion of the core bag, or a portion of an additional
layer positioned at least partially intermediate the topsheet and
the core bag is a different color than a different one of the
portion of the topsheet, the portion of the acquisition material,
the portion of the core bag, or the portion of the additional
layer.
[0014] In a form, the present disclosure is directed, in part to an
absorbent article comprising a liquid permeable topsheet and an
acquisition material. The liquid permeable topsheet or the
acquisition material forms a three-dimensional material comprising
a first surface, a second surface, a generally planar first region,
and a plurality of discrete integral second regions that comprise
deformations forming bulbous protrusions extending outwardly from
the second surface and openings in the first surface. The absorbent
article comprises a liquid impermeable backsheet and an absorbent
core positioned at least partially intermediate the
three-dimensional material and the liquid impermeable backsheet.
The absorbent core comprises an absorbent material at least
partially surrounded by a nonwoven core bag. One of a portion of
the topsheet, a portion of the acquisition material, a portion of
the core bag, or a portion of an additional layer positioned at
least partially intermediate the topsheet and the core bag is a
different color than a different one of the portion of the
topsheet, the portion of the acquisition material, the portion of
the core bag, and the portion of the additional layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] 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 forms of
the disclosure taken in conjunction with the accompanying drawings,
wherein:
[0016] FIG. 1 is a photomicrograph showing the end view of a prior
art tuft;
[0017] FIG. 2 is a schematic end view of a prior art tuft after it
has been subjected to compression;
[0018] FIG. 3 is a photomicrograph of the end of a prior art
nonwoven web showing a plurality of collapsed tufts;
[0019] FIG. 4 is a schematic side view of a prior art
conical-shaped structure before and after it has been subjected to
compression;
[0020] 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;
[0021] 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;
[0022] 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;
[0023] 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;
[0024] 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;
[0025] 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;
[0026] FIG. 11 is a photomicrograph of a cross-section taken along
the transverse axis of a deformation showing one example of a
multilayer 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;
[0027] FIG. 12 is a schematic view of the protrusion shown in FIG.
11 in accordance with the present disclosure;
[0028] 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;
[0029] 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;
[0030] FIG. 15A is a cross-sectional view taken along the
transverse axis of a deformation of one form of a multilayer
nonwoven web shown with the base opening facing upward in
accordance with the present disclosure;
[0031] FIG. 15B is a cross-sectional view taken along the
transverse axis of a deformation of an alternative form of a
multilayer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0032] FIG. 15C is a cross-sectional view taken along the
transverse axis of a deformation of an alternative form of a
multilayer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0033] FIG. 15D is a cross-sectional view taken along the
transverse axis of a deformation of an alternative form of a
multilayer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0034] FIG. 15E is a cross-sectional view taken along the
transverse axis of a deformation of an alternative form of a
multilayer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0035] FIG. 15F is a cross-sectional view taken along the
transverse axis of a deformation of an alternative form of a
multilayer nonwoven web shown with the base opening facing upward
in accordance with the present disclosure;
[0036] FIG. 16 is a plan view photomicrograph of a nonwoven web
with the protrusions oriented upward showing the concentration of
fibers in one layer of a two layer structure in accordance with the
present disclosure;
[0037] 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;
[0038] 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;
[0039] 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;
[0040] 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;
[0041] 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;
[0042] FIG. 22 is an enlarged perspective view of a portion of the
male roll shown in FIG. 21 in accordance with the present
disclosure;
[0043] FIG. 23 is an enlarged perspective view showing the nip
between the rolls shown in FIG. 21 in accordance with the present
disclosure;
[0044] 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;
[0045] FIG. 25 is an absorbent article in the form of a diaper
comprising an example topsheet/acquisition layer composite
structure where 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;
[0046] FIG. 26 is one transverse cross-section of the diaper of
FIG. 25 taken along line 26-26 in accordance with the present
disclosure;
[0047] FIG. 27 is an alternative transverse cross-section of the
diaper of FIG. 25 in accordance with the present disclosure;
[0048] 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;
[0049] 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;
[0050] 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;
[0051] 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;
[0052] 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;
[0053] 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;
[0054] 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;
[0055] 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;
[0056] FIG. 36 is an example absorbent article in the form of a
diaper comprising an example multilayer nonwoven web with the
length of the acquisition layer being less than the length of the
topsheet, with channels in an absorbent core, and with some layers
partially removed in accordance with the present disclosure;
[0057] FIG. 37 is an example cross-sectional view of the absorbent
article of FIG. 36, taken about line 37-37, with the absorbent core
having channels, in accordance with the present disclosure;
[0058] FIG. 38 is an example cross-sectional view of the absorbent
article of FIG. 36, taken about line 37-37, with the absorbent core
at least partially loaded with a fluid in accordance with the
present disclosure;
[0059] FIG. 39 is an example cross-sectional view of an absorbent
article, with an absorbent core and a material intermediate the
absorbent core and a multilayer nonwoven web, both having channels
in accordance with the present disclosure;
[0060] FIG. 40 is an example cross-sectional view of the absorbent
article of FIG. 39 with the absorbent core at least partially
loaded with a fluid in accordance with the present disclosure;
[0061] FIG. 41 is an example cross-sectional view of an absorbent
article, with an absorbent core and two materials intermediate the
absorbent core and a multilayer nonwoven web, all having channels
in accordance with the present disclosure;
[0062] FIG. 42 is an example cross-sectional view of an absorbent
article with an absorbent core, a generally planar topsheet, a
three-dimensional acquisition layer, and two materials intermediate
the absorbent core and the three-dimensional acquisition layer,
wherein the absorbent core and one of the materials intermediate
the absorbent core and the three-dimensional acquisition layer have
channels in accordance with the present disclosure;
[0063] FIG. 43 is an example cross-sectional view of an absorbent
article with a three-dimensional topsheet, an absorbent core, a
generally planar acquisition layer, and two materials intermediate
the absorbent core and the generally planar acquisition layer,
wherein channels are present in the absorbent core and one of the
materials intermediate the absorbent core and the generally planar
acquisition layer in accordance with the present disclosure;
[0064] FIG. 44 is an example cross-sectional view of an absorbent
article, with an absorbent core and a material intermediate the
absorbent core and a multilayer nonwoven web, both having channels
in accordance with the present disclosure;
[0065] FIG. 45 is a plan view of an absorbent article having
channels and the multilayer nonwoven web having a design in
accordance with the present disclosure;
[0066] FIG. 46 is an example cross-sectional view of the absorbent
article of FIG. 45, taken about line 46-46, in accordance with the
present disclosure;
[0067] FIG. 47 is the cross-sectional view of the absorbent article
of FIG. 46, with the absorbent core at least partially loaded with
a fluid in accordance with the present disclosure;
[0068] FIG. 48 is an example cross-sectional view of an absorbent
article having channels and a multilayer nonwoven web having a
design, in accordance with the present disclosure;
[0069] FIG. 49 is an example plan view of a portion of a
wearer-facing surface of a nonwoven web of an absorbent article,
wherein the nonwoven web comprises a design in accordance with the
present disclosure;
[0070] FIG. 50 is an example plan view of a portion of a
wearer-facing surface of a nonwoven web of an absorbent article,
wherein the nonwoven material comprises a design in accordance with
the present disclosure;
[0071] FIG. 51 is an example cross-sectional view of an absorbent
article, with an absorbent core and two materials intermediate the
absorbent core and a multilayer nonwoven web, wherein the absorbent
core and one of the materials intermediate the absorbent core and
the multilayer nonwoven web both have channels, and wherein the
channels do not overlap each other in a Z-direction, in accordance
with the present disclosure;
[0072] FIG. 52 is an example cross-sectional view of an absorbent
article, with an absorbent core and two materials intermediate the
absorbent core and a multilayer nonwoven web, wherein the absorbent
core and both of the materials intermediate the absorbent core and
the multilayer nonwoven web all have channels, and wherein the
channels do not overlap each other in a Z-direction, in accordance
with the present disclosure;
[0073] FIG. 53 is an example plan view of a cellulose based
three-dimensional material for use as at least part of a carrier
layer and/or a distribution material in accordance with the present
disclosure;
[0074] FIG. 54 is an example cross-sectional view of the cellulose
based three-dimensional layer taken about line 54-54 of FIG. 53 in
accordance with the present disclosure;
[0075] FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 illustrate some
example patterns of three-dimensional nonwoven webs in accordance
with the present disclosure;
[0076] FIGS. 56, 59, 61, 64, 66, 69, 71, and 73 illustrate some
example indicia that may underlie any of the example
three-dimensional nonwoven webs having patterns of FIGS. 55, 58,
60, 63, 65, 68, 70, and 72 in accordance with the present
disclosure;
[0077] FIG. 57 illustrates the overlap of the pattern of the
three-dimensional web of FIG. 55 with the indicia of FIG. 56 in
accordance with the present disclosure;
[0078] FIG. 62 illustrates the overlap of the pattern of the
three-dimensional web of FIG. 60 with the indicia of FIG. 61 in
accordance with the present disclosure;
[0079] FIG. 67 illustrates the overlap of the pattern of the
three-dimensional web of FIG. 65 with the indicia of FIG. 66 in
accordance with the present disclosure;
[0080] FIG. 74 is a plan 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, the nonwoven webs of the present disclosure may be
present on this example absorbent article structure; and
[0081] FIG. 75 is a side view of a package of absorbent articles
showing the package width in accordance with the present
disclosure, with the outer surface illustrated as transparent for
purposes of clarity.
DETAILED DESCRIPTION
[0082] Various non-limiting form 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 with indicia and/or color disclosed herein. One or more
examples of these non-limiting forms are illustrated in the
accompanying drawings. Those of ordinary skill in the art will
understand that the absorbent articles with indicia and/or color
described herein and illustrated in the accompanying drawings are
non-limiting example forms and that the scope of the various
non-limiting forms of the present disclosure are defined solely by
the claims. The features illustrated or described in connection
with one non-limiting form may be combined with the features of
other non-limiting forms. Such modifications and variations are
intended to be included within the scope of the present
disclosure.
DEFINITIONS
[0083] The term "absorbent article", as used herein, includes
disposable articles such as sanitary napkins, panty liners,
tampons, interlabial devices, wound dressings, diapers (taped or
pants), 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 materials, nonwoven webs, and/or three-dimensional
materials or webs 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.
[0084] 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.
[0085] The term "channel", as used herein, is a region or zone in a
material layer that has a substantially lower basis weight (e.g.,
less than 50%, less than 70%, less than 90%) than the surrounding
material in the material layer. The channel may be a region in a
material layer that is substantially material-free (e.g., 90%
material-free, 95% material-free, or 99% material-free, or
completely material-free). A channel may extend through one or more
material layers. The channels generally have a lower bending
modulus than the surrounding regions of the material layer,
enabling the material layer to bend more easily and/or contain more
bodily exudates within the channels than in the surrounding areas
of the material layer. Thus, a channel is not merely an
indentation, compressed portion, or embossment in the material
layer that does not create a reduced basis weight in the material
layer in the area of the channel.
[0086] 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, acquisition layer,
distribution material, absorbent core or layers of absorbent cores,
backsheets, and barriers such as barrier layers and barrier
cuffs.
[0087] The term "cross-machine direction" or "CD", as used herein,
means a path that is perpendicular to a machine direction in a
plane of a web.
[0088] 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.
[0089] 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).
[0090] The term "disposable", as used herein, describes 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).
[0091] The term "forming elements", as used herein, refers to any
elements on a surface of a forming member that are capable of
deforming a web.
[0092] 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.
[0093] The terms "join", "joined", "joined to", "attach",
"attached", "attached to", "bond", "bonded", and "bonded to", as
used herein, encompasses configurations in which an element is
directly secured to another element by affixing the element
directly to the other element; 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. These terms encompass 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. These
terms include any known manner in which elements can be secured
including, but not limited to mechanical entanglement.
[0094] The term "machine direction" or "MD", as used herein, means
a path that a material, such as a web, follows through a
manufacturing process.
[0095] 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.
[0096] 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.
[0097] 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.
[0098] The terms "SELF" and "SELF'ing", as used herein, 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.
[0099] 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.
[0100] 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.
[0101] The terms "Z-dimension" or "Z-direction", as used herein,
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
[0102] 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 nonwoven
material, and openings on the other side of the nonwoven material.
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.
[0103] As used herein, the term "nonwoven" or "nonwoven material"
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 or materials 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.
[0104] The nonwoven webs of the present disclosure will first be
described and then channels in various layers of the absorbent
articles of the present disclosure will be set forth. Next, various
color patterns and indica patterns will be described.
[0105] 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.
[0106] For example, FIGS. 1 and 2 show 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.
[0107] 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 material 10 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.
[0108] Prior art nonwoven materials with certain other types of
three dimensional deformations, such as conical structures, may
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.
[0109] The nonwoven materials of at least some forms of the present
disclosure described herein are intended to better preserve the
structure of discrete three-dimensional features in the nonwoven
materials after compression.
[0110] 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.
[0111] 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.
[0112] 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.
[0113] 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.
[0114] FIG. 11 shows one example of a multilayer 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).
[0115] 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.
[0116] 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 forms 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 forms, such as in forms 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.
[0117] 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.
[0118] 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.
[0119] 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. In still
other cases, protrusions 32 can be formed that have substantially
the same width from one end of the protrusion to the other end of
the protrusion. 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.
[0120] 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 form shown in FIGS. 5 and 6, the longitudinal axis LA
is parallel to the MD. In some forms, all the spaced apart
protrusions 32 may have generally parallel longitudinal axes
LA.
[0121] 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 form 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.
[0122] 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.
[0123] 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.
[0124] 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 form 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.
[0125] In some forms, 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.
[0126] 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.
[0127] In some forms, the length of the cap 52 may be in a range
from about 1.5 mm to about 10 mm. In some forms, 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 forms, 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 forms, 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 forms, 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 forms,
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.
[0128] 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
forms of three-dimensional protrusions 32 in multiple layer
materials.
[0129] In certain forms, 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.
[0130] 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 a form, 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 form, 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 form shown, the fibers
38A in the first layer 30A are shorter in length than the fibers
38B in the second layer 30B. In other forms, 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 form, and any of
the other forms 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.
[0131] 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 forms, 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.
[0132] 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
material or absorbent core, which may lead to improved dryness. In
such a form, the layers are not considered to be "nested" in the
area of the protrusion. (In the other forms 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
forms, the flaps 70 can have a more volcano-like structure, as if
the protrusion 32B is erupting from the flaps.
[0133] 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 a form 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.
[0134] 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.
[0135] 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.
[0136] 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.
[0137] 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.
[0138] 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.
[0139] 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.
[0140] The nonwoven webs or three-dimensional materials 30
described herein can comprise any suitable component or components
of an absorbent article. For example, the nonwoven webs can
comprise a 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, for example.
The diaper 82 shown in FIGS. 25-27 also comprises an absorbent core
88, a backsheet 94, and a distribution material 96. The nonwoven
webs or materials of the present disclosure may also form an outer
cover of an absorbent article, such as an outer cover nonwoven
material 223 (see FIG. 29). The nonwoven webs 30 can be placed in
an absorbent article with the deformations 31 in any suitable
orientation. For example, the protrusions 32 may 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 wearer-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 forms, the nonwoven webs 30 can
be made so that they have some protrusions 32 that are oriented
upward, and some protrusions 32 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 may be more effective for cleaning the body from
bodily exudates, while the protrusions that are oriented downward
can be more effective for absorption of bodily exudates into the
absorbent core. Therefore, without being bound to theory, a
combination of these two protrusion orientations may offer an
advantage that the same product may fulfill the two functions.
[0141] 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 forms, 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.
[0142] 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.
Precursor Materials
[0143] 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.
[0144] 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
forms, however, the nonwoven precursor materials can be either
substantially, or completely free, of one or more of these
materials. For example, in some forms, the precursor materials may
be substantially free of cellulose, and/or exclude paper materials.
In some forms, 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 forms, the nonwoven
precursor materials can be either substantially, or completely
free, of tow fibers.
[0145] 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.
[0146] 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.
[0147] 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 multilayer material is the combined basis
weight of the constituent layers and any other added components.
The basis weight of multilayer 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).
[0148] 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 multilayer 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.
[0149] 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 multilayer
structure in which another layer has protrusions 32 as described
herein.
[0150] 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.
[0151] 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 a form, 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 forms, 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.
[0152] 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.
[0153] 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.
[0154] 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.
[0155] 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 multilayer web without the use
or need for adhesives or thermal bonding between the layers. In
other forms, 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.
[0156] 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 forms, each of the layers can be continuous. In
alternative forms, 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
[0157] 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.
[0158] The first and second forming members can be plates, rolls,
belts, or any other suitable types of forming members. In some
forms, 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 form 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.
[0159] First Forming Member.
[0160] 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.
[0161] 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 a form, 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.
[0162] Numerous other forms of the male forming elements 112 are
possible. In other forms, the top 118 of the male forming elements
112 can be rounded. In other forms, 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
forms, the top 118 of the male elements 112 can be of different
shapes from those shown in the drawings. In other forms, 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).
[0163] Second Forming Member.
[0164] 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.
[0165] 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.
[0166] 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.
[0167] 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 forms, 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.
[0168] 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 forms, 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.
[0169] 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.
[0170] 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.)
[0171] 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 forms, 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.
[0172] 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
[0173] 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. These absorbent articles may comprise various color and
indicia designs and/or patterns. The absorbent articles may also
comprise channels in one or more layers intermediate the topsheet
and the absorbent core.
General Description of an Absorbent Article
[0174] 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 a laminate
formed of the topsheet and the acquisition layer. In any event, the
three-dimensional nonwoven materials of the present disclosure may
be liquid permeable. Channels may be present in the absorbent core,
the distribution material, and/or the carrier layer (if the carrier
layer is provided). Channels may also be present in an acquisition
layer if the acquisition layer is not combined with the topsheet.
In some instances, a distribution material may not be provided, and
the channels may only be in the acquisition layer or another layer
intermediate the topsheet and the absorbent core. If channels are
provided in more than one of these materials intermediate the
topsheet and the absorbent core, the channels may fully overlap
each other, partially overlap each other, or be free from any
overlap with each other, all with respect to the Z-direction.
[0175] 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 material
254 and an acquisition layer 252, which will be further discussed
below. The acquisition layer 252 may be nested with the topsheet as
described herein, and illustrated in various figures. 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.
[0176] 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.
[0177] 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.
[0178] 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.
[0179] 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, such as two.
[0180] These and other components of the example absorbent articles
will now be discussed in more details.
Topsheet
[0181] 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 a typical topsheet. 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. In
some instances, the topsheet may be generally planar.
[0182] The topsheet 224 may be joined to the backsheet 225, the
acquisition layer 252, 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.
[0183] 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
[0184] 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.
[0185] 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.
[0186] 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, such as
conventional nonwoven materials. If the outer cover 223 comprises
one or more 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 and/or
same pattern, or similar material and/or similar pattern) a
three-dimensional nonwoven material used as the topsheet, the
acquisition layer, or a laminate of the topsheet and the
acquisition layer of the absorbent article. In other instances, the
outer cover 223 comprising one or more of the three-dimensional
nonwoven materials may compliment or coordinate with one or more
three-dimensional nonwoven materials used as the topsheet, the
acquisition layer, or as a combined topsheet and acquisition layer.
In other instances, the outer cover may have a printed or otherwise
applied pattern that matches, visually resembles, compliments, or
coordinates with the pattern of the three-dimensional nonwoven
materials used as the topsheet, the acquisition layer, 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
[0187] 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. Channels may be
present in this absorbent material comprising superabsorbent
polymers and air-felt. In other instances, embossed areas may form
compressed areas in the absorbent core.
[0188] 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.
[0189] 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.
[0190] 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.
[0191] 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, the acquisition layer, or the topsheet and
acquisition layer laminate, add capillary void space back into the
absorbent articles, while still allowing for minimal in-bag 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.
[0192] 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.
[0193] 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.
[0194] 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.
[0195] 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.
[0196] 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)
[0197] 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.
[0198] 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.
[0199] 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.
[0200] 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.
[0201] 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
[0202] 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.
[0203] 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.
[0204] The substrates may also be air-permeable (in addition to
being liquid or fluid permeable). Films useful herein may therefore
comprise micro-pores.
[0205] 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.
[0206] 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.
[0207] 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
[0208] 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 in Absorbent Core
[0209] 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.
[0210] 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.
[0211] 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.
[0212] 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.
[0213] 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.
[0214] 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.
[0215] 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.
[0216] 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
[0217] 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.
[0218] 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.
[0219] 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
[0220] The absorbent articles of the present disclosure may
comprise an acquisition-distribution layer or system ("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 material 254 and an acquisition layer 252
disposed between the absorbent core and the topsheet, but the
present disclosure is not so limited.
[0221] 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 or just as the topsheet or the
acquisition layer individually. A distribution material may also be
provided on the garment-facing side of the topsheet/acquisition
layer laminate, on the garment-facing side of the acquisition
layer, or on a garment-facing side of a carrier layer, as is
discussed below.
Carrier Layer
[0222] In an instance where the high loft, three-dimensional
nonwoven materials of the present disclosure encompass a topsheet
and acquisition layer laminate or just the acquisition layer, the
distribution material may need to be supported by a carrier layer
(illustrated in later figures) that may comprise one or more
nonwoven materials, cellulose materials, and/or other materials, as
will be further detailed below. The material of the distribution
material 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 material and be in a facing
relationship with the acquisition layer and the distribution
material. The carrier layer may also be positioned intermediate the
distribution material and a wearer-facing surface of the core
bag.
Distribution Material
[0223] The distribution material 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.
[0224] The distribution material 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).
[0225] In other instances, the distribution material may comprise
cellulose fibers or pulp. In some instances, the distribution
material may comprise at least 80%, at least 90%, at least 99% or
100% cellulose fibers or pulp. In certain instances, such a
distribution material may be formed of a single layer or multiple
layers. In still other instances, such a distribution material may
comprise a single layer folded any suitable number of times over
itself. The cellulose fiber or pulp based distribution materials
may be three-dimensional materials. In still other instances, the
distribution material may be formed of any suitable distribution
materials.
Acquisition Layer
[0226] The acquisition layer may be disposed between the
distribution material 254 or carrier layer and the topsheet 224.
The acquisition layer may or may not be nested with the topsheet as
explained herein. If the acquisition layer is not nested with the
topsheet it may be planer or three-dimensional. The acquisition
layer 252 may comprise any suitable material, such as a high
elongation spunbond material, for example.
Fastening System
[0227] 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
[0228] 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
[0229] 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.
Channels in Layers Other than the Absorbent Core
[0230] Various channels e.g., 226, 226' in the absorbent core were
described in detail above. To achieve fluid distribution along a
longitudinal direction of an absorbent article and/or a consumer
impression of the same, the present disclosure provides one or more
channels in one or more other layers intermediate the core bag and
the acquisition layer in addition to the one or more channels in
the absorbent core. Namely, in some instances, these one or more
additional channels may be provided in a distribution material, a
carrier layer, and/or any other suitable layer intermediate the
absorbent core and the acquisition layer. If some instances, if the
acquisition layer is not formed into a laminate with the topsheet
and is generally planar, channels may also be formed in the
acquisition layer. In such an instance, the topsheet may comprise
the three-dimensional materials of the present disclosure. In this
example, the acquisition layer may be positioned intermediate the
topsheet and the absorbent core or may have other layers
intermediate itself and the absorbent core.
[0231] In FIGS. 36-43 and 45-52 the protrusions 250 extend toward
the absorbent core 228, while in FIG. 44 the protrusions 250 extend
away from the absorbent core. The present disclosure encompasses
forms where the protrusions extend away from the absorbent core and
towards the absorbent core.
[0232] FIG. 36 illustrates an example absorbent article 320. The
absorbent article 320 comprises a longitudinal axis 380 and a
lateral axis 390. Absorbent core channels 226 and 226' are defined
in an absorbent material 308 of the absorbent core 228. The
absorbent material 308 is enclosed in a core bag 360 having two
layers or nonwoven layers 316 and 316'. The two nonwoven layers 316
and 316' may form a C-wrap around the absorbent material 308 or
otherwise enclose the absorbent material. The absorbent article 320
may comprise a distribution material 254. The absorbent article may
also comprise a topsheet 224 and an acquisition layer 252 that are
nested together to form a three-dimensional topsheet/acquisition
layer laminate 245, as described in further detail herein. The
three-dimensional topsheet/acquisition layer laminate may comprise
a plurality of protrusions 250. The absorbent article 320 also
comprises a backsheet 225. Other features (e.g., fastening system)
of the absorbent article 320 may be the same as or similar to that
described herein, and as such, will not be described again here for
brevity.
[0233] FIG. 37 illustrates a cross-sectional view of the absorbent
article 320 taken about line 37-37 of FIG. 36. As can be seen, the
layering of the example absorbent article 320 from the
wearer-facing surface ("WFS") to the garment-facing surface ("GFS")
is as follows: a nested topsheet/acquisition layer laminate 245; a
distribution material or layer 254; an absorbent core 228
(including the core bag 360); and a backsheet 225. An outer cover
nonwoven material may also be provided on the GFS to cover the
backsheet.
[0234] FIG. 38 illustrates the cross-sectional view of FIG. 37 with
the absorbent core 228 at least partially loaded with a fluid.
[0235] FIG. 39 illustrates another example cross-sectional view of
an absorbent article 320'. As can be seen, the distribution
material 254 may comprise one or more channels 326 and 326'. Any
suitable number of channels, such as one, two, three, or more, may
be provided in the distribution material 254. This distribution
material 254 may comprise air-felt or any other suitable material,
such as the distribution materials described above. The channels
326 and 326' may have any suitable size, shape, and/or orientation.
The channels 326 and 326' in the distribution material 254 may or
may not overlap in the Z-direction with the channels 226 and 226'
in the absorbent core 228. If the channels 326 and 326' and the
channels 226 and 226' do overlap in the Z-direction they may
partially overlap or fully overlap. For example, the channels 326
and 326' may not be as wide or as long as the channels 226 or 226'
or vice versa. In an instance, only one of the channels 326 and
326' may at least partially overlap or be free of overlap in the
Z-direction with only one of the channels 226 and 226'.
[0236] FIG. 40 is the cross-sectional view of the absorbent article
320' of FIG. 39 with the absorbent core 228 at least partially
loaded with a fluid.
[0237] FIG. 41 illustrates another example cross-sectional view of
an absorbent article 320''. The distribution material 254 may
comprise channels 326 and 326' that may be the same as or similar
to the distribution material channels described above with respect
to FIG. 39. In this instance, however, an optional carrier layer
325 may be provided. The carrier layer 325 may also comprise one or
more channels 327 and 327'. The carrier layer 325 may comprise a
nonwoven material, a cellulose fiber or pulp based material, and/or
or any other suitable material. If the carrier layer 325 comprises
a cellulose fiber or pulp based material, it may comprise at least
80%, at least 90%, at least 99%, or 100% cellulose fiber or pulp by
weight. The carrier layer 325 may comprise a three-dimensional
material comprising at least 80%, at least 90%, at least 99%, or
100% cellulose fiber or pulp by weight. In an instance, the
three-dimensional material of the carrier layer 325 may be a
variable basis weight and variable density material. The carrier
layer 325 may be optional in some absorbent article forms. For
example, a carrier layer may not be desired when the acquisition
layer 252 is generally flat, for example. In some instances, it may
be difficult to attach the distribution material 254 to a
three-dimensional garment-facing surface of the three-dimensional
material (whether an acquisition layer 252 or a
topsheet/acquisition layer laminate). As such, the carrier layer
325 may be used to provide an attachment surface for the
distribution material.
[0238] Any suitable number of channels, such as one, two, three, or
more, may be provided in the carrier layer 325. The channels 327
and 327' may or may not overlap, in the Z-direction, with the
channels 326 and 326' in the distribution material 254 and/or the
channels 226 and 226' in the absorbent core 228. If any of the
channels 327 and 327', 326 and 326', and 226 and 226' do overlap,
in the Z-direction, they may partially overlap or fully overlap.
For example, the channels 327 and 327' may not be as wide or as
long as the channels 326 and 326' and/or the channels 226 or 226'
or vice versa. Some of or all of the channels in the various layers
may or may not at least partially or fully overlap in the
Z-direction. In another instance, at least one channel in one layer
(e.g., distribution material 254) may overlap, in the Z-direction,
with at least one channel in another layer (e.g., the absorbent
core 228), while at least one other channel in the one layer (e.g.,
the distribution material 254) may not overlap, in the Z-direction,
with at least one channel in the another layer (e.g., the absorbent
core 228).
[0239] FIG. 42 illustrates an example cross-sectional view of an
absorbent article 420 with the same channel configuration as the
absorbent article 320' of FIG. 39, but with a carrier layer 325 and
with a topsheet 224 comprising a generally planer or flat material.
The acquisition layer 252, in this instance, comprises the
three-dimensional nonwoven material.
[0240] FIG. 43 illustrates an example cross-sectional view of an
absorbent article 420' with the same channel configuration as the
absorbent article 320' of FIG. 39, but with a carrier layer 325,
and with an acquisition layer 252 comprising a generally planer or
flat material. The topsheet 224, in this instance, comprises the
three-dimensional nonwoven material.
[0241] FIG. 44 illustrates an example cross-sectional view of an
absorbent article 420'' with the same channel configuration as the
absorbent article 320' of FIG. 39, but with the protrusions 250 of
the three-dimensional nonwoven material 245 extending away from the
absorbent core 228.
[0242] FIG. 45 illustrates a plan view of an absorbent article 520
having a longitudinal axis 580 and a lateral axis 590. The
absorbent article 520 may comprise one or more channels 226 and
226' in an absorbent material 308 of an absorbent core 228 and one
or more channels 326 and 326' in a distribution material 254. A
carrier layer may also be provided intermediate an acquisition
layer 252 and the distribution material 254, although not
illustrated in FIG. 45. This carrier layer may comprise one or more
channels (e.g., channels 327 and 327' of FIG. 41). The
three-dimensional nonwoven material 245, the topsheet 224, and/or
the acquisition layer 252 may comprise one or more designs 546 and
546'. The designs 546 and 546' are merely examples of some suitable
designs. Other designs having different shapes, sizes, and/or
orientations are also within the scope of the present disclosure.
In an instance, one design may be the same as or different than the
other design. Any suitable number of designs may be provided. The
designs may differ in color, size, shape, orientation, or other
visual aspect. In general, the designs should be visible from a
wearer-facing surface of the absorbent article 520. In an instance,
the protrusions 250 may only be present in an area of the absorbent
article 520 that corresponds with the acquisition layer 252, or an
area smaller than the acquisition layer 252, for example. In such
instances, the protrusions 250 may not extend fully about the
length of the absorbent article 520 or fully about the width of the
absorbent article 520.
[0243] In some forms, the designs may comprise ink or a structural
difference in the material, for example. The inks may comprise a
pigment that is visibly distinct from remaining portions of the
topsheet and/or acquisition material, for example. The inks may be
printed on, applied to, or formed on either surface of the topsheet
224 or either surface of the acquisition layer 252. The structural
difference in the material may be embossing or a different, size,
shape, and/or orientation of the projections 250, for example. The
structural difference should be visible from the wearer-facing
surface. The structural difference may be areas without any
protrusions as well.
[0244] In some instances, one or more certain designs may be on the
topsheet 224 with one or more other certain designs on the
acquisition layer, for example.
[0245] The designs 546 and 546' may be elongate and may or may not
partially or fully overlap with channels in any of the layers.
[0246] FIG. 46 is a cross-sectional view of the absorbent article
520 taken about line 46-46 of FIG. 45. In the example illustrated
in FIG. 46, the designs 546 and 546' comprise a non-nested,
compressed area in the three-dimensional nonwoven material 245. In
some instances, the designs may be compressed areas or non-nested
areas (e.g., FIG. 48) in the topsheet 224 and/or in the acquisition
layer 252. In any event, the example designs 546 and 546', or other
designs, may fully overlap with, at least partially overlap with,
or be free of overlap with, all in the Z-direction, with the
channels 226 and 226' in the absorbent core 228, the channels 326
and 326' in the distribution material 254, and/or the channels 327
and 327' in the carrier layer, if provided. In some instances, the
designs 546 and 546' may be shorter, longer, wider, narrower, or
have different shapes than any of the channels 226, 226', 326,
326', 327, and/or 327'. The designs 546 and 546' may comprise a
color different than a remainder of the material they are part of,
applied to, and/or printed on.
[0247] FIG. 47 is the cross-sectional view of the absorbent article
520 of FIG. 46 with the absorbent core 228 at least partially
loaded with a fluid.
[0248] FIG. 48 is another example cross-sectional view of the
absorbent article 520 of FIG. 45 taken about line 48-48. The
example of FIG. 48 comprises the same channel configuration as the
example of FIG. 46 and comprises designs 546'' and 546'''. The
designs 546'' and 546''' are areas in the three-dimensional
material that are free of, or at least mostly free of,
three-dimensional protrusions 250. Stated another way, the designs
546'' and 546''' are non-nested areas, or substantially non-nested
areas.
[0249] FIG. 49 illustrates a schematic illustration of a
three-dimensional material 245 with a wearer-facing surface towards
the viewer. The three-dimensional material 245 comprises one or
more designs 546'' and 546''' formed in areas free of protrusions
250. In some instances, the designs 546'' and 546''' may comprise
an ink, adhesive, or other material that has a different color than
a remaining portion of the topsheet 224 and/or a remaining portion
of the acquisition layer 252. The protrusions 250 of the
three-dimensional material 245 may be facing into the page, out of
the page, or into or out of the page. If the designs 546'' and
546''' comprise an ink, adhesive, or other material that has a
different color than the remaining portion of the topsheet 224
and/or the remaining portion of the acquisition layer 252, the ink,
adhesive, or other material may be applied to protrusions or
non-protrusions areas, for example.
[0250] FIG. 50 illustrates a schematic illustration of a
three-dimensional material 245 with a wearer-facing surface towards
the viewer. The three-dimensional material 245 may comprise one or
more designs 547 and 547' that may be at least partially formed by
a first pattern of protrusions 250'. Protrusions 250' may have the
same or a different size, shape, and/or orientation compared to the
other protrusions 250 in the three-dimensional material 245. The
protrusions 250' may be smaller or larger than the protrusions 250.
The protrusions 250' may be the same or different in one or more of
the designs. The protrusions 250' may be continuous or
discontinuous.
[0251] In a form, the designs 547 and 547' may comprise a first
plurality of the protrusions 250' and a remaining portion of the
three-dimensional nonwoven material 245 may comprise a second
plurality of protrusions 250. The first plurality of the
protrusions 250' may be the same as or different than the second
plurality of the protrusions 250. The designs 547 and 547' may also
comprise areas of the three-dimensional nonwoven material 245 that
are free of any protrusions. The protrusions 250 and 250' may both
be facing into the page, out of the page, or into and out of the
page.
[0252] FIG. 51 is an example cross-sectional view of an absorbent
article 620 have certain channel configurations that do not overlap
in the Z-direction. The distribution material 254 may have one or
more channels 326 and 326'. The absorbent core 228 may have one or
more channels 226 and 226'. The channels 326 and 326' may be free
of overlap in the Z-direction with the channels 226 and 226'.
[0253] FIG. 52 is an example cross-sectional view of an absorbent
article 720 have certain channel configurations that do not overlap
in the Z-direction. The distribution material 254 may have one or
more channels 326 and 326'. The absorbent core 228 may have one or
more channels 226 and 226'. The carrier layer 325 may have one or
more channels 327 and 327'. The channels 326 and 326' may be free
of overlap in the Z-direction with the channels 226 and 226' and
the channels 327 and 327'. In other instances, the channels may all
at least partially overlap each other in the Z-direction, but not
be completely overlapping in the Z-direction.
Indicia and/or Color
[0254] FIG. 52 will be referred to in this section to illustrate an
example absorbent article configuration that may comprise indicia
and/or color, although any of the example absorbent article
configurations illustrated herein will also be within the scope of
the present disclosure. For example, the carrier layer 325 may or
may not be provided or the carrier layer 325 may be provided under
the distribution material 254. In another example, the carrier
layer 325 and the distribution material 254 may or may not be
provided. In other instances, the topsheet 224 or the acquisition
layer 254 may be generally flat or planer, as shown in previous
figures. The carrier layer 325 may or may not have channels 327 and
327'. Also, the distribution material 254 may or may not have
channels 326 and 326'. Further, the absorbent core 228 may or may
not have channels 226 and 226'. All of the channels 327 and 327',
226 and 226', and 326 and 326', if provided, may at least partially
overlap each other in the Z-direction, may not overlap each other
in the Z-direction, and/or may fully overlap each other in the
Z-direction. In some instances, a first set of channels (e.g. 226
and 226') may overlap a second set of channels (e.g., 326 and 326')
in the Z-direction, while a third set of channels (e.g., 327 and
327') may not overlap with either of the first and second sets of
channels, for example. The core bag 360 may be in the configuration
shown in FIG. 52, in FIG. 48, or may be in any other suitable
configuration.
[0255] The term "indicia", as used herein, may comprise one or more
inks with pigments, adhesives with pigments, words, designs,
trademarks, graphics, patterns, and/or pigmented areas, for
example. Indicia is not merely a full colored or tinted layer, such
as an acquisition layer, for example. The indicia may typically be
a different color than: (1) the layer that it is printed on,
positioned on, or applied to; or (2) a different color than other
layers of an absorbent article. The phrase a "different color"
means a different shade of the same color (e.g., dark blue and
light blue) or may be completely different color (e.g., blue and
gray). The indicia should be at least partially visible from either
a wearer facing surface, a garment facing surface, or both of an
absorbent article, although the indicia may not be printed on,
positioned or, on applied to the wearer or garment facing surfaces
of the absorbent articles. The indicia may be printed on,
positioned on, or applied to protrusion areas and non-protrusion
areas, protrusion areas only, or non-protrusion areas only, for
example. The indicia may comprise a light activatable material, a
liquid activatable material, a pH activatable material, a
temperature activatable material, a menses activatable material, a
urine activatable material, a BM activatable material, and/or an
otherwise activatable material. These activatable materials may
typically undergo a chemical reaction, or other reaction, to change
the indicia from one color to a different color, from one color to
a different shade of the same color, from a color that is not
visually distinguishable or recognizable in an absorbent article to
a color that is visually distinguishable or recognizable in an
absorbent article, or from a color that is visually distinguishable
or recognizable in an absorbent article to a color that is not
visually distinguishable or recognizable in an absorbent article.
In an instance, the indicia may grow or shrink or display a
graphic/not display a graphic after the indicia undergoes the
reaction. In other instances, the indicia may be activated by a
stress or a strain during manufacture or wear. The indicia may be
white or non-white. If the indicia is white in color, at least one
layer may be non-white so that the indicia is visible from a wearer
and/or garment facing surface of the absorbent articles, for
example. The indicia may comprise embossments, fusion bonds, or
other mechanical deformations. In other instances the indicia may
at least partially overlap embossments, fusion bonds, or other
mechanical deformations. In some instances, the indicia may be
formed within either a sheath or a core of bicomponent fibers. For
example, a core may be white, while a sheath may be blue, or vice
versa.
[0256] The indicia may be on, positioned on, formed on, formed
with, printed on, or applied to all of, or part of, a certain
layer. The indicia may also be on, positioned on, formed on, formed
with, printed on, or applied to one or more layers, or on all
suitable layers of an absorbent article. The indicia may be on,
positioned on, formed on, formed with, printed on, or applied to
either side, or both sides, of the one or more layers of an
absorbent article. In some instances, suitable layers for indicia
placement comprise one or more of a topsheet, a secondary topsheet,
an acquisition material, a distribution material, a carrier layer,
a core bag, a wearer-facing side of the core bag, a garment-facing
side of the core bag, and/or an additional layer positioned at
least partially intermediate the topsheet and the wearer-facing
side of the core bag (hereafter sometimes referred to as "suitable
layers for indicia placement").
[0257] Either in addition to or separate from the indicia described
above, any one or more of the suitable layers for indicia
placement, or a portion thereof, may have a color different than
any one or more of the remaining layers for indicia placement, or a
portion thereof. The definition of the phrase "different color"
above also applies to this part of the disclosure. In some
instances, the indicia may be a different color than any one or
more of the suitable layers for indicia placement. Alternatively,
an indicia may be on one of the suitable layers for indicia
placement while another one of the remaining suitable layers for
indicia placement may be a different color than the indicia. One
example may be a blue indicia on a white carrier layer with the
acquisition layer or topsheet being teal. In another example, a
blue indicia may be on a white carrier layer with the acquisition
layer and topsheet also being white. As such, the blue indicia may
be viewable from a wearer-facing surface. In another example, a
blue indicia may be on an acquisition layer, wherein the topsheet
and the acquisition layer are nested together in the protrusions
250. In an instance where the topsheet and the acquisition layer
are nested together in the protrusions 250, the indicia may be
applied to the acquisition layer or the topsheet before or after
such nesting. In an example, two different indicia may be
positioned on the same or different layers for indicia placement.
The two different indicia may be different in color, pattern,
and/or graphic, for example. If the two different indicia are on
different layers for indicia placement, the two layers may be the
same color or different colors, or have portions that are the same
color or different colors.
[0258] In some instances, a visible color of a portion of, or all
of, the interior (wearer-facing surface) of an absorbent article
may be coordinated with and/or compliment a visible color of a
portion of, or all of, the exterior (garment-facing surface) of the
absorbent article, as described in further detail in U.S. Pat. No.
8,936,584. The indicia visible from the interior may also be
coordinated with and/or compliment the indicia visible from the
exterior of the absorbent article. In such an instance, the indicia
visible from the exterior of the absorbent article may be on the
outer cover nonwoven or the backsheet film. In still other
instances, the visible indicia and/or color from the interior may
also be coordinated with or compliment the indicia and/or color
visible from the exterior of the absorbent article.
[0259] In addition to that described above, a first portion of one
of the suitable layers for indicia placement may be a first color
and a second portion of the same of the suitable layers for indicia
placement may be a second color. The first and second colors may be
a different color. In other instances, a first portion of one of
the suitable layers for indicia placement may be a first color and
a second portion of a different one of the suitable layers for
indicia placement may be a second color. The first and second
colors may be a different color.
[0260] In an instance, in an absorbent article, one of a topsheet,
an acquisition material, a portion of a core bag, or an additional
layer (e.g., a carrier layer) may be a different color than a
different one of the topsheet, the acquisition material, the
portion of the core bag, or the additional layer. In another
instance, in an absorbent article one of a portion of a topsheet, a
portion of an acquisition material, a portion of a core bag, or a
portion of an additional layer may be a different color than a
different one of the portion of the topsheet, the portion of the
acquisition material, the portion of the core bag, or the portion
of the additional layer. In another instance, in an absorbent
article, a first portion of one of a topsheet, an acquisition
material, a core bag, or an additional layer may be a different
color as a second portion of the same one of the topsheet, the
acquisition material, the core bag, or the additional layer.
Cellulose Fibers in Some Suitable Layers for Indicia Placement
[0261] In certain instances, it may be desirable to use a carrier
layer 325 or a distribution material 254 that comprises cellulose
fibers or pulp. In some instances, the carrier layer 325 or the
distribution material 254 may comprise at least 70%, at least 80%,
at least 90%, at least 95% or more of cellulose fibers by weight of
the respective layer or material. The carrier layer or the
distribution material may comprise one or more layers comprising
the cellulose fibers. The layers may be individual layers, or a
single layer folded any suitable number of times over itself. The
carrier layer comprising the cellulosic fibers may be generally
planar or, in some instances, may be three-dimensional. The
distribution material 254 may comprise one or more generally planar
or three-dimensional layers comprising the cellulose fibers. These
three-dimensional layers comprising the cellulose fibers may be wet
formed using a papermaking process. Referring to FIGS. 53 and 54,
an example three-dimensional material or layer 720 is illustrated.
FIG. 53 is a top view of the three-dimensional layer 721 and FIG.
54 is a cross-sectional view of the three-dimensional layer 721
taken about line 54-54 of FIG. 53. The three-dimensional layer 721
may comprise a continuous network region 722 and a plurality of
discrete zones 724. The continuous network region 722 may comprise
a first average density and the plurality of discrete zones 724 may
each comprise a second average density. The plurality of discrete
zones 724 may be dispersed throughout the continuous network region
722. The first and second average densities may be different. The
three-dimensional layer or layers 721 may also comprise a wet
strength resin.
[0262] The continuous network region 722 and the plurality of
discrete zones 724 may have a common intensive property. The common
intensive property of the continuous network region 722 may have a
first value. The common intensive property of the plurality of
discrete zones 724 may have a second value. The first value may be
different than the second value. The common intensive property may
be basis weight, caliper, opacity, average density, or elevation,
for example. Such three-dimensional materials are described in
greater details, in the context of a distribution material, in U.S.
patent application Ser. No. 14/543,967 (P&G Case No. 13605Q),
Ser. No. 14/543,973 (P&G Case No. 13606Q) and Ser. No.
14/543,984 (P&G Case No. 13607Q), all filed on Nov. 18, 2014,
but could also be used in the context of a carrier layer. These
layers comprising cellulose fibers, whether three-dimensional or
not, may be colored or may comprise indicia as described
herein.
Bonding and Colored Layers
[0263] In some instances, it may be desirable to have a layer, such
as a carrier layer 325, for example, under an acquisition
layer/topsheet laminate (as described herein), where the carrier
layer 325 has a different color than the acquisition layer/topsheet
laminate. For instance, the laminate may be white and the carrier
layer may be blue. In such an instance, when the acquisition
layer/topsheet laminate are combined (as described herein)
different opacity and density zones are present within the
laminate. As such, the color of the carrier layer may be either
more visible or less visible from a wearer-facing surface in the
various zones of the laminate owing to the laminate having zones of
high and low density and high and low opacity. In an instance where
a bonded or apertured layer having a first color is positioned over
a layer having second different color, the second different color
of the layer may be more or less visible in the bonds or apertures
compared to the remainder of the layer. In other instances, the
laminate and the carrier layer may be different tones of the same
color to enhance the depth layering perception when viewing a
wearer-facing surface of an absorbent article. If a single
three-dimensional nonwoven material is used as a topsheet or an
acquisition material, the same as described above with respect to
different color layers may also be true.
Indicia
[0264] The three-dimensional nonwoven materials of the present
disclosure may have a plurality of different patterns. At least
portions of these patterns represent protrusions (e.g., like
protrusions 250 described herein) and other portions may represent
embossed areas or printed areas. Some example patterns 601 are
shown in FIGS. 55, 58, 60, 63, 65, 68, 70, and 72. These figures
may represent patterns in a topsheet, an acquisition layer, or a
topsheet/acquisition layer laminate. These patterns 601 of the
three-dimensional nonwoven materials may be combined with an
underlying layer comprising indicia, such as a pigmented adhesive
or ink, for example. Some example indicia patterns 701 are
illustrated in FIGS. 56, 59, 61, 64, 66, 69, 71, and 73. These
figures may represent an acquisition layer, a carrier layer, or
another layer intermediate a topsheet and an absorbent core. The
patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 may be
overlapped with, or at least partially overlapped with, in a
Z-direction, any of the indicia patterns 701 of FIGS. 56, 59, 61,
64, 66, 69, 71, and 73. An example of the overlapping of the
pattern 601 of FIG. 55 and the indicia pattern 701 of FIG. 56 is
illustrated in FIG. 57. An example of the overlapping of the
pattern 601 of FIG. 60 and the indicia pattern 701 of FIG. 61 is
illustrated in FIG. 62. An example of the overlapping of the
pattern 601 of FIG. 65 and the indicia pattern 701 of FIG. 66 is
illustrated in FIG. 67. Any of the patterns 601 and indicia
patterns 701 of FIGS. 58 and 59, FIGS. 63 and 64, FIGS. 68 and 69,
FIGS. 70 and 71, and FIGS. 72 and 73 may be overlapped in the same
or a similar fashion. Any of the patterns 601 of FIGS. 55, 58, 60,
63, 65, 68, 70, and 72 may also be overlapped with any of the
indicia patterns 701 of FIGS. 56, 59, 61, 64, 66, 69, 71, and
73.
[0265] As can be seen in FIGS. 57, 62, and 67, the overlapped
patterns 601 and indicia patterns 701 creates an aesthetically
pleasing portion of an absorbent article structure that provides
(1) a three dimensional topsheet, a three-dimensional acquisition
layer, or a three-dimensional topsheet/acquisition layer laminate;
(2) an impression of depth; (3) an impression of softness or
softness; (4) an impression of absorbency or absorbency; (5) an
impression that bodily exudates will be locked away; and (6) an
impression that bodily exudates will not remain in contact with the
skin. All of these factors are consumer preferred.
[0266] In addition to the patterns and indicia patterns illustrated
in FIGS. 55-73, any of the layers of an absorbent article, or
portions thereof, may have a different color than another layer of
the absorbent article to further enhance the aesthetically pleasing
look of absorbent articles.
[0267] The scale of the indicia patterns 701 may be larger than,
smaller than, or the same as, the scale of the patterns 601
depending on the desired appearance of the overlapped pattern 601
and indicia pattern 701.
Sanitary Napkin
[0268] 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, a portion of, or all of, an
acquisition layer (or secondary topsheet), or portion of, or all
of, a topsheet and acquisition layer (or secondary topsheet) nested
together. In other instances, the three-dimensional nonwoven
materials may form a strip or patch placed on the topsheet of the
sanitary napkin.
[0269] An example sanitary napkin 800 is disclosed in FIG. 74. The
sanitary napkin 800 may comprise a liquid permeable topsheet 814, a
liquid impermeable, or substantially liquid impermeable, backsheet
816, and an absorbent core 818. The absorbent core 818 may have any
or all of the features described herein with respect to the
absorbent cores 228, including one or more channels. The
acquisition layer 815 may have any or all of the features described
herein with respect to the acquisition layers 252, including one
more channels. A carrier layer (like carrier layer 325 herein) and
a distribution material (like distribution material 254 herein) may
also be optionally provided, including one or more channels in each
layer. The sanitary napkin 800 may also comprise wings 820
extending outwardly with respect to a longitudinal axis 880 of the
sanitary napkin 800. The sanitary napkin 800 may also comprise a
lateral axis 890. The wings 820 may be joined to the topsheet 814,
the backsheet 816, and/or the absorbent core 818. The sanitary
napkin 800 may also comprise a front edge 822, a rear edge 824
longitudinally opposing the front edge 822, a first side edge 826,
and a second side edge 828 longitudinally opposing the first side
edge 826. The longitudinal axis 880 may extend from a midpoint of
the front edge 822 to a midpoint of the rear edge 824. The lateral
axis 890 may extend from a midpoint of the first side edge 826 to a
midpoint of the second side edge 828. The sanitary napkin 800 may
also be provided with additional features commonly found in
sanitary napkins as is generally known in the art.
Spunbond Webs
[0270] In the case of spunbond webs, the webs may have a thermal
point bond pattern that is not highly visible to the naked eye. For
example, dense thermal point bond patterns that are equally and
uniformly spaced are typically not highly visible to the naked eye.
After the webs are processed through the mating male and female
rolls, the thermal point bond patterns may still not be highly
visible to the naked eye. Alternatively, the webs may have a
thermal point bond pattern that is highly visible to the naked eye.
For example, thermal point bonds that are arranged into a
macro-pattern, such as a diamond pattern, for example, may be
highly visible to the naked eye. After the webs are processed
through the mating male and female rolls, the thermal point bond
pattern is still highly visible to the naked eye and may provide a
secondary visible texture element to the webs.
Fiber Concentration
[0271] In an instance, the topsheet may comprise a generally planar
first region of the topsheet. The acquisition material may comprise
a generally planar first region of the acquisition material. The
three-dimensional protrusions of the respective topsheet and the
acquisition material may comprise a plurality of discrete integral
second regions. The term "generally planar" is not meant to imply
any particular flatness, smoothness, or dimensionality. Thus, the
first region of the topsheet may comprise other features that
provide the first region of the topsheet with a topography. The
first region of the acquisition material may comprise other
features that provide the first region of the acquisition material
with a topography. Such other features may comprise, but are not
limited to small protrusions, raised network regions around the
base forming an opening, and other types of features. Thus, the
first region of the topsheet and/or the first region of the
acquisition material may be generally planar when considered
relative to the respective second regions. The first region of the
topsheet and/or the first region of the acquisition material may
comprise any suitable plan view configuration. In some instances,
the first region of the topsheet and/or the first region of the
acquisition material may be in the form of a continuous
inter-connected network which comprises portions that surround each
of, or some of, the three-dimensional protrusions.
[0272] The side walls and the area around the base of the majority
of the three-dimensional protrusions may have a visibly
significantly lower concentration of fibers per given area (which
may be evidence of a lower basis weight or lower opacity) than the
portions of the topsheet and/or the acquisition material in the
unformed first region of the respective topsheet and the
acquisition material. The majority of the three-dimensional
protrusions may also have thinned fibers in the side walls. Thus,
the fibers may have a first cross-sectional area when they are in
the undeformed topsheet and the acquisition material, and a second
cross-sectional area in the side walls of the majority of the
three-dimensional protrusions of the topsheet/acquisition material
laminate, wherein the first cross-sectional area is greater than
the second cross-sectional area. The side walls may also comprise
some broken fibers. In some examples, the side walls may comprise
greater than or equal to about 10%, about 20%, about 30%,
alternatively greater than or equal to about 50%, broken
fibers.
[0273] As used herein, the term "fiber concentration" has a similar
meaning as basis weight, but fiber concentration refers to the
number of fibers/given area, rather than g/area as in basis
weight.
[0274] The topsheet/acquisition material laminate may comprise the
majority of the three-dimensional protrusions which are oriented
with the base facing upward in which the concentration of fibers at
the distal end of each respective topsheet and the acquisition
material differs between the topsheet and the acquisition
material.
[0275] The concentration of fibers in the first region of the
acquisition material and in the distal ends of the majority of the
three-dimensional protrusions may be greater than the concentration
of fibers in the side walls of the majority of the
three-dimensional protrusions in the acquisition material.
[0276] The concentration of fibers in the first region of the
topsheet and in the distal ends of the majority of the three
dimensional protrusions may be greater than the concentration of
fibers in the side walls of the majority of the three dimensional
protrusions in the topsheet.
[0277] Alternatively, the concentration of fibers in the first
region of the acquisition material may be greater than the
concentration of fibers in the side walls of the majority of the
three-dimensional protrusions in the acquisition material, and the
concentration of fibers in the side walls of the majority of the
three-dimensional protrusions in the acquisition material may be
greater than the concentration of fibers forming the distal ends of
the majority of the three-dimensional protrusions in the
acquisition material.
[0278] The concentration of fibers in the first region of the
acquisition material may be greater than the concentration of
fibers in the distal ends of the majority of the three-dimensional
protrusions in the acquisition material, and the concentration of
fibers in the first region of the topsheet and the distal ends of
the majority of the three dimensional protrusions may be greater
than the concentration of fibers in the side walls of the majority
of the three-dimensional protrusions in the topsheet.
[0279] A portion of the fibers that form the first region fibers in
the acquisition material and/or the topsheet may comprise thermal
point bonds, and the portion of the fibers in the acquisition
material and/or the topsheet forming the side walls and distal ends
of the majority of the three-dimensional protrusions may be
substantially free of thermal point bonds. In at least some of the
three-dimensional protrusions, at least some of the fibers in the
acquisition material and/or the topsheet may form a nest or circle
around the perimeter of the three-dimensional protrusion at the
transition between the side wall and the base of the
three-dimensional protrusion.
[0280] In some instances, the topsheet or the acquisition material
may have a plurality of bonds (such as thermal point bonds) therein
to hold the fibers together. Any such bonds are typically present
in the precursor materials or webs from which the respective
topsheet or the acquisition material are formed.
[0281] Forming three-dimensional protrusions in the
topsheet/acquisition material laminate may also affect the bonds
(thermal point bonds) within the topsheet and/or the acquisition
material.
[0282] The bonds within the distal end of the three-dimensional
protrusions may remain intact (not be disrupted) by the mechanical
deformation process that formed the three-dimensional protrusions.
In the side walls of the three-dimensional protrusions, however,
the bonds originally present in the precursor topsheet web and/or
the precursor acquisition material web may be disrupted. When it is
said that the bonds may be disrupted, this can take several forms.
The bonds can be broken and leave remnants of a bond. In other
instances, such as where the precursor materials of the respective
topsheet web or the acquisition material web is underbonded, the
fibers can disentangle from a lightly formed bond site (similar to
untying a bow), and the bond site may essentially disappear. In
some instances, after the mechanical deformation process, the side
walls of the majority of the three-dimensional protrusions may be
substantially free (or completely free) of thermal point bonds.
[0283] The bonds within the first region of the topsheet and the
distal end of the three-dimensional protrusions may remain intact.
In the side walls of the three-dimensional protrusions, however,
the bonds originally present in the precursor topsheet web may be
disrupted such that the side walls are substantially free of
thermal point bonds. Such a topsheet could be combined with an
acquisition material in which the concentration of fibers within
the topsheet in the first region and the distal end of the
three-dimensional protrusions is also greater than the
concentration of fibers in the side walls of the three-dimensional
protrusions.
[0284] The acquisition material may have thermal point bonds within
the first region of the acquisition material and the distal end of
the three-dimensional protrusions that remain intact. In the side
walls of the three-dimensional protrusions, however, the bonds
originally present in the precursor acquisition material web
comprising the acquisition material may be disrupted such that the
side walls of the acquisition layer are substantially free of
thermal point bonds.
Packages
[0285] The absorbent articles of the present disclosure comprising
the three-dimensional nonwoven material and certain channels
configurations 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.
[0286] 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.
[0287] FIG. 75 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
[0288] 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
[0289] 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
[0290] 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
[0291] 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.
[0292] 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:
[0293] A. Accelerated Compression Method. [0294] 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. [0295] 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. [0296] 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. [0297] 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). [0298]
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. [0299] 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. [0300] 7. Let the samples rest at 23.+-.2.degree. C. and
at 50.+-.2% relative humidity for 24 hours without any weight on
them. [0301] 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. [0302] 9. If desired, an average of the 10
specimens can be calculated for the pre-compression,
post-compression and post-recovery calipers.
[0303] B. Tensile Method
[0304] 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.
[0305] C. In-Bag Stack Height Test
[0306] The in-bag stack height of a package of the absorbent
articles of the present disclosure is determined as follows:
[0307] Equipment
[0308] 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
[0309] Absorbent article packages are equilibrated at
23.+-.2.degree. C. and 50.+-.5% relative humidity prior to
measurement.
[0310] 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. 75). 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.
[0311] 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.".
[0312] 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.
[0313] 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.
[0314] 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.
* * * * *