U.S. patent application number 14/933034 was filed with the patent office on 2016-05-19 for absorbent articles comprising garment-facing laminates.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Kelyn Anne ARORA, Amanda Margaret BICKING, Jennifer Lynn DUSOLD, Sara Lyn GIOVANNI, Timothy Ian MULLANE, Jill Marlene ORR, Margaret Elizabeth PORTER, Donald Carroll ROE, Jennifer SCHUTTE, John Brian STRUBE, Ann Cecilia TAPP, Rachael Eden WALTHER.
Application Number | 20160136010 14/933034 |
Document ID | / |
Family ID | 54541245 |
Filed Date | 2016-05-19 |
United States Patent
Application |
20160136010 |
Kind Code |
A1 |
ROE; Donald Carroll ; et
al. |
May 19, 2016 |
ABSORBENT ARTICLES COMPRISING GARMENT-FACING LAMINATES
Abstract
An absorbent article is provided. The absorbent article
comprises a liquid permeable topsheet on a wearer-facing side of
the absorbent article and a garment-facing laminate on a
garment-facing side of the absorbent article. The garment-facing
laminate comprises a first nonwoven layer and a second layer joined
to the first nonwoven layer. The first nonwoven layer comprises a
plurality of apertures. At least 3 of the plurality of apertures in
a repeat unit have a different Effective Aperture Area, according
to the Aperture Test herein, a different shape, or a different
Absolute Feret Angle, according to the Aperture Test herein. The
absorbent article comprises an absorbent core disposed at least
partially intermediate the liquid permeable topsheet and the
garment-facing laminate.
Inventors: |
ROE; Donald Carroll; (West
Chester, OH) ; GIOVANNI; Sara Lyn; (Cincinnati,
OH) ; ARORA; Kelyn Anne; (Cincinnati, OH) ;
MULLANE; Timothy Ian; (Union, KY) ; ORR; Jill
Marlene; (Liberty Township, OH) ; SCHUTTE;
Jennifer; (CIncinnati, OH) ; STRUBE; John Brian;
(Okeana, OH) ; TAPP; Ann Cecilia; (West Chester,
OH) ; WALTHER; Rachael Eden; (Union, KY) ;
BICKING; Amanda Margaret; (Cincinnati, OH) ; DUSOLD;
Jennifer Lynn; (Cincinnati, OH) ; PORTER; Margaret
Elizabeth; (Cincinnati, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
54541245 |
Appl. No.: |
14/933034 |
Filed: |
November 5, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62076043 |
Nov 6, 2014 |
|
|
|
62177405 |
Mar 13, 2015 |
|
|
|
Current U.S.
Class: |
604/365 ;
206/526; 604/383; 604/385.01 |
Current CPC
Class: |
A61F 13/51104 20130101;
Y10T 428/24612 20150115; A61F 13/51394 20130101; A61F 2013/51092
20130101; D10B 2509/026 20130101; A61F 13/5123 20130101; Y10T
442/66 20150401; B32B 2307/726 20130101; Y10T 428/24826 20150115;
A61F 2013/51182 20130101; A61F 2013/51377 20130101; B32B 2250/20
20130101; D04H 3/14 20130101; B32B 7/05 20190101; Y10T 428/24322
20150115; A61F 2013/51078 20130101; A61F 2013/8497 20130101; Y10T
428/24314 20150115; A61F 13/515 20130101; Y10T 428/24793 20150115;
Y10T 442/60 20150401; A61F 2013/51147 20130101; A61F 2013/51178
20130101; D04H 1/56 20130101; A61F 13/511 20130101; B32B 5/022
20130101; D04H 3/147 20130101; B32B 3/26 20130101; A61F 13/51476
20130101; A61F 2013/51186 20130101; B32B 3/30 20130101; B32B 5/26
20130101; B32B 2250/03 20130101; B32B 2250/04 20130101; A61F 13/512
20130101; A61F 2013/51165 20130101; A61F 13/51484 20130101; A61F
2013/5128 20130101; B32B 2250/242 20130101; A61F 13/51478 20130101;
B32B 3/06 20130101; A61F 2013/51322 20130101; A61F 13/551 20130101;
B44F 99/00 20130101; B32B 2555/02 20130101; B32B 3/266 20130101;
B32B 2555/00 20130101; A61F 2013/5127 20130101; B32B 5/142
20130101; A61F 13/51121 20130101; A61F 13/5126 20130101; A61F
13/51305 20130101; Y10T 428/24331 20150115; A61F 2013/51486
20130101; A61F 13/15699 20130101; A61F 2013/15715 20130101; A61F
13/5116 20130101 |
International
Class: |
A61F 13/514 20060101
A61F013/514; A61F 13/551 20060101 A61F013/551; A61F 13/515 20060101
A61F013/515 |
Claims
1. An absorbent article comprising: a liquid permeable topsheet on
a wearer-facing side of the absorbent article; a garment-facing
laminate on a garment-facing side of the absorbent article, the
garment-facing laminate comprising: a first nonwoven layer; and a
second layer joined to the first nonwoven layer, wherein the first
nonwoven layer comprises a plurality of apertures, wherein at least
3 of the plurality of apertures in a repeat unit have a different
Effective Aperture Area, according to the Aperture Test herein, a
different shape, or a different Absolute Feret Angle, according to
the Aperture Test herein; and an absorbent core is disposed at
least partially intermediate the liquid permeable topsheet and the
garment-facing laminate.
2. The absorbent article of claim 1, wherein the first nonwoven
layer or the second layer is pre-strained prior to the joining of
the first nonwoven layer to the second layer.
3. The absorbent article of claim 1, wherein the second layer is a
nonwoven layer.
4. The absorbent article of claim 3, wherein the second layer forms
an outermost layer of the garment-facing laminate.
5. The absorbent article of claim 1, wherein the second layer is a
liquid impervious backsheet film.
6. The absorbent article of claim 1, wherein the at least 3 of the
plurality of apertures are non-homogeneous apertures within the
repeat unit.
7. The absorbent article of claim 1, wherein the first nonwoven
layer is joined to the second layer by a pattern of mechanical or
adhesive bonds.
8. The absorbent article of claim 1, wherein the at least 3 of the
plurality of apertures have two of a different Effective Aperture
Area, according to the Aperture Test herein, a different shape, or
a different Absolute Feret Angle, according to the Aperture Test
herein.
9. The absorbent article of claim 1, wherein the first nonwoven
layer is joined to the second layer by a patterned adhesive.
10. The absorbent article of claim 9, wherein the patterned
adhesive has a first color, and wherein the first nonwoven layer or
the second layer has a second, different color.
11. The absorbent article of claim 1, wherein the first nonwoven
layer or the second layer comprises an indicia.
12. The absorbent article of claim 11, wherein the indicia has a
first color, and wherein the first nonwoven layer or the second
layer has a second, different color.
13. The absorbent article of claim 1, wherein the plurality of
apertures are at least partially in a waist region or a hip region
of the absorbent article.
14. The absorbent article of claim 1, wherein the plurality of
apertures have a first pattern in a first area, and wherein the
plurality of apertures have a second, different pattern in a
second, different area.
15. The absorbent article of claim 14, wherein the first area
comprises one or more of a waist region, a hip region, a crotch
region, a front region, a back region, and a buttocks region, and
wherein the second area comprises a different one or more of the
waist region, the crotch region, the front region, the back region,
and the buttocks region.
16. The absorbent article of claim 14, wherein the first pattern
differs from the second, different pattern in Effective Aperture
Area, according to the Aperture Test herein, and aperture
shape.
17. The absorbent article of claim 14, wherein the first pattern
differs from the second, different pattern in Effective Aperture
Area and Aperture Density, both according to the Aperture Test
herein.
18. An absorbent article comprising: a liquid permeable topsheet on
a wearer-facing side of the absorbent article; a garment-facing
laminate on a garment-facing side of the absorbent article, the
garment-facing laminate comprising: a first nonwoven layer; and a
second layer joined to the first nonwoven layer when the first
nonwoven layer or the second layer is in a pre-strained condition
and when the other of the first nonwoven layer or the second layer
is in a non-pre-strained condition to form a three-dimensional
material; wherein the first nonwoven layer comprises a plurality of
apertures; and an absorbent core is disposed at least partially
intermediate the liquid permeable topsheet and the garment-facing
laminate.
19. The absorbent article of claim 18, wherein at least 5 of the
plurality of apertures are non-homogeneous apertures.
20. The absorbent article of claim 18, wherein the second layer
comprises a liquid impermeable backsheet.
21. An absorbent article comprising: a liquid permeable topsheet on
a wearer-facing side of the absorbent article; a garment-facing
layer on a garment-facing side of the absorbent article, the
garment-facing layer comprising: a first zone comprising a
plurality of overbonds; and a second zone comprising a plurality of
apertures; wherein at least 3 of the plurality of apertures in a
repeat unit have a different Effective Aperture Area, according to
the Aperture Test herein, a different shape, or a different
Absolute Feret Angle, according to the Aperture Test herein; a
liquid impermeable backsheet; and an absorbent core is disposed at
least partially intermediate the liquid permeable topsheet and the
backsheet.
22. The absorbent article of claim 21, wherein the second zone at
least partially forms a waist region of the absorbent article, and
wherein the first zone at least partially forms a crotch region of
the absorbent article.
23. A package comprising a plurality of absorbent articles of claim
21, wherein the package has an In-Bag Stack Height in the range of
about 70 mm to about 105 mm, according to the In-Bag Stack Height
Test herein.
24. An absorbent article comprising: a liquid permeable topsheet on
a wearer-facing side of the absorbent article; a garment-facing
laminate on a garment-facing side of the absorbent article, the
garment-facing laminate comprising: a first nonwoven layer; and a
second nonwoven layer joined to the first nonwoven layer, wherein
the first nonwoven layer comprises a plurality of apertures; and an
absorbent core is disposed at least partially intermediate the
liquid permeable topsheet and the garment-facing laminate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application Ser. No.
62/076,043, filed on Nov. 6, 2014, and 62/177,405, filed on Mar.
13, 2015, the entire disclosures of which are hereby incorporated
by reference.
FIELD
[0002] The present disclosure generally relates to webs, apertured
webs, patterned apertured webs, zonal patterned apertured webs,
laminates, pre-strained laminates, moire effect laminates, and
methods for making the same. The webs, apertured webs, patterned
apertured webs, zonal patterned apertured webs, laminates,
pre-strained laminates, and moire effect laminates are particularly
suited for use in disposable absorbent articles, such as diapers,
adult incontinence products, training pants, feminine hygiene
products, wipes, dusting substrates, cleaning substrates, and any
other suitable consumer products or other products.
BACKGROUND
[0003] Apertured webs are sometimes useful in disposable absorbent
products and other consumer products. These apertured webs
typically have uniformly sized and shaped circular or ovate
apertures throughout their area. The circular or ovate apertures
may be uniformly spaced in the cross-machine direction and in the
machine direction with respect to each other. These uniform
aperture patterns provide webs that have the same amount of fluid
penetration and/or absorbency throughout their area owing to the
uniform circular or ovate aperture designs. Furthermore, land areas
(i.e., non-apertured portions) in these apertured webs typically
have the same size, shape, orientation, and spacing with respect to
each other. While such uniform apertured webs may be desirable in
some applications, other applications would benefit from improved
apertured webs. Furthermore, these apertured webs are typically
planar, but some consumers may desire three-dimensional features
and other features.
SUMMARY
[0004] The patterned apertured webs of the present disclosure
provide patterns of nonhomogeneous apertures that have different
sizes, shapes, and/or Absolute Feret Angles. This allows the webs
to have better depth perception, improved fluid handling
properties, and/or aesthetically pleasing appearances relative to
apertured webs that have uniformly sized and shaped, homogeneous
apertures. Laminates having at least one pre-strained layer of the
present disclosure, whether comprising patterned apertured webs,
apertured webs, or not, provide three-dimensional features in the
laminates, thereby providing consumer preferred executions that, in
one example, may keep bodily exudates away from the skin of a
wearer or user. Moire effect laminates may also be provided. Outer
covers, and other components of absorbent articles also benefit
from these patterned apertured webs, pre-strained laminates, moire
effect laminates, and other non-pre-strained laminates of the
present disclosure. Methods of making the patterned apertured webs,
moire effect laminates, and pre-strained or non-pre-strained
laminates are also provided.
[0005] In a form, the present disclosure is directed, in part, to a
patterned apertured web. The patterned apertured web comprises a
plurality of land areas in the patterned apertured web and a
plurality of apertures defined in the patterned apertured web. At
least some of the land areas surround at least some of the
apertures. The patterned apertured web has an Effective Open Area
in the range of about 5% to about 50%, according to the Aperture
Test herein. The patterned apertured web has a plurality of
Interaperture Distances, according to the Aperture Test herein. The
Interaperture Distances have a distribution having a median and a
mean, wherein the mean is greater than the median.
[0006] In a form, the present disclosure is directed, in part, to a
patterned apertured web. The patterned apertured web comprises a
plurality of land areas in the patterned apertured web. At least
some of the land areas have a width of at least 5 mm. The patterned
apertured web comprises a plurality of apertures defined in the
patterned apertured web. At least some of the land areas surround
at least some of the plurality of apertures. The plurality of
apertures are non-homogeneous in a repeat unit such that at least
three of the apertures have a different size, a different shape, or
a different Absolute Feret Angle, according to the Aperture Test
herein. The plurality of the apertures have an Effective Aperture
Area in a range of about 0.3 mm.sup.2 to about 15 mm.sup.2,
according to the Aperture Test herein. The patterned apertured web
has an Effective Open Area in a range of about 5% to about 50%,
according to the Aperture Test herein.
[0007] In a form, the present disclosure is directed, in part, to a
patterned apertured web. The patterned apertured web comprises a
plurality of land areas in the patterned apertured web and a
plurality of apertures defined in the patterned apertured web,
wherein at least some of land areas surround at least some of the
apertures. The plurality of apertures are non-homogeneous in a
repeat unit such that at least three of the apertures have a
different size or a different shape. The patterned apertured web
has an Effective Open Area in the range of about 5% to about 50%,
according to the Aperture Test herein.
[0008] In a form, the present disclosure is directed, in part, to a
patterned apertured web comprising a plurality of first arrays
forming a first zone in the patterned apertured web. At least some
of the first arrays comprise a first plurality of land areas and a
first plurality of apertures. At least some of the first plurality
of land areas surround at least some of the first plurality of
apertures. The first plurality of apertures in the first zone have
a plurality of Interaperture Distances, according to the Aperture
Test herein. The Interaperture Distances of the first zone have a
first distribution having a first mean and a first median. The
first mean is greater than the first median by at least 4%. The
first arrays comprise an Effective Open Area in the range of about
5% to about 50%, according to the Aperture Test herein. The
patterned apertured web comprises a plurality of second, different
arrays forming a second zone. At least some of the second arrays
comprise a second plurality of land areas and a second plurality of
apertures. At least some of the second land areas surround at least
some of the second plurality of apertures. The second plurality of
apertures in the second zone have a plurality of Interaperture
Distances, according to the Aperture Test herein. The Interaperture
Distances of the second zone have a second distribution having a
second mean and a second median. The second mean is greater than
the second median. The second arrays comprise an Effective Open
Area of about 5% to about 50%, according to the Aperture Test
herein.
[0009] In a form, the present disclosure is directed, in part, to a
patterned apertured web. The patterned apertured web comprises a
plurality of first arrays forming a first zone in the patterned
apertured web. At least some of the first arrays comprise a first
plurality of land areas and a first plurality of non-homogeneous
apertures. At least some of the first plurality of land areas
surround at least some of the first plurality of apertures. The
first plurality of apertures have an Average Absolute Feret Angle
of greater than about 20 degrees, according to the Aperture Test
herein. The first arrays comprise an Effective Open Area in the
range of about 5% to about 50%, according to the Aperture Test
herein. The patterned apertured web comprises a plurality of
second, different arrays forming a second zone in the patterned
aperture web. At least some of the second arrays comprise a second
plurality of land areas and a second plurality of non-homogeneous
apertures. At least some of the second plurality of land areas
surround at least some of the second plurality of apertures. The
second arrays comprise an Effective Open Area of about 5% to about
50%, according to the Aperture Test herein.
[0010] In a form, the present disclosure is directed, in part, to a
patterned apertured web. The patterned apertured web comprises a
layer comprising a plurality of apertures and a plurality of land
areas. The plurality of apertures comprise a first set of apertures
in a first zone and a second set of apertures in a second zone. The
first set of apertures in the first zone have Interaperture
Distances, according to the Aperture Test herein. Interaperture
Distances of the first set of apertures have a first distribution
having a first mean and a first median. The first mean is different
than the first median. The second set of apertures in the second
zone have Interaperture Distances, according to the Aperture Test
herein. The Interaperture Distances of the second set of apertures
have a second distribution having a second mean and a second
median. The second mean is different than the second median. The
first and second sets of apertures have different patterns.
[0011] In a form, the present disclosure is directed, in part, to a
laminate. The laminate comprises a first layer comprising a
plurality of lower opacity zones positioned within a higher opacity
zone. The plurality of lower opacity zones form a first pattern.
The laminate comprises a second layer comprising a second pattern.
The first layer is intermittently joined to the second layer to
form the laminate. The laminate comprises a non-joined span of the
first and second layers having a dimension of at least about 20 mm.
A first portion of the second pattern is visible through at least
some of the plurality of lower opacity zones when the first layer,
within the non-joined span, is in a first position relative to the
second layer, within the non-joined span. A second portion of the
second pattern is visible through at least some of the plurality of
lower opacity zones when the first layer, within the non-joined
span, is in a second position relative to the first layer, within
the non-joined span.
[0012] In a form, the present disclosure is directed, in part, to
an absorbent article comprising a laminate. The laminate comprises
a first nonwoven layer comprising a plurality of lower opacity
zones positioned within a higher opacity zone. The plurality of
lower opacity zones form a first pattern. The laminate comprises a
second layer comprising a second pattern. The first layer is
intermittently joined to the second layer to form the laminate. The
laminate comprises a non-joined span of the first and second layers
having a dimension of at least about 20 mm. A first portion of the
second pattern is visible through at least some of the plurality of
lower opacity zones when the first layer, within the non-joined
span, is in a first position relative to the second layer, within
the non-joined span. A second portion of the second pattern is
visible through at least some of the plurality of lower opacity
zones when the first layer, within the non-joined span, is in a
second position relative to the first layer, within the non-joined
span.
[0013] In a form, the present disclosure is directed, in part, to
an absorbent article comprising a laminate. The laminate comprises
a first nonwoven layer comprising a plurality of apertures in a
first pattern and a second layer comprising a second, different
pattern. The first layer is intermittently joined to the second
layer to form the laminate. The laminate comprises a non-joined
span of the first and second layers having a dimension of at least
about 30 mm. A first portion of the second pattern is visible
through at least some of the plurality of apertures when the first
layer, within the non-joined span, is in a first position relative
to the second layer, within the non-joined span. A second portion
of the second pattern is visible through at least some of the
plurality of apertures when the first layer, within the non-joined
span, is in a second position relative to the first layer, within
the non-joined span.
[0014] In a form, the present disclosure is directed, in part, to a
method of producing a patterned apertured web. The method comprises
providing a web having a central longitudinal axis. The web
comprises a plurality of overbonds extending substantially parallel
to the central longitudinal axis. The method comprises conveying
the web in a machine direction that is substantially parallel to a
direction of extension of the central longitudinal axis of the web.
The method comprises stretching the web in a cross-machine
direction that is substantially perpendicular to the machine
direction to cause at least some of the overbonds to at least
partially rupture and at least partially form patterned apertures
in the web. At least some of the patterned apertures have Absolute
Feret Angles, according to the Aperture Test herein, of at least
about 20 degrees. At least some of the patterned apertures have an
Aspect Ratio, according to the Aperture Test herein, in the range
of about 2:1 to about 6:1.
[0015] In a form, the present disclosure is directed, in part, to a
method of forming patterned apertures in a web. The method
comprises providing a web having a central longitudinal axis,
conveying the web in a machine direction that is substantially
parallel to the central longitudinal axis, and creating a plurality
of overbonds in the web. The overbonds have central longitudinal
axes that are substantially parallel to the central longitudinal
axis of the web. The method comprises stretching the web in a
cross-machine direction that is substantially perpendicular to the
machine direction to at least partially form patterned apertures in
the web at, at least some of the overbonds. At least some of the
patterned apertures have Absolute Feret Angles, according to the
Aperture Test herein, of at least about 20 degrees. The at least
some of the patterned apertures have an Aspect Ratio, according to
the Aperture Test herein, of greater than about 2:1.
[0016] In a form, the present disclosure is directed, in part, to a
method of producing a patterned apertured web. The method comprises
providing a web having a central longitudinal axis. The web
comprises a plurality of overbonds extending substantially parallel
to the central longitudinal axis. The method comprises conveying
the web in a machine direction that is substantially parallel to a
direction of extension of the central longitudinal axis of the web.
The method comprises stretching the web in a cross-machine
direction that is substantially perpendicular to the machine
direction to cause at least some of the overbonds to at least
partially rupture and at least partially form patterned apertures
in the web. At least some of the patterned apertures have Absolute
Feret Angles, according to the Aperture Test herein, that are at
least about 25 degrees. At least some of the patterned apertures
have an Aspect Ratio, according to the Aperture Test herein, in the
range of about 2:1 to about 6:1. At least three of the apertures
are nonhomogeneous.
[0017] In a form, the present disclosure is directed, in part, to a
laminate comprising a first nonwoven layer comprising a plurality
of apertures and a second nonwoven layer. One of the first and
second nonwoven layers is a pre-strained layer and is joined to the
other one of the first and second nonwoven layers. The other one of
the first and second nonwoven layers is a non-pre-strained layer.
The pre-strained layer and the non-pre-strained layer together form
a three-dimensional laminate.
[0018] In a form, the present disclosure is directed, in part, to a
laminate comprising a first nonwoven layer comprising a patterned
apertured web comprising a plurality of apertures and a second
nonwoven layer. One of the first and second nonwoven layers is a
pre-strained layer and is joined to the other one of the first and
second nonwoven layers. The other one of the first and second
nonwoven layers is a non-pre-strained layer. The pre-strained layer
and the non-pre-strained layer together form a three-dimensional
laminate. The plurality of apertures have Interaperture Distances,
according to the Aperture Test herein. The Interaperture Distances
have a distribution having a mean and a median, wherein the mean is
greater than the median.
[0019] In a form, the present disclosure is directed, in part, to a
laminate comprising a first nonwoven layer comprising a patterned
apertured web comprising plurality of apertures and a second
nonwoven layer. One of the first and second nonwoven layers is a
pre-strained layer and is joined to the other one of the first and
second nonwoven layers. The other one of the first and second
nonwoven layers is a non-pre-strained layer. The pre-strained layer
and the non-pre-strained layer together form a three-dimensional
laminate. The first nonwoven layer or the second nonwoven layer
comprises an indicia or a patterned adhesive that has a different
color than the first nonwoven layer or the second nonwoven layer.
The plurality of apertures have Interaperture Distances, according
to the Aperture Test herein. The Interaperture Distances have a
distribution having a mean and a median. The mean is greater than
the median. The laminate is free of any elastic strands or elastic
films.
[0020] In a form, the present disclosure is directed, in part, to
an absorbent article. The absorbent article comprises a liquid
permeable topsheet on a wearer-facing side of the absorbent
article, a garment-facing laminate on a garment-facing side of the
absorbent article. The garment-facing laminate comprises a first
nonwoven layer and a second layer joined to the first nonwoven
layer. The first nonwoven layer comprises a plurality of apertures.
At least 3 of the plurality of apertures in a repeat unit have a
different size, a different shape, or a different Absolute Feret
Angle, according to the Aperture Test herein. The absorbent article
comprises an absorbent core disposed at least partially
intermediate the liquid permeable topsheet and the garment-facing
laminate.
[0021] In a form, the present disclosure is directed, in part, to
an absorbent article. The absorbent article comprises a liquid
permeable topsheet on a wearer-facing side of the absorbent article
and a garment-facing laminate on a garment-facing side of the
absorbent article. The garment-facing laminate comprises a first
nonwoven layer and a second layer joined to the first nonwoven
layer when the first nonwoven layer or the second layer is in a
pre-strained condition and when the other of the first nonwoven
layer or the second layer is in a non-pre-strained condition to
form a three-dimensional material. The first nonwoven layer
comprises a plurality of apertures. The absorbent article comprises
an absorbent core disposed at least partially intermediate the
liquid permeable topsheet and the garment-facing laminate.
[0022] In a form, the present disclosure is directed, in part, to
an absorbent article. The absorbent article comprises a liquid
permeable topsheet on a wearer-facing side of the absorbent article
and a garment-facing layer on a garment-facing side of the
absorbent article. The garment-facing layer comprises a first zone
comprising a plurality of overbonds and a second zone comprising a
plurality of apertures. At least 3 of the plurality of apertures in
a repeat unit have a different size, a different shape, or a
different Absolute Feret Angle, according to the Aperture Test
herein. The absorbent article comprises a liquid impermeable
backsheet and an absorbent core disposed at least partially
intermediate the liquid permeable topsheet and the backsheet.
[0023] In a form, the present disclosure is directed, in part, to
an absorbent article. The absorbent article comprises a liquid
permeable topsheet on a wearer-facing side of the absorbent article
and a garment-facing laminate on a garment-facing side of the
absorbent article. The garment-facing laminate comprises a first
nonwoven layer and a second nonwoven layer joined to the first
nonwoven layer. The first nonwoven layer comprises a plurality of
apertures. The absorbent article comprises an absorbent core
disposed at least partially intermediate the liquid permeable
topsheet and the garment-facing laminate.
[0024] In a form, the present disclosure is directed, in part, to a
method of forming a three-dimensional laminate for an absorbent
article. The method comprises providing a first nonwoven layer,
providing a second nonwoven layer, and applying a pre-strain force
to the first nonwoven layer or to the second nonwoven layer. The
method comprises joining the first nonwoven layer to the second
nonwoven layer while the first nonwoven layer or the second
nonwoven layer is in a pre-strained condition, and releasing the
pre-strain force to form the three-dimensional laminate.
[0025] In a form, the present disclosure is directed, in part, to a
method of forming a three-dimensional laminate for an absorbent
article. The method comprises providing a first layer, providing a
separate, second layer, and applying a pre-strain force to the
first layer or to the second layer. The method comprises
overbonding the first layer and the second layer while the first
layer or the second layer is in a pre-strained condition to join
the first layer and the second layer, and releasing the pre-strain
force to form the three-dimensional laminate.
[0026] In a form, the present disclosure is directed, in part, to a
method of forming a three-dimensional laminate for an absorbent
article. The method comprises providing a nonwoven first layer,
providing a separate, nonwoven second layer, and applying a
pre-strain force substantially in the machine direction to the
first nonwoven layer or to the second nonwoven layer. The method
comprises overbonding the first layer and the second layer while
the first layer or the second layer is in a pre-strained condition
to join the first layer and the second layer. The method comprises
stretching the first and second nonwoven layers in a substantially
cross-machine direction to cause at least some of the overbonds to
at least partially rupture and at least partially form apertures in
the first and second nonwoven layers, and releasing the pre-strain
force to form the three-dimensional laminate. The three-dimensional
laminate is free of elastic strands or elastic films.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] While the specification concludes with claims particularly
pointing out and distinctly claiming the subject matter which is
regarded as forming the present invention, it is believed that the
invention will be better understood from the following description
which is taken in conjunction with the accompanying drawings in
which the designations are used to designate substantially
identical elements and in which:
[0028] FIGS. 1-4 are photographs of portions of example patterned
apertured webs in accordance with the present disclosure;
[0029] FIG. 5 is a schematic representation of a cross-sectional
view of a patterned apertured web having two layers, with one layer
having patterned apertures and the other layer being non-apertured
in accordance with the present disclosure;
[0030] FIG. 6 is a schematic representation of a cross-sectional
view of a patterned apertured web having two layers, with both
layers having patterned apertures and with the apertures in the
layers being aligned in accordance with the present disclosure;
[0031] FIG. 7 is a schematic representation of a cross-sectional
view of a patterned apertured web having two layers, with both
layers having patterned apertures and with the apertures in one
layer being fully overlapped by land areas in the other layer in
accordance with the present disclosure;
[0032] FIG. 8 is a schematic representation of a cross-sectional
view of a patterned apertured web having two layers, with both
layers having patterned apertures and with the apertures in one
layer being partially overlapped by land areas in the other layer
in accordance with the present disclosure;
[0033] FIG. 9 is a schematic representation of a cross-sectional
view of a patterned apertured web having two layers, with a first
patterned apertured layer and a second non-apertured layer and with
printing or ink on one of the layers in accordance with the present
disclosure;
[0034] FIG. 10 is a schematic representation of a cross-sectional
view of a patterned apertured web having two layers, with a first
patterned apertured layer and a second non-apertured layer and with
a colored adhesive on one of the layers or positioned intermediate
the layers in accordance with the present disclosure;
[0035] FIGS. 11-15 are example patterned apertured webs in
accordance with the present disclosure;
[0036] FIG. 16 is a schematic representation of an example method
for producing the patterned apertured webs of the present
disclosure in accordance with the present disclosure;
[0037] FIG. 17 is a perspective view of a web weakening arrangement
of FIG. 16 in accordance with the present disclosure;
[0038] FIG. 18 is a photograph of an example roller that can be
used as roller 110 in the weakening arrangement of FIG. 17 in
accordance with the present disclosure;
[0039] FIGS. 19-23 are example overbond patterns for roller 110 of
FIG. 17 used to produce patterned apertured webs in accordance with
the present disclosure;
[0040] FIG. 24 is a perspective view of an incremental stretching
system of the method of FIG. 16 in accordance with the present
disclosure;
[0041] FIG. 25 is an enlarged view showing the details of teeth of
the incremental stretching system of FIG. 24 in accordance with the
present disclosure;
[0042] FIG. 26 is a perspective view of an example cross machine
directional tensioning apparatus of the method of FIG. 16 in
accordance with the present disclosure;
[0043] FIG. 27 is a schematic representation of a front view of an
example cross machine directional tensioning apparatus with outer
longitudinal portions in an unexpanded and non-angled position
relative to a middle portion in accordance with the present
disclosure;
[0044] FIG. 28 is a schematic representation of a front view of the
cross machine directional tensioning apparatus of FIG. 27 with the
outer longitudinal portions in a longitudinally expanded position
relative to the middle portion in accordance with the present
disclosure;
[0045] FIG. 29 is a schematic representation of a front view of the
cross machine directional tensioning apparatus of FIG. 27 with the
outer longitudinal portions in an angled and expanded position
relative to the middle portion in accordance with the present
disclosure;
[0046] FIG. 30 is a schematic representation of a front view of a
cross machine directional tensioning apparatus with outer
longitudinal portions fixed in an angled position relative to a
middle portion in accordance with the present disclosure;
[0047] FIG. 31 is an example overbond pattern for the roller 110 of
FIG. 17 in accordance with the present disclosure;
[0048] FIG. 32 is a photograph of an example patterned apertured
web produced using the overbond pattern of FIG. 31 and having been
subjected to a 25% cross directional stretch using the equipment
illustrated in FIG. 26 in accordance with the present
disclosure;
[0049] FIG. 33 is a photograph of an example patterned apertured
web produced using the overbond pattern of FIG. 31 and having been
subjected to a 35% cross directional stretch using the equipment
illustrated in FIG. 26 in accordance with the present
disclosure;
[0050] FIG. 34 is a photograph of an example patterned apertured
web produced using the overbond pattern of FIG. 31 and having been
subjected to a 45% cross directional stretch using the equipment
illustrated in FIG. 26 in accordance with the present
disclosure;
[0051] FIG. 35 is a photograph of an example patterned apertured
web produced using the overbond pattern of FIG. 31 and having been
subjected to a 55% cross directional stretch using the equipment
illustrated in FIG. 26 in accordance with the present
disclosure;
[0052] FIG. 36 is a plan view of an example disposable absorbent
article having portions cut away to reveal underlying structure
that may comprise one or more patterned apertured webs, the inner
surface of the absorbent article is facing the viewer, in
accordance with the present disclosure;
[0053] FIG. 37 is a top view of an example absorbent core of an
absorbent article with some layers partially removed, wherein the
absorbent core comprises one or more channels in accordance with
the present disclosure;
[0054] FIG. 38 is a cross-sectional view of the absorbent core
taken about line 38-38 of FIG. 37 in accordance with the present
disclosure;
[0055] FIG. 39 is a cross-sectional view of the absorbent core
taken about line 39-39 of FIG. 37 in accordance with the present
disclosure;
[0056] FIG. 40 is a top view of an absorbent article of the present
disclosure, having portions cut away to reveal underlying
structure, that is a sanitary napkin in accordance with the present
disclosure;
[0057] FIG. 41 is a top view of a patterned adhesive applied to a
substrate in accordance with the present disclosure;
[0058] FIG. 42 is a top view of another patterned adhesive applied
to a substrate in accordance with the present disclosure;
[0059] FIGS. 43-52 represent schematic illustrations of patterned
apertures and land area in various patterned apertured webs, with
the apertures being the black portions and the land areas being the
white portions, in accordance with the present disclosure;
[0060] FIG. 53 represents a schematic illustration of an example
overbond pattern having overbonds with central longitudinal axes
that are substantially parallel to a machine direction in
accordance with the present disclosure;
[0061] FIG. 53A is a photograph of a patterned apertured web
produced using an overbond roll having the overbond pattern of FIG.
53 in according with the present disclosure;
[0062] FIG. 54 is a photograph of a portion of a patterned
apertured web comprising fused or melted portions surrounding the
apertures in accordance with the present disclosure;
[0063] FIGS. 55-60 illustrate schematic illustrations of example
overbond roller patterns used to create patterns of overbonds in
webs in accordance with the present disclosure;
[0064] FIG. 61 is a schematic illustration of a patterned apertured
web with one of the layers being pre-strained prior to being joined
to at least one of the other layers in accordance with the present
disclosure;
[0065] FIG. 62 is a photograph of a portion of a patterned
apertured web with at least one of the layers being pre-strained
prior to being joined to at least one of the other layers in
accordance with the present disclosure;
[0066] FIG. 63 is a cross-sectional view of a patterned apertured
web with at least one of the layers being pre-strained prior to
being joined to at least one of the other layers in accordance with
the present disclosure;
[0067] FIG. 64 is a photograph of an overbonded web free of any
pre-strained layers in accordance with the present disclosure;
[0068] FIG. 65 is a photograph of the overbonded web of FIG. 64
with a pre-strained layer in accordance with the present
disclosure;
[0069] FIG. 66 is a photograph of an overbonded web free of any
pre-strained layers in accordance with the present disclosure;
[0070] FIG. 67 is a photograph of the overbonded web of FIG. 66
with a pre-strained layer in accordance with the present
disclosure;
[0071] FIG. 68 is a photograph of a patterned apertured web free of
any pre-strained layers in accordance with the present
disclosure;
[0072] FIG. 69 is a photograph of the patterned apertured web of
FIG. 68 with a pre-strained layer in accordance with the present
disclosure;
[0073] FIG. 70 is a photograph of a patterned apertured web free of
any pre-strained layers in accordance with the present
disclosure;
[0074] FIG. 71 is a photograph of the patterned apertured web of
FIG. 70 with a pre-strained layer in accordance with the present
disclosure;
[0075] FIGS. 72-75 are schematic representations of layers of
various webs in accordance with the present disclosure;
[0076] FIGS. 76-79 are plan views of absorbent articles,
garment-facing surfaces facing the viewer, in accordance with the
present disclosure;
[0077] FIGS. 80 and 81 are photographs of webs with only some of
the overbonds ruptured to form apertures in accordance with the
present disclosure;
[0078] FIG. 82 is a photograph of a patterned apertured web for a
feminine hygiene product, wherein outer portions of the web have
embossed areas in accordance with the present disclosure;
[0079] FIG. 83 is a photograph of an example patterned apertured
web in accordance with the present disclosure;
[0080] FIG. 84 is a photograph of an example moire effect laminate
with a first layer in a first position relative to a second layer,
wherein a first portion of a second pattern of the second layer is
at least partially visible through a first portion of a first
pattern of the first layer, in accordance with the present
disclosure;
[0081] FIG. 85 is a photograph of the example moire effect laminate
of FIG. 84 with the first layer in a second position relative to
the second layer, wherein a second portion of the second pattern is
at least partially visible through a second portion of the first
pattern, in accordance with the present disclosure;
[0082] FIG. 86 is a photograph of the example moire effect laminate
of FIG. 84 with the first layer in a third position relative to the
second layer, wherein a third portion of the second pattern is at
least partially visible through a third portion of the first
pattern, in accordance with the present disclosure;
[0083] FIG. 87 is a photograph of the example moire effect laminate
of FIG. 84 with the first layer in a fourth position relative to
the second layer, wherein a fourth portion of the second pattern is
at least partially visible through a fourth portion of the first
pattern, in accordance with the present disclosure;
[0084] FIGS. 88-90 are example absorbent articles with bonds or
joined portions, garment-facing surfaces removed to show the
position of the bond or joined portions, in accordance with the
present disclosure;
[0085] FIG. 91 is an example illustration of a moire effect
laminate or other laminate of the present disclosure with a first
layer having a different path length of a second layer, in
accordance with the present disclosure;
[0086] FIG. 92 is an example of a first layer having a first
pattern of a moire effect laminate, in accordance with the present
disclosure;
[0087] FIG. 93 is an example of a second layer having a second
pattern of moire effect laminate, in accordance with the present
disclosure;
[0088] FIG. 94 is an example the first layer of FIG. 92 overlaid on
the second layer of FIG. 93 to form a moire effect laminate,
wherein the first layer is in a first position relative to the
second layer, in accordance with the present disclosure;
[0089] FIG. 95 is an example the first layer of FIG. 92 overlaid on
the second layer of FIG. 93 to form a moire effect laminate,
wherein the first layer is in a second position relative to the
second layer, in accordance with the present disclosure;
[0090] FIG. 96 is an example of a first layer having a first
pattern of a moire effect laminate, in accordance with the present
disclosure;
[0091] FIG. 97 is an example of a second layer having a second
pattern of moire effect laminate, in accordance with the present
disclosure;
[0092] FIG. 98 is an example the first layer of FIG. 96 overlaid on
the second layer of FIG. 97 to form a moire effect laminate,
wherein the first layer is in a first position relative to the
second layer, in accordance with the present disclosure;
[0093] FIG. 99 is an example the first layer of FIG. 96 overlaid on
the second layer of FIG. 97 to form a moire effect laminate,
wherein the first layer is in a second position relative to the
second layer, in accordance with the present disclosure;
[0094] FIG. 100 is a cross-sectional illustration of a portion of a
non-joined span of a moire effect laminate, wherein a first layer
is in a first position relative to a second layer, and wherein a
first portion of a second pattern of the second layer is visible
through a first pattern of the first layer, in accordance with the
present disclosure;
[0095] FIG. 101 is a cross-sectional illustration of a portion of a
non-joined span of the moire effect laminate of FIG. 100, wherein
the first layer has been moved into a second position relative to
the second layer, and wherein a second portion of the second
pattern is visible through the first pattern, in accordance with
the present disclosure;
[0096] FIG. 102 is a cross-sectional illustrate of a portion of a
non-joined span of a moire effect laminate, wherein a first layer
is in a first position relative to a second layer, and wherein a
first portion of a second pattern of the second layer is visible
through a first pattern of the first layer, in accordance with the
present disclosure;
[0097] FIG. 103 is a cross-sectional illustration of the portion of
the non-joined span of the moire effect laminate of FIG. 102,
wherein the first layer has been moved into a second position
relative to the second layer, and wherein a second portion of the
second pattern is visible through the first patter, in accordance
with the present disclosure;
[0098] FIGS. 104-107 illustrate patterned apertured webs on an
absorbent article that have various zones, in accordance with the
present disclosure; and
[0099] FIG. 108 is a side view of a package of absorbent articles
in accordance with the present disclosure. The outer surface is
illustrated as transparent for purposes of clarity.
DETAILED DESCRIPTION
[0100] Various non-limiting forms 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 comprising garment-facing laminates 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 comprising
garment-facing laminates specifically 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.
[0101] As used herein, the terms "nonwoven material", "nonwoven",
or "nonwoven layer" are used in their normal sense and
specifically, refers to a web that has a structure of individual
fibers or threads which are interlaid, but not in any regular,
repeating manner. Nonwoven materials, nonwovens, or nonwoven layers
have been, in the past, formed by a variety of processes, such as,
for example, meltblowing processes, spunbonding processes and
bonded carded web processes.
[0102] As used herein, the term "microfibers", refers to small
diameter fibers having an average diameter not greater than about
100 microns.
[0103] As used herein, the term "nanofibers", refers to very small
diameter fibers having an average diameter less than about 1
micron.
[0104] As used herein, the term "meltblown", refers to fibers
formed by extruding a molten thermoplastic material through a
plurality of fine, usually circular, die capillaries as molten
threads or filaments into a high velocity gas (e.g., air) stream
which attenuates the filaments of molten thermoplastic material to
reduce their diameter, which may be to a microfiber diameter.
Thereafter, the meltblown fibers are carded by the high velocity
gas stream and are deposited on a collecting surface to form a web
of randomly dispersed meltblown fibers.
[0105] As used herein, the term "spunbond", refers to small
diameter fibers which are formed by extruding a molten
thermoplastic material as filaments from a plurality of fine,
usually circular, capillaries of a spinneret with the diameter of
the extruded filaments then being rapidly reduced as by, for
example, eductive drawing or other well-known spunbonding
mechanisms.
[0106] As used herein, the term "polymer" generally includes, but
is not limited to, homopolymers, copolymers, such as, for example,
block, graft, random, and alternating copolymers, terpolymer, etc.,
and blends and modifications thereof. Furthermore, unless otherwise
specifically limited, the term "polymer" shall include all possible
geometrical configurations of the material. These configurations
include, but are not limited to, isotactic, syndiaotactic and
random symmetries.
[0107] As used herein, the terms "join", "joined", "joining",
"bond", "bonded", "bonding", "attach", "attached", or "attaching"
encompass configurations whereby an element is directly secured to
another element by affixing the element directly to the other
element, and configurations whereby an element is indirectly
secured to another element by affixing the element to intermediate
member(s) which in turn are affixed to the other element.
[0108] As used herein, the term "elastic" refers to any material
that, upon application of a biasing force, can stretch to an
elongated length of at least about 110% of its relaxed, original
length (i.e., can stretch to 10 percent), without rupture or
breakage, and upon release of the applied force, recovers at least
about 40% of its elongation. For example, a material that has an
initial length of 100 mm can extend at least to 110 mm, and upon
removal of the force would retract to a length of 106 mm (40%
recovery). "Elastic" may refer to a single material, or it may
refer to a combination of materials making up a laminate in an
article. An elastic material may be incorporated into a laminate
which is not elastic, or which is less elastic than one or more of
the elastic materials of the laminate.
[0109] As used herein, the term "nonelastic" refers to any material
which does not fall within the definition of "elastic" above.
[0110] As used herein, the term "extensible" refers to any material
which, upon application of a biasing force, is elongatable, at
least about 10%, at least about 20%, at least about 30%, at least
about 50%, without experiencing catastrophic failure. Recovery of
the elongation is not required, but may at least partially
occur.
[0111] As used herein, the term "melt-stabilized" refers to
portions of a nonwoven material which have been subjected to
localized heating and/or localized pressure to substantially
consolidate the fibers of the nonwoven material into a stabilized
film-like form.
[0112] As used herein, the term "absorbent article", refers to
devices which absorb and contain bodily exudates (e.g., BM, urine,
blood), and, more specifically, refers to devices which are placed
against or in proximity to the body of the wearer to absorb and
contain the various bodily exudates discharged from the body. The
term absorbent article includes, but is not limited to, diapers,
pants, training pants, adult incontinence products, sanitary
napkins, tampons, wipes, and liners. The term "absorbent article"
may also encompass cleaning or dusting pads or substrates that have
some absorbency.
[0113] The term "machine direction" (MD) is used herein to refer to
the primary direction of material, strip of substrate, or article
flow through a process.
[0114] The term "cross direction" (CD) is used herein to refer to a
direction that is generally perpendicular to the machine
direction.
[0115] As used herein, the term "aperture aspect ratio" is the
ratio of the major axis to the minor axis of a single aperture.
[0116] As used herein, the term "pre-strain" or "pre-strained"
means a material that has been elongated to at least 105% of one of
its original (i.e., before being strained) dimensions and then is
capable of at least partial recovery after the elongating force is
removed.
Patterned Apertured Webs
[0117] The patterned apertured webs of the present disclosure
provide many benefits over conventional apertured topsheets, as
will be described herein. Four examples of patterned apertured webs
10 are illustrated in FIGS. 1-4. As illustrated, the patterned
apertured webs 10 may take on a number of configurations. The
apertures are labeled 12 and the land areas (non-apertured areas)
are labeled 14. Additional examples of patterned apertured webs are
illustrated in subsequent figures. Some of the patterned apertured
webs may have land area widths of at least about 4 mm, at least
about 5 mm, at least about 6 mm, at least about 7 mm, at least
about 8 mm, at least about 9 mm, at least about 10 mm, or in the
range of about 4 mm to about 15 mm, specifically reciting all 0.1
mm increments within the specified range and all ranges formed
therein. These land area widths may be measured using a NIST
traceable/certified ruler from a perimeter of one aperture to a
perimeter of another aperture in any direction. As an example, FIG.
2 illustrates discrete aperture patterns (e.g., set apart from
other aperture patterns).
Layers
[0118] The patterned apertured webs of the present disclosure may
comprise a single apertured layer (see FIGS. 1-4) or more than one
layer (apertured or non-apertured), for example, two, three, or
four layers. The term "layer" means a self-sustaining web (e.g., a
nonwoven or a film) and not a non-self-sustaining web (e.g., a
spunbond layer of an SMMS nonwoven). Thus, a
Spunbond-Meltblown-Meltblown-Spunbond (SMMS) nonwoven material
would be considered a single layer for purposes of this disclosure,
much like a film would be considered a single layer. The patterned
apertured webs may comprise one or more non-apertured layers that
have not been put through an aperturing process, but merely have
pores (that are not apertures for purposes of this disclosure)
created in the formation of the material. If two apertured layers
are provided in a patterned apertured web, each layer may have the
same aperturing pattern or a different aperturing pattern.
[0119] Referring to FIG. 5, a schematic illustration of an example
cross-sectional view of a patterned apertured web 10 comprising two
layers is illustrated. Although the examples of the patterned
apertured webs of FIG. 5-10 comprise more than one layer, patterned
apertured webs of the present disclosure may only have one layer
(see, for example, FIGS. 1-4). The patterned apertured web 10 may
comprise a patterned apertured layer 16 and a non-apertured layer
18. The patterned apertured layer 16 may comprise any of the
various aperture patterns disclosed herein, for example. The
patterned aperture layer 16 may be combined with, bonded to,
adhesively joined to, or joined to the non-apertured layer 18 to
form a laminate. The patterned apertured layer 16 may have
apertures and land areas at least partially, or fully, surrounding
the apertures.
[0120] If both or all layers of a multi-layer patterned apertured
web are apertured, the apertures may be aligned or overlapping, not
aligned or not overlapping, or partially aligned or partially
overlapping in the Z-direction. For instance, the apertures in one
layer may be 100% aligned or overlapping in the Z-direction with
the apertures in a second layer thus forming apertures through both
layers of the patterned apertured web. In such an instance, the
apertures may be formed by overbonding both layers together to join
the layers and then rupturing the overbonds to form apertures in
both of the layers (or more than two of the layers). In other
instances, the apertures may be less than 100% aligned or
overlapping in the Z-direction. Stated another way, the apertures
in one layer may be offset in the CD, MD, or other direction or
different patterns of apertures may be formed in each layer to
create the misalignment of the apertures. In such instances, the
area of the apertures in one layer may overlap the area of the
apertures in another layer, in the Z-direction, by 10% to 90%, 10%
to 100%, 10% to 80%, 25% to 75%, 25%, 50%, or 75%, for example,
specifically reciting all 0.5% increments within the specified
ranges and all ranges formed therein or thereby.
[0121] In instances where more than one layer of a patterned
apertured web includes apertures, the apertures may be coincident
in the Z-direction, i.e., penetrate through both layers. In a form,
this may be achieved by forming the apertures after bonding,
joining and/or laminating the two or more layers together.
Alternatively, the apertures in one layer may have a different
pattern, size, and/or shape from the apertures in a second layer
and/or may be oriented in a different direction. In a form, this
may be achieved by forming the apertures in each of the layers
prior to combining the two or layers into a laminated structure. In
absorbent article forms comprising a patterned apertured web having
an apertured layer and a non-apertured layer, the apertured layer
may be oriented on the wearer-facing side of the patterned
apertured web or on the garment-facing side of the patterned
apertured web. In still other forms, the patterned apertured layer
may be positioned intermediate two non-apertured layers or may be
positioned under one or more non-apertured layers. In yet another
form, two patterned apertured layers may sandwich one or more
non-apertured layers in a patterned apertured web.
[0122] A first layer of a patterned apertured web may have the same
or a different hydrophilicity as another layer of the same
patterned apertured web. Both layers may be hydrophilic or
hydrophobic, but one may be more hydrophilic or hydrophobic. As an
example, a wearer-facing layer of a patterned apertured web may be
hydrophobic while a garment-facing layer of the patterned apertured
web may be hydrophilic to help wick fluid into the apertures and
into an absorbent core. As another example, a first layer of a
patterned apertured web may be a hydrophobic topsheet with
apertures and a second layer of a patterned apertured web may be
hydrophilic acquisition layer or material. This can promote fluid
wicking or drainage into the absorbent core and provide depth
perception.
[0123] In an instance, again referring to FIG. 5, the patterned
apertured layer 16 may have a different color as the non-apertured
layer 18, such that the apertures in the layer 16 are easily
visible or more readily apparent to a user. The aperture pattern in
the patterned apertured layer 16 may also form indicia that may
indicate the correct orientation of an absorbent article comprising
the patterned apertured web 10 on a wearer. Such indicia may
include any object or shape that has a commonly understood vertical
orientation, such as a heart shape, a face, a building, a letter or
numeral, a car, for example. This may also apply to other patterned
apertured webs described herein, regardless of how many apertured
or non-apertured layers are provided.
[0124] Any of the patterned apertured webs described herein may
have gradients of color to indicate which side of the product
comprising the web is the top and which side is the bottom or to
indicate depth in an absorbent article or to provide an enhanced
depth perception.
[0125] The layers of the patterned apertured webs of the present
disclosure may have the same basis weights or different basis
weights. In an instance, again referring to FIG. 5, the layer 16
may have a higher basis weight than the layer 18. This may provide
better softness on a surface of the layer 16 (e.g., a topsheet
contacting a baby's skin), while also providing enhanced fluid
penetration owing to the apertures in the layer 16. The various
layers of the patterned apertured webs of the present disclosure
may also be the same or different in material compositions,
density, caliper, opacity, lotion concentration, or any other
properties of nonwoven materials.
[0126] The basis weight of a patterned apertured web, or a layer
thereof, may in the range of about 6 gsm to about 200 gsm, about 10
gsm to about 100 gsm, about 10 to about 50 gsm, or about 10 gsm to
about 40 gsm, specifically reciting all 0.1 gsm increments within
the above-specified range and all ranged formed therein or thereby.
Basis weight is measured according to the Basis Weight Test
herein.
[0127] The predominant fiber orientation of the fibers in the
layers of the multi-layer patterned apertured webs may be the same
or different. In an instance, a predominant fiber orientation may
be about 45 degrees to about 135 degrees, for example, off-axis
relative to a machine direction, while another layer may have a
predominant fiber orientation substantially along a machine
direction or +/- about 10 to about 20 degrees from the machine
direction. Providing different layers in a patterned apertured web
with different predominant fiber orientations may provide increased
strength and resistance to tearing of the patterned apertured web
when the two or more layers are joined or bonded together.
[0128] Referring to FIG. 6, a schematic illustration of an example
cross-sectional view of another patterned apertured web 10 is
illustrated. The patterned apertured web 10 may comprise a first
patterned apertured layer 20 and a second patterned apertured layer
22. Apertures of the first patterned apertured layer 20 in FIG. 6
may be about 80%, about 85%, about 90%, about 95%, about 80% to
about 100%, or about 100% aligned, in the Z-direction (indicated by
arrow Z), with apertures in the second patterned apertured layer
22, specifically reciting all 0.5% increments within the specified
range and all ranges formed therein. The first patterned apertured
layer 20 may be combined with, bonded to, or joined to the second
patterned aperture layer 22 to form a laminated patterned apertured
web. The patterned apertured web 10 of FIG. 6, or any of the other
patterned apertured webs of the present disclosure, may comprise a
third layer 21 (or more than three layers) that may be
non-apertured or apertured. The second patterned apertured layer 22
may be combined with, bonded to, or joined to the third
non-apertured layer 21.
[0129] Again referring to FIG. 6, the apertures in the second
patterned apertured layer 22 may be smaller than (e.g., about 10%
less area, about 20% less area, about 30% less area etc.) the
apertures in the first patterned apertured layer 20. Such a feature
may allow BM penetration through the first layer 20 while also
providing adequate liquid bodily exudate (e.g., urine and menses)
fluid strikethrough through the second layer 22 or rewet from the
first layer compared to a non-apertured second layer.
[0130] Referring to FIG. 7, a schematic illustration of an example
cross-sectional view of another patterned apertured web 10 is
illustrated. The patterned apertured web 10 may comprise a first
patterned apertured layer 24 and a second patterned apertured layer
26. Apertures of the first patterned apertured layer 24 may be
fully overlapped by non-apertured portions or "land areas" of the
second patterned apertured layer 26 in the Z-direction (indicated
by arrow Z). The first patterned apertured layer 24 may be combined
with, bonded to, or joined to the second patterned aperture layer
26 to form a laminated patterned apertured web.
[0131] Referring to FIG. 8, a schematic illustration of an example
cross-sectional view of another patterned apertured web 10 is
illustrated. The patterned apertured web 10 may comprise a first
patterned apertured layer 28 and a second patterned apertured layer
30. Apertures of the first patterned apertured layer 28 may be
partially overlapped by non-apertured portions or "land areas" of
the second patterned apertured layer 30 in the Z-direction
(indicated by arrow Z). The first patterned apertured layer 28 may
be combined with, bonded to, or joined to the second patterned
aperture layer 30 to form a laminated patterned apertured web. The
overlap of the areas of the apertures in the first patterned
apertured layer 28 and the areas of the apertures in the second
patterned apertured layer may be in the range of about 5% to about
95%, about 10% to about 90%, about 20% to about 80%, about 25% to
about 75%, about 25%, about 50%, or about 75%, specifically
reciting all 0.5% increments within the specified ranges and all
ranges formed therein or thereby.
[0132] The example patterned apertured web 10 of FIG. 8 may also
comprise a pigmented substance (full continuous layer) or a
patterned pigmented substance 29 at least partially intermediate
the first and second patterned apertured layers 28 and 30. This
concept may also apply to any of the examples in FIGS. 5-10 or
other examples herein. The pigmented substance may also be
positioned on either of the layers 28 and 30. The pigmented
substance or patterned pigmented substance 29 may comprise
graphics, inks, pigmented adhesives or other pigmented substances
and may be viewable through the overlapping areas of the apertures
from either side of the patterned apertured web 10. In a form, the
pigmented substance or patterned pigmented substance 29 may be
positioned under the second patterned apertured layer 30 and may
still be viewable through the overlapping areas of the apertures
when viewing from the first patterned apertured layer 28. The first
patterned apertured layer 28, the second patterned apertured layer
30, and the pigmented substance or the patterned pigmented
substance 29 may be the same color or may each be a different
color. Alternatively, the patterned apertured layers 28 and 30 may
have a different color as the pigmented substance or the patterned
pigmented substance 29. Such forms allow for a three-dimensional
appearance to be provided in the patterned apertured web 10 without
actually making the patterned apertured web 10 three-dimensional,
such as through embossing, for example.
Materials
[0133] Any of the layers of the patterned apertured webs described
herein may comprise any materials known in the art including, but
not limited to, nonwovens, wovens, cellulosic materials, films,
elastic materials, non-elastic materials, highloft materials,
and/or foams. The patterned apertured webs may also comprise one or
more layers of one or more nonwoven materials, one or more films,
combinations of different nonwoven materials, combinations of
different films, combinations of one or more films and one or more
nonwoven materials, or combinations of one or more different
materials, for example. Patterned apertured webs having one or more
layers of the same or similar materials are also within the scope
of the present disclosure. The basis weight, color, opacity,
hydrophilicity, Average Interaperture Distance, Average Absolute
Feret Angle, Effective Aperture Area, Effective Open Area, or other
parameters or characteristics of the various materials in the
various layers may be the same or different.
[0134] Some precursor web materials for the patterned apertured
webs may comprise PE/PP bicomponent fiber spunbond webs. Other
suitable precursor webs may comprise spunbond webs comprising
side-by-side crimped fibers (e.g., PE/PP or PP/PP) that are bonded
via calendar (thermal point) bonding or through-air bonding. Other
suitable precursor webs may comprise carded, through-air bonded or
resin bonded (highloft) nonwovens comprising PE/PP or PE/PET
fibers. The precursor webs may comprise microfibers and/or
nanofibers, optionally with other fibers. In some circumstances,
multiple layer webs may be desired over a single layer webs (even
at the same basis weight) due to increased uniformity/opacity and
the ability to combine webs having different properties. For
example, an extensible spunbond nonwoven carrier layer may be
combined with a soft, highloft nonwoven (spunbond or carded) to
create an apertured web that is both soft and strong. The layers
may have the same or different surface energy. For example, the top
layer may be hydrophobic and the lower layer may be hydrophilic.
The layers may have different permeability/capillarity, e.g. the
upper layer may have higher permeability and the lower layer have
higher capillarity in order to set up a capillary gradient and aid
in moving fluid away from the surface (or topsheet) of an absorbent
article and into an absorbent core of the absorbent article. Fibers
of the precursor web materials may comprise any suitable
thermoplastic polymers.
[0135] Example thermoplastic polymers are polymers that melt and
then, upon cooling, crystallize or harden, but that may be
re-melted upon further heating. Suitable thermoplastic polymers may
have a melting temperature (also referred to as solidification
temperature) from about 60.degree. C. to about 300.degree. C., from
about 80.degree. C. to about 250.degree. C., or from about
100.degree. C. to about 215.degree. C., specifically reciting all
0.5.degree. C. increments within the specified ranges and all
ranges formed therein or thereby. And, the molecular weight of the
thermoplastic polymer may be sufficiently high to enable
entanglement between polymer molecules and yet low enough to be
melt spinnable.
[0136] The thermoplastic polymers may be derived from any suitable
material including renewable resources (including bio-based and
recycled materials), fossil minerals and oils, and/or
biodegradeable materials. Some suitable examples of thermoplastic
polymers include polyolefins, polyesters, polyamides, copolymers
thereof, and combinations thereof. Some example polyolefins include
polyethylene or copolymers thereof, including low density, high
density, linear low density, or ultra-low density polyethylenes
such that the polyethylene density ranges between about 0.90 grams
per cubic centimeter to about 0.97 grams per cubic centimeter or
between about 0.92 and about 0.95 grams per cubic centimeter, for
example. The density of the polyethylene may be determined by the
amount and type of branching and depends on the polymerization
technology and co-monomer type. Polypropylene and/or polypropylene
copolymers, including atactic polypropylene; isotactic
polypropylene, syndiotactic polypropylene, and combination thereof
may also be used. Polypropylene copolymers, especially ethylene may
be used to lower the melting temperature and improve properties.
These polypropylene polymers may be produced using metallocene and
Ziegler-Natta catalyst systems. These polypropylene and
polyethylene compositions may be combined together to optimize
end-use properties. Polybutylene is also a useful polyolefin and
may be used in some forms. Other suitable polymers include
polyamides or copolymers thereof, such as Nylon 6, Nylon 11, Nylon
12, Nylon 46, Nylon 66; polyesters or copolymers thereof, such as
maleic anhydride polypropylene copolymer, polyethylene
terephthalate; olefin carboxylic acid copolymers such as
ethylene/acrylic acid copolymer, ethylene/maleic acid copolymer,
ethylene/methacrylic acid copolymer, ethylene/vinyl acetate
copolymers or combinations thereof; polyacrylates,
polymethacrylates, and their copolymers such as poly(methyl
methacrylates).
[0137] The thermoplastic polymer component may be a single polymer
species or a blend of two or more thermoplastic polymers e.g., two
different polypropylene resins. As an example, fibers of a first
nonwoven layer of a patterned apertured web may comprise polymers
such as polypropylene and blends of polypropylene and polyethylene,
while a second nonwoven layer of the patterned apertured web may
comprise fibers selected from polypropylene,
polypropylene/polyethylene blends, and polyethylene/polyethylene
terephthalate blends. In some forms, the second nonwoven layer may
comprise fibers selected from cellulose rayon, cotton, other
hydrophilic fiber materials, or combinations thereof. The fibers
may also comprise a super absorbent material such as polyacrylate
or any combination of suitable materials.
[0138] The fibers of the layer of the patterned apertured web may
comprise monocomponent fibers, bi-component fibers, and/or
bi-constituent fibers, round fibers or non-round fibers (e.g.,
capillary channel fibers), and may have major cross-sectional
dimensions (e.g., diameter for round fibers) ranging from about 0.1
microns to about 500 microns. The fibers may also be a mixture of
different fiber types, differing in such features as chemistry
(e.g. polyethylene and polypropylene), components (mono- and bi-),
denier (micro denier and >2 denier), shape (i.e. capillary and
round) and the like. The fibers may range from about 0.1 denier to
about 100 denier.
[0139] Example materials are contemplated where a first plurality
of fibers and/or a second plurality of fibers comprise additives in
addition to their constituent chemistry. For example, suitable
additives include additives for coloration, antistatic properties,
lubrication, softness, hydrophilicity, hydrophobicity, and the
like, and combinations thereof. These additives, for example
titanium dioxide for coloration, may generally be present in an
amount less than about 5 weight percent and more typically less
than about 2 weight percent or less.
[0140] As used herein, the term "monocomponent fiber(s)" refers to
a fiber formed from one extruder using one or more polymers. This
is not meant to exclude fibers formed from one polymer to which
small amounts of additives have been added for coloration,
antistatic properties, lubrication, hydrophilicity, etc.
[0141] As used herein, the term "bi-component fiber(s)" refers to
fibers which have been formed from at least two different polymers
extruded from separate extruders but spun together to form one
fiber. Bi-component fibers are also sometimes referred to as
conjugate fibers or multicomponent fibers. The polymers are
arranged in substantially constantly positioned distinct zones
across the cross-section of the bi-component fibers and extend
continuously along the length of the bi-component fibers. The
configuration of such a bi-component fiber may be, for example, a
sheath/core arrangement wherein one polymer is surrounded by
another, or may be a side-by-side arrangement, a pie arrangement,
or an "islands-in-the-sea" arrangement. Some specific examples of
fibers which may be used in the first nonwoven layer include
polyethylene/polypropylene side-by-side bi-component fibers.
Another example is a polypropylene/polyethylene bi-component fiber
where the polyethylene is configured as a sheath and the
polypropylene is configured as a core within the sheath. Still
another example is a polypropylene/polypropylene bi-component fiber
where two different propylene polymers are configured in a
side-by-side configuration. Additionally, forms are contemplated
where the fibers of a nonwoven layer are crimped.
[0142] Bi-component fibers may comprise two different resins, e.g.
a first polypropylene resin and a second polypropylene resin. The
resins may have different melt flow rates, molecular weights, or
molecular weight distributions. Ratios of the 2 different polymers
may be about 50/50, 60/40, 70/30, 80/20, or any ratio within these
ratios. The ratio may be selected to control the amount of crimp,
strength of the nonwoven layer, softness, bonding or, the like.
[0143] As used herein, the term "bi-constituent fiber(s)" refers to
fibers which have been formed from at least two polymers extruded
from the same extruder as a blend. Bi-constituent fibers do not
have the various polymer components arranged in relatively
constantly positioned distinct zones across the cross-sectional
area of the fiber and the various polymers are usually not
continuous along the entire length of the fiber, instead usually
forming fibrils which start and end at random. Bi-constituent
fibers are sometimes also referred to as multi-constituent fibers.
In other examples, a bi-component fiber may comprise
multiconstituent components.
[0144] As used herein, the term "non-round fiber(s)" describes
fibers having a non-round cross-section, and includes "shaped
fibers" and "capillary channel fibers." Such fibers may be solid or
hollow, and they may be tri-lobal, delta-shaped, and may be fibers
having capillary channels on their outer surfaces. The capillary
channels may be of various cross-sectional shapes such as
"U-shaped", "H-shaped", "C-shaped" and "V-shaped". One practical
capillary channel fiber is T-401, designated as 4DG fiber available
from Fiber Innovation Technologies, Johnson City, Tenn. T-401 fiber
is a polyethylene terephthalate (PET polyester).
[0145] Other example nonwoven materials for the patterned apertured
webs may comprise spunbond materials, carded materials, melt blown
materials, spunlace materials, needle punched materials, wet-laid
materials, or air-laid materials, for example.
[0146] Some other example materials for at least one layer of the
patterned apertured webs of the present disclosure are those that
are capable of elongation in the cross-machine direction of greater
than about 100%, greater than about 120%, or greater than about
150%. This enables the web to extend upon stretching and minimizes
the number of broken fibers and/or tears between apertures. One
example of this type of web is a spunbond web comprising
sheath/core bicomponent fibers of polyethylene in the sheath and
polypropylene in the core. An example may be a 25 gsm nonwoven
comprising fibers that are 2.8 denier per filament with a 50/50
polyethylene/polypropylene ratio available from Fitesa in
Washougal, Wash.
[0147] It may be desirable for individual precursor materials, or
at least one of the layer within a patterned apertured web, to be
capable of undergoing an elongation of greater than or equal to
about one of the following amounts: about 100% (that is double its
unstretched length), about 110%, about 120%, or about 130% up to
about 200%, or more, at or before reaching the peak tensile force.
It may also desirable for the precursor materials to be capable of
undergoing plastic deformation to ensure that the structure of the
deformations is "set" in place so that the nonwoven laminate will
not tend to recover or return to its prior configuration. However,
in the case crimped fiber spunbond layers, it may be desirable for
the precursor material for these specific layer(s) to be capable of
experiencing no or minimal plastic deformation during
processing.
[0148] In contrast to spunbond nonwoven layers, the constituent
fibers of the crimped fiber spunbond nonwoven layers typically are
uncoiled and/or displaced when processed. Because the crimped
fibers tend to coil to some extent, the processing typically
displaces/uncoils the crimped fibers as opposed to elongating the
crimped fibers.
[0149] Extensibility of a nonwoven layer may be impacted by bonding
between constituent fibers. This is true for both spunbond nonwoven
layer and crimped fiber spunbond nonwoven layers. For example, to
increase extensibility in a nonwoven layer, it may be desirable for
the nonwoven layer to be underbonded as opposed to optimally bonded
prior to processing. A thermally bonded nonwoven web's tensile
properties may be modified by changing the bonding temperature. A
web may 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 may stretch and break around
the bond sites 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 can be separated easily from
the bond sites to allow the fibers to pull out of the bond sites
and rearrange when the material is strained. 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.
Joining of Layers
[0150] If more than one layer is provided in a particular patterned
apertured web, the layers may be bonded together using any bonding
methods known to those of skill in the art, such as adhesive
bonding, patterned adhesive coating, ultrasonic bonding, thermal
bonding, mechanical bonding, or any combination of these bonding
methods. Alternatively, the various layers may be bonded together
only at the perimeter of the apertures, or partially the perimeter
of the apertures, through an overbonding process. The bonding may
be done in a pattern of bonds or in arrays of bonds. The pattern
may be a regular, homogeneous and uniform pattern or an irregular,
non-uniform and non-homogeneous pattern. The bonding patterns may
comprise a substantially continuous bond pattern or may be formed
of discrete bonding points. The discrete bonding points may form a
pattern. The pattern of bonding points may be homogeneous or
non-homogeneous. A bond pattern in one region of a patterned
apertured web may differ from a bond pattern in another region of
the patterned apertured web. For example, the bond pattern may be
different in the machine direction or the cross-machine direction
of the patterned apertured web laminate. An absorbent article
including the patterned apertured web may have a different bond
pattern in the front region vs. the back region, the center region
vs. side regions, the crotch region vs. waist regions, or a first
portion and a second portion of a topsheet or an outer cover, of
the absorbent article, for example. Bonding in patterned apertured
webs is typically accomplished by joining the land areas of various
layers of the patterned apertured webs. If an adhesive is used in
the bonding process, the adhesive may be tinted, pigmented, and/or
patterned to create a complementary or contrasting pattern compared
to the aperture pattern or patterns.
Color/Printing/Adhesives
[0151] Any of the layers of the patterned apertured webs may have a
color that is the same or different than another layer of the
patterned apertured web, regardless of whether a layer is apertured
or non-apertured. For instance, in a two layer patterned apertured
web, a first layer may be blue and a second layer may be white, or
a first layer may be dark blue and the second layer may be light
blue. There may be a Delta E difference between at least some of
the layers. The layers may also have the same opacity or a
different opacity, as described in further detail below. Single
layer patterned apertured webs may also have a color.
[0152] Either in addition to or in lieu of the various layered
being colored, referring to FIG. 9, one or more of the layers of
the patterned apertured webs 10 of the present disclosure may
comprise printing 32, e.g., with ink or a pigmented or colored
pattern. Single layer patterned apertured webs may also comprise
ink or a pigmented or colored pattern. The ink may be deposited via
any printing process known in the art including, but not limited
to, flexographic printing and digital inkjet printing. The printing
may form graphics or other indicia. The printing may be on an
external surface of a first layer 34 of the patterned apertured web
10, between the first and second layers 34, 36 (as illustrated) of
the patterned apertured web 10, or may be on a surface beneath the
second layer 36 of the patterned apertured web 10. The printing may
also be situated in any suitable location if the patterned
apertured web has more than two layers (e.g., on the surface of any
of the layers). The printing may also be deposited in zones of the
patterned apertured web, or layers thereof, and/or in patterns
throughout the patterned apertured web, or layers thereof. The
printing may be different or the same in different zones of the
patterned apertured web, or layers thereof. If the printing is
covered by one of the layers (e.g., layer 34), the covering layer
(e.g., layer 34) may have a relatively low opacity to enhance the
visual appearance of the printing. The density of the printing
(e.g., clarity and contrast) may be enhanced by including
small-denier fibers in the printed layer including, but not limited
to, melt-blown fibers, microfibers, and nanofibers. In an instance,
the printing may indicate the proper orientation of an absorbent
article on a wearer (e.g., front/rear). It will be understood that
printing may be used with any of the various forms and
configurations of the patterned apertured webs disclosed herein. In
some forms, more than one type or color, for example, of printing
may be used in a single patterned apertured web, or layer thereof.
Additional layers may also be provided in a pattered apertured web
having one or more prints.
[0153] Either in addition to or in lieu of the various layered
being colored and/or having printing, referring to FIG. 10, the
patterned apertured webs may comprise a pigmented adhesive 38 or
other pigmented substance (hereinafter "colored adhesive"). The
pigmented adhesive 38 may include a dye, for example. The colored
adhesive, in a form, may be positioned between a first layer 40 and
second layer 42 of a patterned apertured web 10. The colored
adhesive may be formed in a pattern that corresponds with,
coordinates with, matches, or does not correspond with, does not
coordinate with, or does not match the aperture pattern in one or
more aperture layers 40. It will be understood that a pigmented
adhesive may be used with any of the various forms and
configurations of the patterned apertured webs disclosed herein. In
some forms, more than one colored adhesive may be used in a single
patterned apertured web. The pigmented adhesive may also be
situated in any suitable location if the patterned apertured web
has more than two layers (e.g., on the surface of or intermediate
any of the layers). The pigmented adhesive may also be deposited in
zones of the patterned apertured web, or layers thereof, and/or in
patterns throughout the patterned apertured web, or layers thereof.
The pigmented adhesive may be different or the same in different
zones of the patterned apertured web, or layers thereof. The
pigmented adhesive may be positioned intermediate the two layers
40, 42 or positioned on any other surfaces of the layers 40, 42.
Additional layers may also be provided in a patterned apertured web
having one or more colored adhesives.
[0154] In an instance, a colored adhesive may be positioned between
two low basis weight materials (e.g., about 15 gsm or less, about
10 gsm or less) forming a patterned apertured web, so that the
colored adhesive may be visible from either side of the patterned
apertured web. In a topsheet context, this can provide a high basis
weight multilayer topsheet to achieve improved softness, while
still retaining the benefit of seeing the colored adhesive from
either side of the patterned apertured web.
Example Patterned Apertured Webs
[0155] Additional examples of patterned apertured webs 10 are
illustrated in FIGS. 11-15.
Opacity
[0156] The opacity of at least one of the layers of a patterned
apertured web may differ from the opacity of at least one of the
other layers of the patterned apertured web. Opacity is measured
according to the Opacity Test herein. In some instances, the layer
of the patterned apertured web closest to an external observer may
have a lower opacity than an underlying layer in order to maximize
observable contrast differences between the layers and/or to
observe printing or colored adhesives. Alternatively, the layer of
the patterned apertured web closest to an external observer may
have a higher opacity than an underlying layer in order to more
effectively mask bodily exudates (e.g., urine, menses, or BM) or to
provide for greater color contrast with the layers below. When a
patterned apertured web is used as a fluid-permeable topsheet, the
layer closest to an external observer would be the wearer-facing
surface. In a form, where the patterned apertured web is located on
the external surface of an absorbent article (e.g., an outer cover,
fastening system element, stretch ear, wing of a sanitary napkin,
belt, or side panel), the layer closest to an external observer
would be the garment-facing surface. For example, the opacity of a
non-apertured layer may be lower than that of a patterned apertured
layer, or vice versa, depending on the specific orientation of a
patterned apertured web in an absorbent article.
[0157] A nonwoven web may have a high opacity. This enables an
aperture pattern to be more easily distinguished, provides contrast
to any colors and materials underneath, and in the case of a diaper
topsheet or a sanitary napkin topsheet, masks the presence of
bodily fluids contained within the absorbent core, providing a
cleaner appearance to the wearer. To achieve this benefit,
opacities of about 30%, about 40%, about 50%, about 60%, about 70%,
about 80%, about 90%, in the range of about 40% to about 100%, or
about 50% to about 90%, specifically reciting all 0.1% increments
within the specified ranges and all ranges formed therein or
thereby, may be desired. Increases in opacity may be achieved via
any known mechanisms including fillers (e.g. TiO2), fiber shape
(e.g. Trilobal vs. round), smaller fiber diameters (including
microfibers and/or nano fibers), etc. One example of such a web may
have an SMS construction. Another example is a nonwoven comprising
nanofibers, such as those produced by melt film fibrillation (e.g.,
U.S. Pat. No. 8,487,156 and U.S. Pat. Appl. Publ. Serial No.
2004/0266300).
Components of Absorbent Articles
[0158] The patterned apertured webs of the present disclosure may
be used as components of absorbent articles. More than one
patterned apertured web may be used in a single absorbent article.
In such a context, the patterned apertured webs may form at least a
portion of: a topsheet; a topsheet and an acquisition layer; a
portion of a sanitary napkin, a wing of a sanitary napkin, a
topsheet and a distribution layer; a topsheet, an acquisition
layer, and a distribution layer (and any other layers intermediate
the topsheet and an absorbent core, such as a carrier layer for a
distribution layer as disclosed in U.S. patent application Ser. No.
14/844,037, filed on Sep. 3, 2015 (P&G Docket No. 13971MQ), an
acquisition layer and a distribution layer; an outer cover; an
outer cover and a backsheet, wherein a film (non-apertured layer)
of the patterned apertured web forms the backsheet and a nonwoven
material forms the outer cover; a leg cuff; an ear or side panel; a
fastener; a waist band; a belt, or portion thereof; or any other
suitable portion of an absorbent article. The patterned apertured
webs may take on different configurations and patterns of land and
aperture areas depending on their particular use in an absorbent
article on other product. The number of layers in a patterned
apertured web may also be determined by the patterned apertured
webs' particular use.
[0159] As referenced above, any of the patterned apertured webs of
the present disclosure may be disposed on an external surface of
the absorbent article (i.e., the outer cover or garment
facing-surface). In such an instance, the patterned apertures or
properties of the same may be the same or different in different
regions of the external surface. In an outer cover example,
effective aperture areas and effective open areas may be higher in
a waist region than in a crotch region of the outer cover for
better breathability. In another outer cover form, the waist
regions may include patterned apertures of the present disclosure,
while the crotch region comprises more uniform aperture patterns or
no apertures. In each of these forms, the effective aperture area
and effective open area, or apertures may provide higher air
porosity in the waist region than in the crotch region, allowing
more sweat evaporation and better breathability in the tightly
occluded waist area
Feminine Hygiene Products
[0160] The patterned apertured webs may also be used as components
of absorbent articles, such as feminine hygiene products, including
sanitary napkins (or wings thereof), liners, and tampons. More than
one patterned apertured web may be used in a single feminine
hygiene product. In a sanitary napkin context, the patterned
apertured webs may form at least a portion of: a topsheet; a
topsheet and an acquisition layer; a topsheet and a distribution
layer; a topsheet and a secondary topsheet; an outer cover; an
outer cover and a backsheet; wings; wings and a topsheet or a
backsheet; an outer covering for a tampon; or any other suitable
portion of a feminine hygiene product. The patterned apertured webs
may take on different configurations and patterns of land and
aperture areas depending on their particular use in a feminine
hygiene product. The number of layers in a patterned apertured web
may also be determined by the patterned apertured webs' particular
use.
Other Consumer Products
[0161] The patterned apertured webs may also be used as components
of absorbent articles, such as cleaning substrates, dusting
substrates, and/or wipes. More than one patterned apertured web may
be used in a single cleaning or dusting substrate and/or a single
wipe. The patterned apertured webs may take on different
configurations and patterns of land and aperture areas depending on
their particular use in a cleaning substrate, dusting substrate,
and/or a wipe. The number of layers in a patterned apertured web
may also be determined by the patterned apertured webs' particular
use.
Physical Characteristics
[0162] The patterned apertured webs of the present disclosure may
take on different physical characteristics depending on their
intended or desired use in absorbent articles, feminine hygiene
products, cleaning substrates, dusting substrates, wipes, or other
consumer products. For instance, the properties of density, basis
weight, aperture pattern, land area pattern, caliper, opacity,
three-dimensionality, and/or elasticity, for example, may be varied
depending on the desired use of the patterned apertured web. More
than one patterned apertured web may be combined with other,
similar or different, patterned apertured webs in some instances
for certain design criteria.
Methods of Making
[0163] The patterned apertured webs of the present disclosure may
be made generally by using the process generally described in U.S.
Pat. No. 5,628,097 entitled "Method for Selectively Aperturing a
Nonwoven Web" which issued May 13.sup.th, 1997 and U.S. Patent
Publication 2003/0021951 entitled "High Elongation Apertured
Nonwoven Web and Method of Making" which published Jan. 20.sup.th,
2003. This process is described in further detail below. The
patterned apertured webs may also be made by hydroforming carded
webs, laser cutting, punching with a patterned roll, or other
suitable methods.
[0164] Referring to FIG. 16 there is schematically illustrated at
100 one process for forming the patterned apertured webs of the
present disclosure.
[0165] First, a precursor material 102 is supplied as the starting
material. The precursor material 102 can be supplied as discrete
webs, e.g. sheets, patches, etc. of material for batch processing.
For commercial processing, however, the precursor material 102 may
be supplied as roll stock, and, as such it can be considered as
having a finite width and an infinite length. In this context, the
length is measured in the machine direction (MD). Likewise, the
width is measured in the cross machine direction (CD).
[0166] The precursor material 102 may be one or more nonwoven
materials (same or different), one or more films (same or
different), a combination of one or more nonwoven materials and one
or more films, or any other suitable materials or combinations
thereof. The precursor material 102 may be purchased from a
supplier and shipped to where the patterned apertured webs are
being formed or the precursor material 102 formed at the same
location as where the patterned apertured web are being
produced.
[0167] The precursor material 102 may be extensible, elastic, or
nonelastic. Further, the precursor material 102 may be a single
layer material or a multilayer material. In an instance, the
precursor material 102 may be joined to a polymeric film to form a
laminate.
[0168] The precursor material 102 may comprise or be made of
mono-component, bi-component, multi-constituent blends, or
multi-component fibers comprising one or more thermoplastic
polymers. In an example, the bicomponent fibers of the present
disclosure may be formed of a polypropylene core and a polyethylene
sheath. Further details regarding bi-component or multi-component
fibers and methods of making the same may be found in U.S. Patent
Application Publ. No. 2009/0104831, published on Apr. 23, 2009,
U.S. Pat. No. 8,226,625, issued on Jul. 24, 2012, U.S. Pat. No.
8,231,595, issued on Jul. 31, 2012, U.S. Pat. No. 8,388,594, issued
on Mar. 5, 2013, and U.S. Pat. No. 8,226,626, issued on Jul. 24,
2012. The various fibers may be sheath/core, side-by-side, islands
in the sea, or other known configurations of fibers. The fibers may
be round, hollow, or shaped, such as trilobal, ribbon, capillary
channel fibers (e.g., 4DG). The fibers may comprise microfibers or
nanofibers.
[0169] The precursor material 102 may be unwound from a supply roll
104 and travel in a direction indicated by the arrow associated
therewith as the supply roll 104 rotates in the direction indicated
by the arrow associated therewith. The precursor material 102
passes through a nip 106 of a weakening roller (or overbonding)
arrangement 108 formed by rollers 110 and 112, thereby forming a
weakened precursor material. The weakened precursor material 102
has a pattern of overbonds, or densified and weakened areas, after
passing through the nip. At least some of, or all of, these
overbonds are used to form apertures in the precursor material 102.
Therefore, the overbonds correlate generally to the patterns of
apertures created in the precursor material 102.
[0170] Referring to FIG. 17, the precursor material weakening
roller arrangement 108 may comprises a patterned calendar roller
110 and a smooth anvil roller 112. One or both of the patterned
calendar roller 110 and the smooth anvil roller 112 may be heated
and the pressure between the two rollers may be adjusted by known
techniques to provide the desired temperature, if any, and pressure
to concurrently weaken and melt-stabilize (i.e., overbond) the
precursor material 102 at a plurality of locations 202. The
temperature of the calendar roller 110 (or portions thereof) and/or
the smooth anvil roller 112 (or portions thereof) may be ambient
temperature or may be in the range of about 100.degree. C. to about
300.degree. C., about 100.degree. C. to about 250.degree. C., about
100.degree. C. to about 200.degree. C., or about 100.degree. C. to
about 150.degree. C., specifically reciting all 0.5.degree. C.
increments within the specified ranges and all ranges formed
therein or thereby. The pressure between the calendar roller 110
and the smooth anvil roller 112 may be in the range of about 2,000
pli (pounds per linear inch) to about 10,000 pli, about 3,000 pli
to about 8,000 pli, or about 4,500 to about 6,500 pli, specifically
reciting all 0.1 pli increments within the specified ranges and all
ranges formed therein or thereby. As will be discussed in further
detail below, after the precursor material 102 passes through the
weakening roller arrangement 108, the precursor material 102 may be
stretched in the CD, or generally in the CD, by a cross directional
tensioning force to at least partially, or fully, rupture the
plurality of weakened, melt stabilized locations 202, thereby
creating a plurality of at least partially formed apertures in the
precursor material 102 coincident with the plurality of weakened,
melt stabilized locations 202.
[0171] The patterned calendar roller 110 is configured to have a
cylindrical surface 114, and a plurality of protuberances or
pattern elements 116 which extend outwardly from the cylindrical
surface 114. The pattern elements 116 are illustrated as a
simplified example of a patterned calendar roller 110, but more
detailed patterned calendar rollers that can be used to produce
patterned apertured webs of the present disclosure will be
illustrated in subsequent figures. The protuberances 116 may be
disposed in a predetermined pattern with each of the protuberances
116 being configured and disposed to precipitate a weakened,
melt-stabilized location in the precursor material 102 to affect a
predetermined pattern of weakened, melt-stabilized locations 202 in
the precursor material 102. The protuberances 116 may have a
one-to-one correspondence to the pattern of melt stabilized
locations in the precursor material 102. As shown in FIG. 17, the
patterned calendar roller 110 may have a repeating pattern of the
protuberances 116 which extend about the entire circumference of
surface 114. Alternatively, the protuberances 116 may extend around
a portion, or portions of the circumference of the surface 114.
Also, a single patterned calendar roller may have a plurality of
patterns in various zones (i.e., first zone, first pattern, second
zone, second pattern). The protuberances 116 may have a
cross-directional width in the range of about 0.1 mm to about 10
mm, about 0.1 mm to about 5 mm, about 0.1 mm to about 3 mm, about
0.15 mm to about 2 mm, about 0.15 mm to about 1.5 mm, about 0.1 mm
to about 1 mm, about 0.1 mm to about 0.5 mm, or about 0.2 to about
0.5 mm, specifically reciting all 0.05 mm increments within the
specified ranges and all ranges formed therein or thereby. The
protuberances 116 may have an aspect ratio in the range of about
10:1, about 9:1, about 8:1, about 7:1, about 6:1, about 5:1, about
4:1, about 3:1, about 2:1, about 1.5:1, or about 1.1:1, for
example. Other aspect ratios of the protuberances 116 are also
within the scope of the present disclosure. The protuberances 116,
in some forms, may be angled, relative to the machine direction on
either side, in the range of about 60 degrees to about 1 degree,
about 50 degrees to about 2 degrees, about 45 degrees to about 2
degrees, about 45 degrees to about 5 degrees, about 40 degrees to
about 5 degrees, or about 35 degrees to about 5 degrees,
specifically reciting all 0.1 degree increments within the
specified ranges and all ranges formed therein or thereby. Spacing
between adjacent protuberances 116 in any direction may be greater
than about 0.5 mm, greater than about 0.6 mm, greater than about
0.7 mm, greater than about 0.8 mm, greater than about 0.9 mm,
greater than about 1 mm, greater than about 1.1 mm, greater than
about 1.2 mm, greater than about 1.3 mm, greater than about 1.4 mm,
greater than about 1.5 mm, greater than about 2 mm, greater than
about 3 mm, or may be in the range of about 0.7 mm to about 20 mm,
or about 0.8 to about 15 mm, specifically reciting all 0.1 mm
increments within the specified ranges and all ranges formed
therein or thereby.
[0172] A photograph of an example roller that may be used as
patterned calendar roller 110 in the process 100 of FIG. 16 to
produce the patterned apertured webs of the present disclosure is
illustrated in FIG. 18. The pattern of protuberances 116 on the
roller in FIG. 18 would be formed in the precursor web 102, much
like the melt-stabilized locations 202 of FIG. 17.
[0173] The protuberances 116 may extend radially outwardly from
surface 114 and have distal end surfaces 117. The anvil roller 112
may be a smooth surfaced, circular cylinder of steel, rubber or
other material. The anvil roller 112 and the patterned calendar
roller 110 may be switched in position (i.e., anvil on top) and
achieve the same result.
[0174] From the weakening roller arrangement 108, the material 102
passes through a nip 130 formed by an incremental stretching system
132 employing opposed pressure applicators having three-dimensional
surfaces which at least to a degree may be complementary to one
another.
[0175] Additional example patterns for protuberances 116 of roller
110 of FIG. 17 are illustrated in FIGS. 19-23. The machine
direction "MD" of the patterns is indicated. The pattern of FIG. 22
was used to produce the patterned apertured web of FIG. 3.
[0176] Referring now to FIG. 24, there is shown a fragmentary
enlarged view of the incremental stretching system 132 comprising
two incremental stretching rollers 134 and 136. The incremental
stretching roller 134 may comprise a plurality of teeth 160 and
corresponding grooves 161 which may about the entire circumference
of roller 134. The incremental stretching roller 136 may comprise a
plurality of teeth 162 and a plurality of corresponding grooves
163. The teeth 160 on the roller 134 may intermesh with or engage
the grooves 163 on the roller 136 while the teeth 162 on the roller
136 may intermesh with or engage the grooves 161 on the roller 134.
The spacing and/or pitch of the teeth 162 and/or the grooves 163
may match the pitch and/or spacing of the plurality of weakened,
melt stabilized locations 202 in the precursor material 102 or may
be smaller or larger. As the precursor material 102 having
weakened, melt-stabilized locations 202 passes through the
incremental stretching system 132 the precursor material 102 is
subjected to tensioning in the CD causing the material 102 to be
extended (or activated) in the CD, or generally in the CD.
Additionally the material 102 may be tensioned in the MD, or
generally in the MD. The CD tensioning force placed on the material
102 is adjusted such that it causes the weakened, melt-stabilized
locations 202 to at least partially, or fully, rupture thereby
creating a plurality of partially formed, or formed apertures 204
coincident with the weakened melt-stabilized locations 202 in the
material 102. However, the bonds of the material 102 (in the
non-overbonded areas) are strong enough such that they do not
rupture during tensioning, thereby maintaining the material 102 in
a coherent condition even as the weakened, melt-stabilized
locations rupture. However, it may be desirable to have some of the
bonds rupture during tensioning.
[0177] Referring to FIG. 25, a more detailed view of the teeth 160
and 162 and the grooves 161 and 163 on the rollers 134 and 136 is
illustrated. The term "pitch" refers to the distance between the
apexes of adjacent teeth. The pitch may be between about 0.02
inches to about 0.30 inches (about 0.51 mm to about 7.62 mm) or may
be between about 0.05 inches and about 0.15 inches (about 1.27 mm
to about 3.81 mm), specifically reciting all 0.001 inch increments
within the above-specified ranges and all ranges formed therein or
thereby. The height (or depth) of the teeth is measured from the
base of the tooth to the apex of the tooth, and may or may not be
equal for all teeth. The height of the teeth may be between about
0.010 inches (about 0.254 mm) and about 0.90 inches (about 22.9 mm)
or may be between about 0.025 inches (about 0.635 mm) and about
0.50 inches (about 12.7 mm), specifically reciting all 0.01 inch
increments within the above-specified ranges and all ranges formed
therein or thereby. The teeth 160 in one roll may be offset by
about one-half of the pitch from the teeth 162 in the other roll,
such that the teeth of one roll (e.g., teeth 160) mesh in the
valley (e.g., groove 163) between teeth in the mating roll. The
offset permits intermeshing of the two rolls when the rolls are
"engaged" or in an intermeshing, operative position relative to one
another. The teeth of the respective rolls may only be partially
intermeshing in some instances. The degree to which the teeth on
the opposing rolls intermesh is referred to herein as the "depth of
engagement" or "DOE" of the teeth. The DOE may be constant or not
constant. As shown in FIG. 25, the DOE, indicated as "E", is the
distance between a position designated by plane P1 where the apexes
of the teeth on the respective rolls are in the same plane (0%
engagement) to a position designated by plane P2 where the apexes
of the teeth of one roll extend inward beyond the plane P1 toward
the groove on the opposing roll. The optimum or effective DOE for
particular laminate webs may be dependent upon the height and the
pitch of the teeth and/or the structure of the material. Some
example DOEs may in the range of about 0.01 inches to about 0.5
inches, about 0.03 inches to about 0.2 inches, about 0.04 inches to
about 0.08 inches, about 0.05 inches, or about 0.06 inches,
specifically reciting all 0.001 inch increments within the
above-specified ranges and all ranges formed therein or
thereby.
[0178] As the material 102 having the weakened, melt-stabilized
locations 202 passes through the incremental web stretching
apparatus 132, the material 102 is subjected to tensioning in the
cross machine direction, or substantially in the cross machine
direction, thereby causing the nonwoven web 102 to be extended in
the cross machine direction. The tensioning force placed on the
material 102 may be adjusted by varying the pitch, DOE, or teeth
size, such that the incremental stretching is sufficient to cause
the weakened, melt-stabilized locations 202 to at least partially,
or fully rupture, thereby creating, or at least partially creating,
a plurality of apertures 204 coincident with the weakened,
melt-stabilized locations 202 in the material 102.
[0179] After the material 102 passes through the incremental web
stretching apparatus 132, the web 102 may be advanced to and at
least partially around a cross machine directional tensioning
apparatus 132' (see e.g., FIGS. 16 and 26). The cross machine
directional tensioning apparatus 132' may be offset from the main
processing line by running the web partially around two idlers 133
and 135 or stationary bars, for example. In other instances, the
cross machine tensioning apparatus 132' may be positioned in line
with the main processing line. The cross machine directional
tensioning apparatus 132' may comprise a roll that comprises at
least one outer longitudinal portion that expands along a
longitudinal axis, A, of the roll, relative to a middle portion of
the roll, to stretch and/or expand the material 102 in the cross
machine direction. Instead of or in addition to expanding along the
longitudinal axis, A, of the roll, the outer longitudinal portion
may be angled relative to the longitudinal axis, A, of the roll in
a direction away from the material 102 being advanced over the roll
to stretch the material 102 in the cross machine direction or
generally in the cross machine direction. In an instance, the roll
may comprise two outer longitudinal portions that each may expand
in opposite directions generally along the longitudinal axis, A, of
the roll. The two outer portions may both be angled downwards in a
direction away from the material 102 being advanced over the roll.
This movement or positioning of the outer longitudinal portions of
the roll allows for generally cross machine directional tensioning
of the material 102, which causes the plurality of weakened
locations 202 to rupture and/or be further defined or formed into
apertures 204.
[0180] The outer longitudinal portions of the roll may comprise
vacuum, a low tack adhesive, a high coefficient of friction
material or surface, such as rubber, and/or other mechanisms and/or
materials to hold the material 102 to the outer lateral portions of
the roll during movement of the outer longitudinal portion or
portions relative to the middle portion of the roll. The vacuum,
low tack adhesive, high coefficient of friction material or
surface, and/or other mechanisms and/or materials may prevent, or
at least inhibit, the held portions of the material 102 from
slipping relative to the longitudinal axis, A, of the roll during
stretching of the outer lateral portions of the material in the
cross machine direction or generally in the cross machine
direction.
[0181] FIG. 26 is a top perspective view of the example cross
machine directional tensioning apparatus 132'. The cross machine
directional tensioning apparatus 132' may comprise a roll
comprising a middle portion 2000 and two outer longitudinal
portions 2020 situated on either end of the middle portion 2000.
The roll may rotate about its longitudinal axis, A, on a drive
shaft 2040. The roll may rotate relative to the drive shaft 2040 or
in unison with the drive shaft 2040, as will be recognized by those
of skill in the art. The material 102 may be advanced over the
entire cross machine directional width of the middle portion 2000
and at least portions of the cross machine directional widths of
the outer longitudinal portions 2020. The material 102 may be
advanced over at least about 5% up to about 80% of the
circumference of the roll so that the cross machine directional
stretching may be performed.
[0182] FIG. 27 is a schematic representation of a front view of an
example cross machine directional tensioning apparatus with outer
longitudinal portions 2020 in an unexpanded or non-angled position
relative to the middle portion 2000. FIG. 28 is a schematic
representation of a front view of the cross machine directional
tensioning apparatus of FIG. 27 with the outer longitudinal
portions 2020 in a longitudinally expanded position relative to the
middle portion 2000. FIG. 29 is a schematic representation of a
front view of the cross machine directional tensioning apparatus of
FIG. 27 with the outer longitudinal portions 2020 in an angled and
expanded position relative to the middle portion 2000. In regard to
FIG. 29, the outer longitudinal portions 2020 may merely move or
slide in a direction generally perpendicular to the machine
direction of the material passing over the roll to apply the cross
machine directional tensioning force to the material 102. FIG. 30
is a schematic representation of a front view of a cross machine
directional tensioning apparatus with the outer longitudinal
portions 2020 fixed in an angled position relative to the middle
portion 2000 to apply the cross machine directional tensioning
force to the material 102. In such a form, the middle portion 2000
and each of the outer longitudinal portions 2020 may comprise a
separate roll.
[0183] Regardless of whether one or both of the outer longitudinal
portions 2020 is moved, slid, rotated, fixed, and/or expanded
relative to the middle portion 2000, this relative motion or
positioning between the outer longitudinal portions 2020 and the
middle portion 2000 stretches the materials 102 in a cross machine
direction to further rupture or further define the weakened
locations 2020 in the material 102 and create, or further form, a
plurality the apertures 2040 the material 102. The cross machine
directional tensioning force applied by the cross machine
directional tensioning apparatus 132' may be, for example, 10-25
grams or 15 grams. In an instance, the cross machine directional
tensioning apparatus may be similar to, or the same as, the
incremental stretching apparatus 132 to apply the cross machine
directional tensioning force. In still other instances, any
suitable cross machine directional tensioning apparatus may be used
to apply the cross machine directional tensioning force to the
material 102.
[0184] If desired, the incremental stretching step or the cross
machine directional stretching step described herein may be
performed at elevated temperatures. For example, the material 102
and/or the rolls may be heated. Utilizing heat in the stretching
step may serve to soften the material, and may aid in extending the
fibers without breaking.
[0185] Referring again to FIG. 16, the material 102 may be taken up
on wind-up roll 180 and stored. Alternatively, the material 102 may
be fed directly to a production line where it is used to form a
portion of an absorbent article or other consumer product.
[0186] It is important to note that the overbonding step
illustrated in FIGS. 16 and 17 could be performed by the material
supplier and then the material may be shipped to a consumer product
manufacturer to perform step 132. In fact, the overbonding step may
be used in the nonwoven production process to form overbonds, which
may be in addition to, or in lieu of, primary bonds formed in the
nonwoven production process. Alternatively, the material supplier
may fully perform the steps illustrated in FIG. 16 and then the
material may be shipped to the consumer product manufacturer. The
consumer product manufacturer may also perform all of the steps in
FIG. 16 after obtaining a nonwoven material from a nonwoven
material manufacturer.
[0187] One of ordinary skill in the art will recognize that it may
be advantageous to submit the material 102 to multiple incremental
stretching processes depending on various desired characteristics
of the finished product. Both the first and any additional
incremental stretching may either be done on-line or off-line.
Furthermore, one of ordinary skill will recognize that the
incremental stretching may be done either over the entire area of
the material or only in certain regions of the material depending
on the final desired characteristics.
[0188] Returning now to FIGS. 11-15, there is shown photographs of
example patterned apertured webs after having been subjected to the
tensioning force applied by the incremental stretching system 132
and the cross machine directional tensioning apparatus 132'. As can
be seen in the photographs of FIGS. and 11-15, the patterned
apertured webs now include a plurality of apertures 204 which are
coincident with the weakened, melt-stabilized locations made by the
roller 110 (with various patterns). A portion of the
circumferential edges of an aperture 204 may include remnants 205
of the melt-stabilized locations. It is believed that the remnants
205 help to resist further tearing of the material particularly
when the material is used as a portion of an absorbent article or
another consumer product.
Percent of CD Stretch
[0189] The extent to which the material 102 is stretched in the CD
may have a correlation to the size, shape, and area of the
apertures. In general, the apertures may have a larger area and be
more open the more the material 102 is stretched in the CD
direction by the cross machine directional tensioning apparatus
132'. As such, a manufacturer can further vary an aperture pattern
based on the amount of CD tensioning applied to a material even
when the melt-stabilized pattern in the material is the same. As an
example, FIG. 31 illustrates an overbond pattern in a material 102
prior to the incrementally stretching step 132 and the cross
machine directional tension step 132'. The plurality of
melt-stabilized locations are indicated as 202. The material is
then run through the incrementally stretching step 132 and the
cross machine directional tensioning apparatus 132'. The cross
machine directional tensioning apparatus 132' may be set to extend
the material 102 to over 100% of its CD width "W" after exiting the
incremental stretching apparatus 132, such as 125%, 135%, 145%,
155% of W. In other instances, the material 102 may be stretched in
the cross machine direction in the range of about 110% to about
180% of W, about 120% to about 170% of W, specifically reciting all
0.5% increments within the specified ranges and all ranged formed
therein or thereby. FIG. 32 illustrates an example of the material
102 with the overbond pattern of FIG. 31 and stretched to 125% of
W. FIG. 33 illustrates an example of the material 102 with the
overbond pattern of FIG. 31 and stretched to 135% of W. FIG. 34
illustrates an example of the material 102 with the overbond
pattern of FIG. 31 and stretched to 145% of W. FIG. 35 illustrates
an example of the material 102 with the overbond pattern of FIG. 31
and stretched to 155% of W. As illustrated, the amount of CD
stretch can be a significant factor on the patterned apertured web
produced.
Absorbent Article
[0190] As described herein, the patterned apertured webs of the
present disclosure may be used as one or more components of an
absorbent article. An example absorbent article is set forth below.
FIG. 36 is a plan view of an example absorbent article that is a
diaper 520 in its flat-out, uncontracted state (i.e., with elastic
induced contraction pulled out) with portions of the structure
being cut-away to more clearly show the construction of the diaper
520 and with the portion of the diaper 520 which faces the wearer,
the inner surface 540, facing the viewer. The diaper 520 may
comprise a chassis 522 comprising a liquid pervious topsheet 524, a
liquid impervious backsheet 26 joined to the topsheet, and an
absorbent core 528 positioned at least partially between the
topsheet 24 and the backsheet 26. The diaper 520 may comprise
elasticized side panels 530, elasticized leg cuffs 532, elasticized
waistbands 534, and a fastening system 536 that may comprise a pair
of securement members 537 and a landing member or landing zone on a
garment-facing surface or outer surface 542. The diaper 520 may
also comprise an outer cover 533 that may comprise one or more of
the patterned adhesive webs of the present disclosure. The outer
cover 533 may comprise nonwoven materials and/or films.
[0191] The diaper 520 is shown to have an inner surface 540 (facing
the viewer in FIG. 36), an outer surface 542 opposed to the inner
surface 540, a rear waist region 544, a front waist region 546
opposed to the rear waist region 544, a crotch region 548
positioned between the rear waist region 544 and the front waist
region 546, and a periphery which is defined by the outer perimeter
or edges of the diaper 520 in which the longitudinal edges are
designated 550 and the end edges are designated 552. The inner
surface 540 of the diaper 520 comprises that portion of the diaper
520 which is positioned adjacent to the wearer's body during use
(i.e., the inner surface 540 generally is formed by at least a
portion of the topsheet 524 and other components joined to the
topsheet 524). The outer surface 542 comprises that portion of the
diaper 520 which is positioned away from the wearer's body (i.e.,
the outer surface 542 is generally formed by at least a portion of
the backsheet 526 and other components joined to the backsheet
526). The rear waist region 544 and the front waist region 546
extend from the end edges 552 of the periphery to the crotch region
548.
[0192] The diaper 520 also has two centerlines, a longitudinal
centerline 590 and a transverse centerline 592. The term
"longitudinal", as used herein, refers to a line, axis, or
direction in the plane of the diaper 520 that is generally aligned
with (e.g., approximately parallel with) a vertical plane which
bisects a standing wearer into left and right halves when the
diaper 520 is worn. The terms "transverse" and "lateral", as used
herein, are interchangeable and refer to a line, axis or direction
which lies within the plane of the diaper that is generally
perpendicular to the longitudinal direction (which divides the
wearer into front and back body halves).
[0193] The chassis 522 of the diaper 520 is shown in FIG. 36 as
comprising the main body of the diaper 520. The containment
assembly 522 may comprise at least the topsheet 524, the backsheet
526, and the absorbent core 528. When the absorbent article 520
comprises a separate holder and a liner, the chassis 522 may
comprise the holder and the liner (i.e., the chassis 522 comprises
one or more layers of material to define the holder while the liner
comprises an absorbent composite such as a topsheet, a backsheet,
and an absorbent core.) For unitary absorbent articles (or one
piece), the chassis 522 comprises the main structure of the diaper
with other features added to form the composite diaper structure.
Thus, the chassis 522 for the diaper 520 generally comprises the
topsheet 524, the backsheet 526, and the absorbent core 528.
[0194] FIG. 36 shows a form of the chassis 522 in which the
topsheet 524 and the backsheet 526 have length and width dimensions
generally larger than those of the absorbent core 528. The topsheet
524 and the backsheet 526 extend beyond the edges of the absorbent
core 528 to thereby form the periphery of the diaper 520. While the
topsheet 524, the backsheet 526, and the absorbent core 528 may be
assembled in a variety of well known configurations know to those
of skill in the art.
[0195] The absorbent core 528 may be any absorbent member which is
generally compressible, conformable, non-irritating to the wearer's
skin, and capable of absorbing and retaining liquids such as urine
and other certain body exudates. As shown in FIG. 36, the absorbent
core 528 has a garment-facing side, a body-facing side, a pair of
side edges, and a pair of waist edges. The absorbent core 528 may
be manufactured in a wide variety of sizes and shapes (e.g.,
rectangular, hourglass, "T"-shaped, asymmetric, etc.) and from a
wide variety of liquid-absorbent materials commonly used in
disposable diapers and other absorbent articles such as comminuted
wood pulp which is generally referred to as airfelt. The absorbent
core may comprise superabsorbent polymers (SAP) and less than 15%,
less than 10%, less than 5%, less than 3%, or less than 1% of
airfelt, or be completely free of airfelt. Examples of other
suitable absorbent materials comprise creped cellulose wadding,
meltblown polymers including coform, chemically stiffened, modified
or cross-linked cellulosic fibers, tissue including tissue wraps
and tissue laminates, absorbent foams, absorbent sponges,
superabsorbent polymers, absorbent gelling materials, or any
equivalent material or combinations of materials. The absorbent
core may also comprise SAP and air felt in any suitable ranges.
[0196] The configuration and construction of the absorbent core 528
may vary (e.g., the absorbent core may have varying caliper zones,
a hydrophilic gradient, a superabsorbent gradient, or lower average
density and lower average basis weight acquisition zones; or may
comprise one or more layers or structures). Further, the size and
absorbent capacity of the absorbent core 528 may also be varied to
accommodate wearers ranging from infants through adults. However,
the total absorbent capacity of the absorbent core 528 should be
compatible with the design loading and the intended use of the
diaper 520.
[0197] Referring to FIGS. 37-39, the absorbent core 528 of the
absorbent articles may comprise one or more channels 626, 626',
627, 627' (627 and 627' are shown in dash in FIG. 36), such as two,
three, four, five, or six channels. The absorbent core 528 may
comprise a front side 280, a rear side 282, and two longitudinal
sides 284, 286 joining the front side 280 and the rear side 282.
The absorbent core 528 may comprise one or more absorbent
materials. The absorbent material 628 of the absorbent core 528 may
be distributed in higher amounts towards the front side 280 than
towards the rear side 282 as more absorbency may be required at the
front of the absorbent core 528 in particular absorbent articles.
The front side 280 may be positioned generally in the front waist
region of an absorbent article and the rear side 282 may be
positioned generally in the rear waist region of an absorbent
article.
[0198] A core wrap (i.e., the layers enclosing the absorbent
material of the absorbent core 528) may be formed by two nonwoven
materials, substrates, laminates, films, or other materials 616,
616'. The core wrap may be at least partially sealed along the
front side 280, the rear side 282, and/or the two longitudinal
sides 284, 286 of the absorbent core 528 so that substantially no
absorbent material is able to exit the core wrap. In a form, the
core wrap may only comprise a single material, substrate, laminate,
or other material wrapped at least partially around itself. The
first material, substrate, or nonwoven 616 may at least partially
surround a portion of the second material, substrate, or nonwoven
116' to form the core wrap, as illustrated as an example in FIG.
37. The first material 616 may surround a portion of the second
material 616' proximate to the first and second side edges 284 and
286 and/or the front side 280 and the rear side 282. Patterned
apertured webs of the present disclosure may have forms where the
patterned apertures in, for example a topsheet, a wearer-facing
laminate, an outer cover, and/or a garment-facing laminate may only
have patterned apertures overlapping at least some of the core
channels (e.g., channels 626 and 626' of FIG. 37). In other
instances, the patterned apertures in the topsheet, the
wearer-facing laminate, the outer cover, and/or the garment-facing
laminate may coordinate with or compliment the core channels in
such a way as the core channels are highlighted to a caregiver or
wearer. This concept may also apply to sanitary napkins having core
channels.
[0199] The absorbent core 528 of the present disclosure may
comprise one or more adhesives, for example, to help immobilize the
SAP or other absorbent materials 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 core wrap may extend to a
larger area than required for containing the absorbent material(s)
within.
[0200] Absorbent cores comprising relatively high amounts of SAP
with various core designs are disclosed in U.S. Pat. No. 5,599,335
to Goldman et al., EP 1,447,066 to Busam et al., WO 95/11652 to
Tanzer et al., U.S. Pat. Publ. No. 2008/0312622A1 to Hundorf et
al., and WO 2012/052172 to Van Malderen.
[0201] The absorbent material may comprise one or more continuous
layers present within the core wrap with channels having no, or
little (e.g., 0.1%-10%) absorbent material positioned therein. In
other forms, the absorbent material may be formed as individual
pockets or stripes within the core wrap. In the first case, the
absorbent material may be, for example, obtained by the application
of the continuous layer(s) of absorbent material, with the
exception of the absorbent material free, or substantially free,
channels. The continuous layer(s) 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 to Hundorf
et al., for example. The absorbent core 528 may comprise a first
absorbent layer and at least a second absorbent layer. The first
absorbent layer may comprise the first material 616 and a first
layer 661 of absorbent material, which may be 100% or less of SAP,
such as 85% to 100% SAP, 90% to 100% SAP, or even 95% to 100% SAP,
specifically including all 0.5% increments within the specified
ranges and all ranges formed therein or thereby. The second
absorbent layer may comprise the second material 616' and a second
layer 662 of absorbent material, which may also be 100% or less of
SAP (including the ranges specified above). The absorbent core 528
may also comprise a fibrous thermoplastic adhesive material 651 at
least partially bonding each layer of the absorbent material 661,
662 to its respective material 616, 616'. This is illustrated in
FIGS. 38 and 39, 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 amount of absorbent material (SAP)
to provide a profiled basis weight along the longitudinal axis 580'
of the core 528.
[0202] The fibrous thermoplastic adhesive material 651 may be at
least partially in contact with the absorbent material 661, 662 in
the land areas and at least partially in contact with the materials
616 and 616' in the channels 626, 626'. This imparts an essentially
three-dimensional structure to the fibrous layer of thermoplastic
adhesive material 651, 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 651 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 (including the ranges specified above).
[0203] The channels 626, 626' may be continuous or discontinuous
and may have a length of L' and a width, W.sub.c, for example, or
any other suitable length or width. The channels 626, 626', 627,
and 627' may have a lateral vector component and a longitudinal
vector component or may extend entirely longitudinally or entirely
laterally. The channels may each have one or more arcuate portions.
One or more channels may extend across the lateral axis or the
longitudinal axis 580' of the absorbent core 528, or both.
[0204] Referring to FIG. 38, it can be seen that the channels 626
and 626' do not comprise absorbent material. In other instances,
the channels 626 and 626' may comprise a relatively small amount
(compared to the amount of the absorbent material within the
remainder of the absorbent core 528) of absorbent material. The
relatively small amount of absorbent material within the channels
may be in the range of 0.1% to 20%, specifically reciting all 0.1%
increments within the specified ranges and all ranges formed
therein.
[0205] Referring again to FIG. 37, the absorbent core 528 may
comprise one or more pockets 650 (shown in dash). The one or more
pockets 650 may be provided in addition to the one or more channels
or instead of the one or more channels. The pockets 650 may be
areas in the absorbent core 528 that are free of, or substantially
free of absorbent material, such as SAP (including the ranges
specified above). The pockets 650 may overlap the longitudinal axis
580' and may be positioned proximate to the front side 280, the
rear side 282, or may be positioned at a location intermediate the
front side 280 and the rear side 282, such as longitudinally
centrally, or generally longitudinally centrally between the front
side 280 and the rear side 282.
[0206] Other forms and more details regarding channels and pockets
that are free of, or substantially free of absorbent materials,
such as SAP, within absorbent cores are discussed in greater detail
in U.S. Patent Application Publication Nos. 2014/0163500,
2014/0163506, and 2014/0163511, all published on Jun. 12, 2014.
[0207] The diaper 520 may have an asymmetric, modified T-shaped
absorbent core 528 having ears in the front waist region 546 but a
generally rectangular shape in the rear waist region 544. Example
absorbent structures for use as the absorbent core 528 of the
present disclosure that have achieved wide acceptance described in
U.S. Pat. No. 4,610,678, entitled "High-Density Absorbent
Structures" issued to Weisman et al., on Sep. 9, 1986; U.S. Pat.
No. 4,673,402, entitled "Absorbent Articles With Dual-Layered
Cores", issued to Weisman et al., on Jun. 16, 1987; U.S. Pat. No.
4,888,231, entitled "Absorbent Core Having A Dusting Layer", issued
to Angstadt on Dec. 19, 1989; and U.S. Pat. No. 4,834,735, entitled
"High Density Absorbent Members Having Lower Density and Lower
Basis Weight Acquisition Zones", issued to Alemany et al., on May
30, 1989. The absorbent core may further comprise the dual core
system containing an acquisition/distribution core of chemically
stiffened fibers positioned over an absorbent storage core as
detailed in U.S. Pat. No. 5,234,423, entitled "Absorbent Article
With Elastic Waist Feature and Enhanced Absorbency" issued to
Alemany et al., on Aug. 10, 1993; and in U.S. Pat. No. 5,147,345
entitled "High Efficiency Absorbent Articles For Incontinence
Management", issued to Young et al. on Sep. 15, 1992.
[0208] The backsheet 526 is positioned adjacent the garment-facing
surface of the absorbent core 528 and may be joined thereto by
attachment methods (not shown) such as those well known in the art.
For example, the backsheet 526 may be secured to the absorbent core
528 by a uniform continuous layer of adhesive, a patterned layer of
adhesive, or an array of separate lines, spirals, or spots of
adhesive. Alternatively, the attachment methods may comprise using
heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical
bonds, or any other suitable attachment methods or combinations of
these attachment methods as are known in the art. Forms of the
present disclosure are also contemplated wherein the absorbent core
is not joined to the backsheet 526, the topsheet 524, or both in
order to provide greater extensibility in the front waist region
546 and the rear waist region 544.
[0209] The backsheet 526 may be impervious, or substantially
impervious, to liquids (e.g., urine) and may be manufactured from a
thin plastic film, although other flexible liquid impervious
materials may also be used. As used herein, the term "flexible"
refers to materials which are compliant and will readily conform to
the general shape and contours of the human body. The backsheet 526
may prevent, or at least inhibit, the exudates absorbed and
contained in the absorbent core 528 from wetting articles which
contact the diaper 520 such as bed sheets and undergarments,
however, the backsheet 526 may permit vapors to escape from the
absorbent core 528 (i.e., is breathable). Thus, the backsheet 526
may comprise a polymeric film such as thermoplastic films of
polyethylene or polypropylene. A suitable material for the
backsheet 526 is a thermoplastic film having a thickness of from
about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils), for
example.
[0210] The topsheet 524 is positioned adjacent the body-facing
surface of the absorbent core 528 and may be joined thereto and to
the backsheet 526 by attachment methods (not shown) such as those
well known in the art. Suitable attachment methods are described
with respect to joining the backsheet 526 to the absorbent core
528. The topsheet 524 and the backsheet 526 may be joined directly
to each other in the diaper periphery and may be indirectly joined
together by directly joining them to the absorbent core 528 by the
attachment methods (not shown).
[0211] The topsheet 524 may be compliant, soft feeling, and
non-irritating to the wearer's skin. Further, the topsheet 524 may
be liquid pervious permitting liquids (e.g., urine) to readily
penetrate through its thickness. A suitable topsheet 524 may
comprise one or more of the patterned apertured webs of the present
disclosure forming one or more layers. As described herein, the
patterned apertured webs of the present disclosure may form any
other suitable components, or portions thereof, of an absorbent
article or the example diaper 520, such as an outer cover; an outer
cover and a backsheet; a carrier layer (as referenced above); an
ear panel; an acquisition material; a distribution material; an
acquisition material and a topsheet; a distribution material and a
topsheet; a first acquisition material; a second acquisition
material; a first acquisition or distribution material and a second
acquisition or distribution material; a topsheet, a first
acquisition or distribution material, and a second acquisition or
distribution material; a topsheet, a patch joined to or positioned
on a topsheet; and a topsheet and a secondary topsheet, for
example. Apertures may be formed through any or all of these
materials, for example. In an example, an apertured or patterned
apertured topsheet may be embossed or otherwise joined to an
acquisition material, to an acquisition material and a distribution
material, or to an acquisition material, a distribution material
and a carrier layer, for example.
[0212] In an instance of a patterned apertured web, a first layer
may comprise a topsheet and a second layer may comprise an
acquisition material or layer. The acquisition material or layer
may be a discrete patch that is not as long and/or wide as the
topsheet or that may be the same size as the topsheet. The first
layer and/or the second layer may have patterned apertures having
any of the features described herein. Either of the layers may be
pre-strained prior to being joined to the other layer, as described
herein, thereby creating three-dimensional features in the
topsheet/acquisition material laminate. By providing a patterned
apertured web comprising a topsheet as a first layer and comprising
an acquisition material as a second layer, improved fluid
acquisition may be achieved as well as improved depth perception of
the absorbent article owing to the relatively high basis weight of
the acquisition material. In a feminine care context, the
acquisition material may be a secondary topsheet.
Sanitary Napkin
[0213] Referring to FIG. 40, the absorbent article may be a
sanitary napkin 310. A topsheet, a secondary topsheet, wings, or
another portion of the sanitary napkin may comprise one or more of
the patterned apertured webs of the present disclosure. The
sanitary napkin 310 may comprise a liquid permeable topsheet 314, a
liquid impermeable, or substantially liquid impermeable, backsheet
316, and an absorbent core 318 positioned intermediate the topsheet
314 and the backsheet 316. The absorbent core 318 may have any or
all of the features described herein with respect to the absorbent
cores 28 and, in some forms, may have a secondary topsheet instead
of the acquisition layer(s) disclosed above. The sanitary napkin
310 may comprise wings 320 extending outwardly with respect to a
longitudinal axis 380 of the sanitary napkin 310. The sanitary
napkin 310 may also comprise a lateral axis 390. The wings 320 may
be joined to the topsheet 314, the backsheet 316, and/or the
absorbent core 318. The sanitary napkin 310 may also comprise a
front edge 322, a rear edge 324 longitudinally opposing the front
edge 322, a first side edge 326, and a second side edge 328
longitudinally opposing the first side edge 326. The longitudinal
axis 380 may extend from a midpoint of the front edge 322 to a
midpoint of the rear edge 324. The lateral axis 390 may extend from
a midpoint of the first side edge 328 to a midpoint of the second
side edge 328. The sanitary napkin 310 may also be provided with
additional features commonly found in sanitary napkins as is known
in the art.
Patterned Adhesive
[0214] Any of the patterned apertured webs and/or absorbent
articles of the present disclosure, or portions thereof, may
comprise one or more patterned adhesives applied thereto or printed
thereon. The patterned adhesives may be present on the patterned
apertured webs or under the patterned apertured webs such that at
least a portion of the patterned adhesives may be viewable through
the patterned apertured webs, either though apertures or
non-apertured areas. Patterned adhesives are adhesives that are
applied to one or more layers of the patterned apertured webs, or
between layers of the same, in particular patterns to provide the
absorbent articles, or portions thereof, with certain patterns,
visible patterns, and/or certain textures.
[0215] FIGS. 41 and 42 illustrate example patterns of adhesives, or
pigmented adhesives, that can be used with the patterned apertured
webs of the present disclosure. For example, these adhesive
patterns may be used with the example patterned apertured web
pattern of FIG. 15. These patterned adhesives can also be used with
non-apertured layers having overbonds or embossments. The patterned
adhesives may be printed on one or more apertured or non-apertured
layers of the patterned apertured webs or patterned webs having
embossments or overbonds. Other adhesive patterns having any
suitable configuration are also within the scope of the present
disclosure. The patterned adhesives may be printed on or otherwise
applied to any suitable layer of the patterned apertured webs or
applied above or beneath them. Methods for applying patterned
adhesives to layers or substrates by adhesive printing are
disclosed, for example, in U.S. Pat. No. 8,186,296, to Brown et
al., issued on May 29, 2012, and in U.S. Pat. Appl. Publ. No.,
2014/0148774, published on May 29, 2014, to Brown et al. Other
methods of applying patterned adhesives to substrates known to
those of skill in the art are also within the scope of the present
disclosure.
[0216] A patterned adhesive may have the same color or a different
color as at least one layer of a patterned apertured web. In some
instances, the patterned adhesive may have the same or a different
color as both or all layers of a patterned apertured web. In some
instances, aperture patterns in at least one layer of a patterned
apertured web may coordinate with a patterned of a patterned
adhesive to visually create a three-dimensional appearance. The
apertured patterns may be the same or different than patterns of
the patterned adhesive.
[0217] In an instance, a patterned apertured web may comprise a
first layer comprising a plurality of apertures and a plurality of
land areas and a second layer comprising a plurality of apertures
and a plurality of land areas. A patterned pigmented substance,
such as ink or a patterned adhesive, may be positioned at least
partially intermediate the first layer and the second layer. The
patterned pigmented substance may be positioned on land areas of
the first layer and/or the second layer. The plurality of apertures
of the first layer may be at least partially aligned with the
plurality of apertures of the second layer (see e.g., FIG. 8). The
patterned pigmented or colored substance (e.g., 29 of FIG. 8) may
be at least partially viewable through the apertures in one of the
first or second layers.
Patterns
[0218] The apertures in at least one layer of a patterned apertured
web may be grouped in spaced arrays of apertures (see e.g., FIGS.
1-4 and 43). FIG. 43 shows example arrays of apertures, labeled as
"A". An aperture array may include two or more, or three or more
apertures having much closer spacing between the apertures than the
distance between the aperture arrays. The distance between the
array and other apertures may be at least about 1.5, at least about
2 times, or at least about 3 times the maximum distance between
apertures in the array. The aperture arrays may form a regular or
recognizable shape, such as a heart shape, polygon, ellipse, arrow,
chevron, and/or other shapes known in the pattern art. The
apertures arrays may differ in one portion of the patterned
apertured web compared to another portion of the patterned
apertured web. In an absorbent article context, the aperture arrays
may differ in one region of the absorbent article compared to
another region of the absorbent article. The aperture arrays may
have perimeters that are concave, convex, or may include
concavities and convexities. The aperture arrays may be organized
into "macro-arrays" having a higher order structure. For example,
referring to FIGS. 43 and 44, a patterned apertured web 1000 is
illustrated with aperture arrays 1002 that may be separated by a
continuous, inter-connected land area pattern 1004. In such an
instance, the land area pattern 1004 may function as a fluid
distribution pathway and the aperture arrays 1002 may function as
fluid "drains" thereby promoting fluid access to the underlying
absorbent material or absorbent core. The shape of the aperture
arrays may enhance the ability of the arrays to manage fluid, such
as bodily exudates (i.e., urine, runny BM, menses). For example,
aperture arrays including a concavity facing a fluid insult
location in an absorbent article may function as fluid collection
"traps" as the fluid may travel along the "land area" in the
concavity to a point where the concavity ends. At this location,
the fluid may enter the apertures in the direction of the fluid
path or those on either side of the concavity if the fluid turns in
either lateral direction. Example aperture array shapes having a
concavity include heart shapes, star shapes, some polygons,
crescents, and chevrons, to name a few examples.
[0219] In an instance, referring to FIGS. 45-47, apertures, or
arrays thereof, in a patterned apertured web 1000, may form one or
more continuous or semi-continuous patterns 1006, resulting in
discrete "macro" land areas 1008. In such an instance, the discrete
macro land areas 1008 may function as fluid deposition regions.
Fluid moving from the discrete macro land areas 1008 in any
direction may be absorbed into the apertures of the continuous or
semi-continuous pattern 1006.
[0220] In an instance, referring to FIGS. 48-52, the apertures, or
aperture arrays thereof, in a patterned apertured web 1000 may form
linear patterns 1110 alternating with continuous or semi-continuous
land areas 1112. The patterned apertured webs may include
unidirectional or multi-directional (and intersecting) aperture or
aperture array patterns. Linear aperture or array patterns may be
oriented parallel to the longitudinal or lateral axis, or at an
angle between 0 and 90 degrees, specifically reciting all 0.5
degree increments within the specified range and all ranges formed
therein, from either the longitudinal or lateral axis. Linear
apertures or aperture array patterns may function to restrict fluid
movement along the patterned apertured web to a greater degree in
one direction compared to another direction.
[0221] The aperture pattern in a patterned apertured web may
coordinate with graphics, indicia, printing, inks, color, and/or
patterned adhesives, for example, located beneath the patterned
apertured web or within the patterned apertured web. In an
instance, the patterned apertured web may be used a topsheet, an
outer cover, an ear, wings of a sanitary napkin, or other portion
of an absorbent article.
[0222] The aperture pattern in a patterned apertured web may
coordinate with features under it, such as bond sites, material
edges, channels, and/or discolored or colored materials. By
coordinating with these features it is meant that the patterned
apertured web may be used to accentuate or block/hide these
features. The aperture patterns of a patterned apertured web may
also be used to indicate the correct front vs. rear, left vs. right
orientation of an absorbent article or other consumer product.
[0223] If a patterned apertured web is used as part, or all of, an
outer cover (garment-facing layer) of an absorbent article, the
aperture pattern or patterns may provide enhanced breathability in
certain regions (e.g., waist, hips) or reduced breathability in
areas over an absorbent core, for example. The aperture pattern or
patterns in a patterned apertured web used as an outer cover may
also provide enhanced textures and/or signals in certain regions of
the outer cover. Such texture and/or signals may provide intuitive
instructions on how to property apply the absorbent article, where
to grip the absorbent article, and/or where/how to fasten the
absorbent article, among other functions, such as to enhance
graphics or aesthetics.
[0224] If a patterned apertured web is used as a portion of a leg
cuff of an absorbent article, an apertured pattern of the patterned
apertured web of the leg cuff may coordinate with an aperture
pattern of a patterned apertured web used as a topsheet and/or an
outer cover of the same absorbent article to signal a holistic
function.
[0225] If a patterned apertured web is used as a portion of a
fastener (e.g., taped fastener) of an absorbent article, an
apertured pattern of a patterned apertured web of the fastener may
indicate how to grip and fasten the fastener and indicate when it
is and is not fastened correctly. An apertured pattern of the
patterned apertured web used as a fastener, or portion thereof, may
coordinate with an aperture pattern of a patterned apertured web
used as a topsheet and/or an outer cover of the same absorbent
article to signal a holistic function.
[0226] The optimum balance of bodily exudate acquisition speed and
rewet in an absorbent article comprising a patterned apertured web
as a topsheet and/or topsheet and acquisition system may be derived
from a combination of aperture diameter, shape or area, depth or
thickness of the patterned apertured web, and the spacing between
the various apertures or aperture arrays within the patterned
apertured web.
[0227] An absorbent article comprising a patterned apertured web as
a topsheet and/or a topsheet and an acquisition system may comprise
a longitudinal axis, much like the longitudinal axis of 590 of FIG.
36. Arrays of apertures in the patterned apertured web may repeat
themselves along a line that is angled about 20 degrees to about
160 degrees, specifically reciting all 1 degree increments within
the specified range and all ranges formed therein, relative to the
longitudinal axis. Additionally, there may be a plurality of
aperture sizes, shapes, or areas along the line or the spacing
between the apertures may not the same between all of the apertures
along the line for purposes of channeling liquid bodily exudates
into preferred areas of the absorbent article or the absorbent core
thereof to help avoid leakage.
[0228] An aperture pattern in a patterned apertured web may form a
recognizable visual element, such as a heart or a water droplet,
for example. An aperture pattern that forms one or more water
droplet shapes in a patterned apertured web used as a topsheet or
an outer cover of an absorbent article may be used to aid
communication of absorbency and/or wetness. Such a feature may be
combined with a wetness indicator of an absorbent article.
[0229] Various commonly understood shapes may be created in a
patterned apertured web. These shapes may be shapes that have
commonly understood proper orientations, such as hearts, for
example. An example is the use of one or more hearts on an outer
cover or a topsheet of a front waist region and/or a back waist
region of a diaper. The caregiver would understand to place the
diaper on the wearer with the point of the heart facing toward the
wearer's feet because of the common knowledge of the orientation of
hearts.
[0230] In an instance, a patterned apertured web may comprise a
first non-apertured layer comprising a pattern having a color and a
second patterned apertured layer comprising a pattern of apertures.
The pattern on the first non-apertured layer may be printed on the
layer, for example, and may form graphics or other indicia. At
least 50% to 100% of the pattern on the first non-apertured layer
may be aligned with the pattern of apertures in the second
patterned apertured layer to draw attention to the apertures. The
alignment, or partial alignment, of the pattern of apertures on the
first layer with the pattern having a color of the second layer may
make aid in aligning the product on a wearer if the patterned
apertured web is provided on an absorbent article.
Zones
[0231] In any context of a patterned apertured web, but especially
in an absorbent article context, the patterned apertured webs may
be employed in a zonal fashion. For instance, a first zone of a
topsheet or outer cover of an absorbent article may have a first
patterned apertured web having a first pattern, while a second zone
of the topsheet or the outer cover of the absorbent may have a
second patterned apertured web having a second, different pattern.
In a topsheet context, for example, the patterns in the different
zones may be configured to receive certain bodily exudates or
inhibit or encourage their flow in any desired direction. For
example, the first pattern may be better configured to receive
and/or direct the flow of urine, while the second pattern may be
better configured to receive and/or direct the flow of runny BM. In
other instances where the patterned apertured webs are used as a
topsheet of an absorbent article, a first patterned apertured web
having a first pattern may be configured to receive heavy gushes of
bodily exudates, while a second patterned apertured web having a
second different pattern may be configured to restrict lateral
bodily exudate flow in any desired direction. The first pattern may
be situated in, for instance, the middle of the absorbent article
or in the crotch region, while the second pattern may be situated
in the front and rear waist regions or outer perimeter topsheet
regions of the absorbent article.
[0232] The zones in a patterned apertured web may be positioned in
the machine direction, the cross direction, or may be concentric.
If a product, such as an absorbent article, has two different zones
in the machine direction, the zones may have the same or a similar
cross-direction width (e.g., +/-2 mm) for ease in processing. One
or more of the zones may have curved or straight boundaries or
partial boundaries.
[0233] Any suitable zones, including more than two, of different or
the same patterned apertured webs, are envisioned within the scope
of the present disclosure. The various zones may be in the topsheet
as mentioned above, but may also be present on an outer cover, a
barrier leg cuff, or any other portion of ab absorbent article or
other product, for example. In some instances, the same or a
different pattern of zones of patterned apertured webs may be used
on the wearer-facing surface (e.g., topsheet) and the
garment-facing surface (e.g., outer cover).
[0234] In an instance, a topsheet or other portion of an absorbent
article may have two or more zones in a patterned apertured web. A
first zone of the patterned apertured web may have a different
aperture pattern than a second zone. The first zone and the second
zone may have different functionalities owing to the different
aperture patterns. A functionality of the first zone may be to
provide liquid bodily exudate distribution (fluid moving on the
patterned apertured web), while the functionality of the second
zone may be to provide liquid bodily exudate acquisition (fluid
penetrating the patterned apertured web). Benefits of such a zoned
patterned apertured web can be better use of an absorbent core and
more efficient liquid bodily exudate distribution within the
absorbent core.
[0235] In an instance, an absorbent article may comprise a
patterned apertured web that forms a first portion and a second,
different portion thereof. Aperture patterns in each portion of the
patterned apertured web may be the same, substantially similar, or
different. In another instance, an absorbent article may comprise a
patterned apertured web that comprises a first portion of an
absorbent article, and wherein a second portion of the absorbent
article has graphics, printing, patterned adhesives, or other
indicia that forms a pattern that is similar to, substantially
similar to, coordinates with, or is different than an aperture
pattern in the patterned apertured web.
[0236] In an instance, a patterned apertured web may have a
plurality of zones. A first zone may have at least some apertures
having a first angle (central longitudinal axis of aperture vs.
MD), first size, and/or first shape, while a second zone (or third
or fourth zone etc.) may have apertures having a second, different
angle (central longitudinal axis of aperture vs. MD), second,
different size, and/or second, different shape.
Visual Texture
[0237] Apertures, patterned apertures, aperture arrays,
three-dimensional elements, printing, patterned adhesives, or any
combinations of these "texture elements" may impart a variable
visually observed texture in a patterned apertured web. Variations
in observable textures have been extensively studied in the
psychological and neurological sciences. Some small texture
elements are much more readily ("instantly") detected by the human
visual perception system than others. Most texture patterns having
similar "second order" (iso-dipole) statistics cannot be
discriminated in a brief "flash" observation. However, exceptions
to this (i.e., iso-dipole texture elements that are easily
discriminated) have been defined and are known in the literature as
"textons". Patterned apertured webs including texture elements
forming texton shapes provide a way to create easily recognizable
"zones" on a laminate or in an absorbent article, signaling regions
having different functions, and/or providing strong cues as to
correct product orientation on a wearer (e.g., front/back). Forms
of the patterned apertured webs of the present disclosure may
include texture elements forming texton shapes, including
quasi-collinearity, corner features, and closure of local features.
A reference is Julesz, B., et al, Visual Discrimination of Textures
with Identical Third-Order Statistics, Biological Cybernetics vol.
31, 1978, pp. 137-140).
Effective Open Area
[0238] A patterned apertured web may have an Effective Open Area
between about 3% to about 50%, about 5% to about 50%, about 5% to
about 40%, about 10% to about 40%, about 10% to about 35%, about
10% to about 30%, or about 15% to about 30%, specifically reciting
all 0.1% increments within the specified ranges and all ranges
formed therein or thereby. All Effective Open Area percents are
determined using the Aperture Test described herein. Patterned
apertured webs having a higher Effective Open Area may have utility
as a topsheet or acquisition layer or system in an absorbent
article (more functional to absorbent bodily exudates), while
patterned apertured webs having a lower Effective Open Area may
have utility as an outer cover of an absorbent article (more
decorative or for breathability purposes).
Effective Aperture Area
[0239] A patterned apertured web may have apertures having an
Effective Aperture Area in the range of about 0.3 mm.sup.2 to about
15 mm.sup.2, 0.3 mm.sup.2 to about 14 mm.sup.2, 0.4 mm.sup.2 to
about 12 mm.sup.2, 0.3 mm.sup.2 to about 10 mm.sup.2, 0.5 mm.sup.2
to about 8 mm.sup.2, or 1.0 mm.sup.2 to about 8 mm.sup.2,
specifically reciting all 0.05 mm increments within the specified
ranges and all ranges formed therein or thereby. All Effective
Aperture Areas are determined using the Aperture Test described
herein. A plurality of the apertures in a patterned apertured web
may be different in Effective Aperture Areas. The Relative Standard
Deviation of the Effective Aperture Areas in a patterned apertured
web may be at least about 50%, or at least about 55%, or at least
about 60%, for example.
Aperture Aspect Ratio
[0240] The apertures of the patterned apertured webs of the present
disclosure may have an aspect ratio of greater than one, for
example, greater than two, greater than 3, greater than 5, or
greater than 10, but typically less than 15, according to the
Aperture Test herein. The aperture patterns in the patterned
apertured web may comprise apertures having more than one aspect
ratio, such as two or more distinct populations or having a
substantially continuous distribution of aspect ratios having a
slope greater than zero. Additionally, the aperture patterns of the
patterned apertured webs may comprise apertures with more than two
effective aperture areas, either as two or more distinct
populations or as a distribution of aperture areas having a slope
greater than zero. The Relative Standard Deviation of the aperture
aspect ratios in a patterned apertured web may be at least about
30%, at least about 40%, or at least about 45%.
Aperture Density
[0241] The apertures of the patterned aperture webs of the present
disclosure may have an Aperture Density, according to the Aperture
Test herein, of at least about 150, at least about 175, at least
about 200, or at least about 300, for example.
Method
[0242] A method of producing a patterned apertured web is provided.
The method may comprise providing a web having a central
longitudinal axis. The web may comprise a plurality of overbonds
extending substantially parallel to, or parallel to, the central
longitudinal axis. Substantially parallel means +/-5 degrees or
+/-3 degrees or less. The method may comprise conveying the web in
a machine direction. The machine direction may be substantially
parallel to, or parallel to, a direction of extension of the
central longitudinal axis of the web. The method may comprise
stretching the web in a cross-machine direction that is
substantially perpendicular (+/-5 degrees or +/-3 degrees or less)
to the machine direction to cause at least some of, most of, or all
of, the overbonds to at least partially rupture, or fully rupture,
and at least partially form, or form, patterned apertures in the
web. At least some of the patterned apertures may have Absolute
Feret Angles, according to the Aperture Test herein, of at least
about 10 degrees, at least about 15 degrees, at least about 20
degrees, at least about 25 degrees, at least about 30 degrees, at
least about 35 degrees, at least about 40 degrees, at least about
45 degrees, or in the range of about 10 degrees to about 45, or
about 15 to about 35 degrees, specifically reciting all 0.1 degree
increments within the specified ranges and all ranges formed
therein or thereby. At least some of the patterned apertures may
have an Aspect Ratio, according to the Aperture Test herein, of
greater than about 1.5:1, greater than about 1.8:1, greater than
about 2:1, greater than about 2.5:1, greater than about 3:1, or in
the range of about 1.5:1 to about 10:1, about 2:1 to about 6:1,
about 2:1 to about 5:1, or about 2:1 to about 4:1, specifically
reciting all 0.1 increments (e.g., 1.6:1, 1.7:1, 1.8:1) within the
specified ranges and all ranges formed therein or thereby. The
overbond may be at least partially ruptured, or fully ruptured, to
form the patterned apertures using the process illustrated and
described with respect to FIGS. 16, 17, and 24-30, for example.
[0243] At least some of the patterned apertures may have Absolute
Feret Angles, according to the Aperture Test herein, in the range
of about 0 degrees to about five degrees, or about 0 degrees (i.e.,
+/-2 degrees). Thus, some of the patterned apertures may be angled
relative to the machine direction, while others may not. The
patterned apertures may comprise a first plurality of patterned
apertures and a second plurality of patterned apertures. Central
longitudinal axes of the first plurality of patterned apertures may
extend in a first direction relative to the machine direction.
Central longitudinal axes of the second plurality of apertures may
extend in a second, different direction relative to the machine
direction. The second different direction may be at least about 5
degrees, at least about 10 degrees, at least about 15 degrees, at
least about 20 degrees, at least about 30 degrees, at least about
40 degrees, at least about 50 degrees, at least about 60 degrees,
at least about 70 degrees, at least about 80 degrees, at least
about 90 degrees, or in the range of about 10 degrees to about 90
degrees, or about 20 degrees to about 70 degrees, specifically
reciting all 0.1 degree increments within the above-specified
ranges and all ranges formed therein or thereby, different than the
first direction. The first direction may have a positive slope
relative to the machine direction and the second direction may have
a negative slope relative to the machine direction. In other
instances, the first direction and the second direction may both
have a positive slope or may both have a negative slope. At least
some of the plurality of the overbonds may form a diamond-shaped or
diamond-like pattern in the web. Land areas may be formed at least
partially around, or fully around, at least some of the plurality
of the overbonds or the patterned apertures. At least some of the
patterned apertures, such as 2 or more, 3 or more, or 4 or more may
be non-homogenous meaning that they are designed to have a
different size, shape, Absolute Feret Angle, according to the
Aperture Test herein, and/or Aspect Ratio, according to the
Aperture Test herein.
[0244] A method of forming patterned apertures in a web is
provided. The method may comprise providing a web having a central
longitudinal axis, conveying the web in a machine direction that is
substantially parallel to the central longitudinal axis, and
creating a plurality of overbonds in the web. The overbonds may
have central longitudinal axes that are substantially parallel to
the central longitudinal axis of the web. The method may comprise
stretching the web in a cross-machine direction that is
substantially perpendicular to, or perpendicular to, the machine
direction to at least partially form, or fully form, patterned
apertures in the web at, at least some of, or most of, or all of,
the overbonds. At least some of the patterned apertures may have
Absolute Feret Angles, according to the Aperture Test herein, of at
least about 20 degrees (and other numbers and ranges set forth
above). At least some of the patterned apertures may have an Aspect
Ratio, according to the Aperture Test herein, of greater than about
2:1 (and other numbers and ranges set forth above). At least some
of patterned apertures may have Absolute Feret Angles, according to
the Aperture Test herein, of at least about 30 degrees (and other
numbers and ranges set forth above). The patterned apertures may
comprise a first plurality of patterned apertures and a second
plurality of patterned apertures. Central longitudinal axes of the
first plurality of patterned apertures may extend in a first
direction. Central longitudinal axes of the second plurality of
patterned apertures may extend in a second, different direction.
The second different direction may be at least about 10 degrees or
at least about 30 degrees (and other numbers and ranges set forth
above) different than the first direction.
[0245] A method of producing a patterned apertured web is provided.
The method may comprise providing a web having a central
longitudinal axis. The web may comprise a plurality of overbonds
extending substantially parallel to, or parallel to, the central
longitudinal axis. The method may comprise conveying the web in a
machine direction that is substantially parallel to, or parallel
to, a direction of extension of the central longitudinal axis of
the web. The method may comprise stretching the web in a
cross-machine direction that is substantially perpendicular to, or
perpendicular to, the machine direction to cause at least some of,
or most of, or all of, the overbonds to at least partially rupture,
or fully rupture, and at least partially form, or fully form,
apertures in the web. At least some of the apertures have Absolute
Feret Angles, according to the Aperture Test herein, that are at
least about 25 degrees (and other numbers and ranges set forth
above). At least some of the apertures have an Aspect Ratio,
according to the Aperture Test herein, in the range of about 2:1 to
about 6:1 (and other ratios and ranges as set forth above. At least
two, three, four, or five of the apertures may be
nonhomogeneous.
[0246] Patterned apertured webs having apertures having different
Absolute Feret Angles may provide liquid bodily exudate handling
benefits when the patterned apertured webs are used as topsheets in
absorbent articles, for example. For example, fluid run-off may be
reduced in the front or back of the absorbent article when all of
the Absolute Feret Angles are not all about 0 degrees, but instead
are greater than 0 degrees, such as about 15 degrees, about 20
degrees, about 30 degrees, about 45 degrees, or even about 90
degrees, as the apertures can more readily acquire the liquid
bodily exudates. Therefore, it may be desirable to have apertures
having different Absolute Feret Angles to most effectively acquire
liquid bodily exudates running along the surface of the patterned
apertured web and prevent, or at least inhibit, run-off and soiling
of garments.
[0247] In some example patterned apertured webs of the present
disclosure, a pattern of overbonds, each of which is oriented
solely in the machine direction, or substantially in the machine
direction (i.e., +/-5 degrees +/-3 degrees or less from the machine
direction), may be used to create a patterned apertured web with
apertures having Absolute Feret Angles or central longitudinal axes
that are not all oriented in the machine direction or, stated
another way, that are angled more than 5 degrees with respect to
the machine direction or have Absolute Feret Angles that are
greater than 5 degrees, greater than 10 degrees, greater than 15
degrees, greater than 25 degrees, or greater than 30 degrees.
Referring to FIG. 53, an example overbond pattern having overbonds
"O" oriented solely in the machine direction are illustrated. The
overbond pattern of FIG. 53 may be used to produce the patterned
apertured web 10 of FIG. 53A, for example. The patterned apertured
web 10 of FIG. 53A may have some apertures 12 having a central
longitudinal axis, L, having an angle with respect to the machine
direction or an Absolute Feret Angle greater than 5 degrees. The
Absolute Feret Angle may be any of the numbers or ranges set for
the above. Some of the apertures 12 in the patterned apertured web
10 may also have a central longitudinal axis, L1, that extends
parallel to, or substantially parallel to (e.g., +/- less than 5
degrees), the machine direction or apertures 12 having Absolute
Feret Angles in the range of about 0 to about 5 degrees. The cross
directional stretching step or steps described herein may be used
to create the apertures and to orient the central longitudinal
axes, L, of at least some of the apertures in a direction not
parallel to, or substantially parallel to, the machine direction.
At least some of the apertures in a patterned apertured web having
their central longitudinal axes not parallel to, or substantially
parallel to, the machine direction may have a first plurality of
apertures having central longitudinal axes extending in a first
direction with respect to the machine direction and a second
plurality of apertures having central longitudinal axes extending
at a second, different direction relative to the machine direction.
Those of skill in the art will recognize that other angles relative
to the machine direction are also within the scope of the present
disclosure.
[0248] The apertures in a patterned apertured web having a central
longitudinal axis angled with respect to the machine direction and
produced by machine direction overbonds may be more open (i.e.,
have a lower aspect ratio) than they would have been if the
overbonds had been oriented at an angle (5 degrees or more) with
respect to the machine direction. Overbonds oriented at an angle
with respect to the machine direction typically produce apertures
having higher aspect ratios post cross-directional stretching that
are less open.
Fused Portions
[0249] Referring to FIG. 54, areas surrounding at least a portion
of an aperture 12 in a patterned apertured web of the present
disclosure may comprise one or more fused portions 5000. The fused
portions 5000 may at least partially surround the apertures 12, or
fully surround the apertures 12. The fused portions 5000 may
surround at least 25% of a perimeter of the apertures 12 up to
about 100% of the perimeter of the apertures 12. In some instances,
the fused portions 5000 may be formed on the lateral sides of the
apertures 12 and not on the leading and trailing edges of the
apertures 12 (see MD and CD arrows for reference in FIG. 54). The
fused portions 5000 are believed to be formed during the
overbonding step and are believed to add strength to the patterned
apertured webs.
Example Overbond Patterns for Patterned Apertured Webs
[0250] Some example schematic representations of additional
overbond patterns that could be used on an overbonding roller, like
roller 110 of FIG. 16 are illustrated in FIGS. 55-60. Those of
skill in the art will recognize that other suitable overbond
patterns are also within the scope of the present disclosure, along
with variations of the illustrated patterns.
Interaperture Distance and Average Interaperture Distance
[0251] The patterned apertured webs or layers thereof may have
apertures that have an Average Interaperture Distance of less than
about 3.5 mm, less than about 3 mm, less than about 2.5 mm, less
than about 2 mm, less than about 1.5 mm, less than about 1 mm, in
the range of about 1 mm to about 3.5 mm, in the range of about 1 mm
to about 3 mm, in the range of about 1 mm to about 2.5 mm, or in
the range of about 3.5 mm to about 10 mm, specifically reciting all
0.1 mm increments within the above-specified ranges and all ranges
formed therein or thereby, according to the Aperture Test
herein.
[0252] A patterned apertured web may have Interaperture Distances,
calculated according to the Aperture Test herein. The Interaperture
Distances may have a distribution having a mean and a median. The
mean may be greater than, different than, or less than the median.
The mean may be greater than, different than, or less than the
median in the range of about 3% to about 25%, about 4% to about
25%, about 5% to about 20%, about 8% to about 20%, or about 4% to
about 15%, for example, specifically reciting all 0.1% increments
within the above-specified ranges and all ranges formed therein or
thereby. A first zone of a patterned apertured web may have
Interaperture Distances. The Interaperture Distances of the first
zone may have a first distribution having a first mean and a first
median. The first mean may be greater than, different than, or less
than the first median by the ranges set forth above in this
paragraph. A second zone of the patterned apertured web may have
Interaperture Distances. The Interaperture Distances of the second
zone may have a second distribution having a second mean and a
second median. The second mean may be greater than, less than, or
different than the second median by the ranges set forth above in
this paragraph. A third zone of the patterned apertured web may
have Interaperture Distances. The Interaperture Distances of the
third zone may have a third distribution having a third mean and a
third median. The third mean may be greater than, different than,
or less than the third median by the ranges set forth above in this
paragraph. The first, second, and third means may be the same or
different. The first, second, and third medians may be the same or
different. The first, second, and third zones may be in a topsheet,
a topsheet layer, an acquisition layer, an outer cover, an outer
cover layer, or any other component of an absorbent article or
other consumer products.
[0253] In other instances, a first portion of an absorbent article
or other consumer product may have a first patterned apertured web
that has Interaperture Distances, according to the Aperture Test
herein. The Interaperture Distances of the first portion have a
first distribution. A second portion of an absorbent article or
other consumer product may have a second patterned apertured web
that has Interaperture Distances, according to the Aperture Test
herein. The Interaperture Distances of the second portion have a
second distribution. A third portion of an absorbent article or
other consumer product may have a third patterned apertured web
that has Interaperture Distances, according to the Aperture Test
herein. The Interaperture Distances of the third portion have a
third distribution. The first, second, and third distributions may
be the same or different. The first distribution may have a first
mean and a first median. The first mean may be greater than, less
than, or different than the first median in the range of about 3%
to about 25%, about 4% to about 25%, about 5% to about 20%, about
8% to about 20%, or about 4% to about 15%, for example,
specifically reciting all 0.1% increments within the
above-specified ranges and all ranges formed therein or thereby.
The second distribution may have a second mean and a second median.
The second mean may be greater than, different than, or less than
the second median by the ranges set forth above in this paragraph.
The third distribution may have a second mean and a second median.
The second mean may be greater than, different than, or less than
the second median by the ranges set forth above in this paragraph.
The first, second, and third means may be the same or different.
The first, second, and third medians may be the same or different.
The Relative Standard Deviation of the Interaperture Distances of a
patterned apertured web may be at least about 50%, or at least
about 55%. The Maximum Interaperture Distance in a given patterned
apertured web may be at least about 8 mm, or at least about 10 mm,
for example.
Average Absolute Feret Angle and Absolute Feret Angle
[0254] A patterned apertured web may have one or more apertures
having an Absolute Ferret Angle, according to the Aperture Test
herein, of at least about 15 degrees, at least about 18 degrees, at
least about 20 degrees, at least about 22 degrees, at least about
25 degrees, at least about 30 degrees, at least about 35 degrees,
at least about 40 degrees, in the range of about 15 degrees to
about 80 degrees, in the range of about 20 degrees to about 75
degrees, in the range of about 20 degrees to about 70 degrees, or
in the range of about 25 degrees to about 65 degrees, specifically
reciting all 0.1 degrees increments within the above-specified
ranges and all ranges formed therein or thereby.
[0255] A patterned apertured web may have a plurality of apertures
having an Average Absolute Ferret Angle, according to the Aperture
Test, of at least about 15 degrees, at least about 18 degrees, at
least about 20 degrees, at least about 22 degrees, at least about
25 degrees, at least about 30 degrees, at least about 35 degrees,
at least about 40 degrees, in the range of about 15 degrees to
about 80 degrees, in the range of about 20 degrees to about 75
degrees, in the range of about 20 degrees to about 70 degrees, or
in the range of about 25 degrees to about 65 degrees, specifically
reciting all 0.1 degrees increments within the above-specified
ranges and all ranges formed therein or thereby. These apertures
may all be within a single repeat unit of the patterned apertured
web. The Relative Standard Deviation of the Absolute Feret Angles
in a patterned apertured web may be at least about 30%, or at least
about 40%, or at least about 50%. A repeat unit is an area in a
patterned apertured web that can be identified as having a full
aperture pattern or array. Multiple repeat units may be present in
a patterned apertured web, with one full aperture pattern or array
being present in each repeat unit.
[0256] At least two, at least 3, at least 4, at least 5, at least
6, at least 7, at least 8, at least 9, or at least 10 of the
apertures in a patterned apertured web, or a repeat unit of a
patterned apertured web, may each have a different Absolute Feret
Angle, according to the Aperture Test herein. In other instances,
some of the apertures may have Absolute Feret Angles that are the
same, while other of the apertures may have Absolute Feret Angles
that are different. In addition to having different Absolute Feret
Angles, the at least two, at least 3, at least 4, at least 5, at
least 6, at least 7, at least 8, at least 9, or at least 10
apertures may have different sizes and/or shapes. At least some of
the at least two, at least 3, at least 4, at least 5, at least 6,
at least 7, at least 8, at least 9, or at least 10 apertures may
also have the same size and/or shape, while having different
Absolute Feret Angles. The Absolute Feret Angles of at least some
of the apertures within a repeat unit may differ by at least about
5 degrees, at least about 10 degrees, at least about 15, degrees,
at least about 20 degrees, at least about 25 degrees, or at least
about 30 degrees, for example.
Pre-Strained Laminates
[0257] One or more layers of a laminate may comprise one or more
pre-strained layers. The pre-strained layers may be apertured or
non-apertured. Other layers of the laminate may be apertured or
non-apertured. The apertured layer(s) may have uniformly sized and
spaced apertures or may have nonhomogeneous patterned apertures,
such as the various patterned aperture patterns described herein.
The patterned apertures may have any of the features or parameters
described herein. The layers may comprise nonwovens, films,
cellulosic webs, foams, or other materials. In some instances,
non-apertured layers may comprise a plurality of overbonds arranged
in a pattern. The pre-strained layer or layers may be joined to the
non-pre-strained layer or layers to form a three-dimensional
laminate upon the release of the pre-strain. The pre-strained
layers may be pre-strained in an amount of about 5% of their length
or width to about 40% of their length or width or about 5% of their
length or width to about 20% of their length or width, specifically
reciting all 0.1% increments within the specified ranges and all
ranges formed therein or thereby. In other instances, the
pre-strained layers may be pre-strained in an amount of about 5%,
about 10%, about 15%, or about 20%, for example. The pre-strained
layer should at least partially recover after being joined to a
non-pre-strained layer to create three-dimensional features in the
non-pre-strained layer.
[0258] In an instance, referring to FIG. 61, an example schematic
cross-sectional view of a laminate 7000 may comprise a first layer
7002 and a second layer 7004. The second layer 7004 was
pre-strained prior to being joined to the first layer 7002, thereby
resulting in the three-dimensional features 7006 in the first layer
7002 upon relaxation of the laminate. Either or both of the first
layer 7002 and the second layer 7004 may comprise uniform and
homogeneous apertures, nonhomogeneous patterns of apertures,
overbonds (either homogeneous or non-homogeneous), or embossments.
The first layer 7002 and/or the second layer 7004 (or any
additional layer) may also comprise indicia 7008. The indicia 7008
may comprise a patterned adhesive, a patterned pigmented adhesive,
a printed ink, or a printed pigmented ink, for example. The indicia
7008 may be at least partially visible through apertures or
patterned apertures in one layer of the laminate 7000 or through a
non-apertured layer of the laminate 7000. The indicia 7008 may be a
different color than the first layer 7002 and/or the second layer
7004. For example, the indicia may be teal and the first and second
layers may be white. The first and second layers 7002 and 7004 may
also have different or the same colors or opacities. Although the
example laminate 7000 is described in a two layer form, it will be
understood that laminates having any suitable number of layers are
within the scope of the present disclosure. In such instances, any
suitable number of the layers may comprise indicia, apertures,
patterned apertures, embossments, overbonds, and/or may be
pre-strained. As an example, a third layer 7010, illustrated in
dash, may be joined to the first layer 7002. The third layer 7010
may also be joined to the second layer 7004, for example. The third
layer 7010 may be apertured or non-apertured.
[0259] An example of a top view of a pre-strained laminate is
illustrated in FIG. 62. A cross-sectional view of the pre-strained
laminate of FIG. 62 is illustrated in FIG. 63. The laminate has
apertured areas 7012 and non-apertured areas 7014. The laminate has
one pre-strained layer 7016 and one non-pre-strained layer 7018.
Upon release of the pre-strain force of the pre-strained layer
7016, three dimensional features 7020 are formed in the
non-pre-strained layer 7018.
[0260] Again referring to FIG. 61 the first layer 7002 having the
three-dimensional features 7006 may have a greater path length than
the second layer 7004 that was pre-strained. The path length is the
distance traveled between a first edge 7001 of the material and a
second edge 7003 of the material (following the material from the
left to the right in FIG. 61). If the third layer 7010 is attached
to the first layer 7002 or to the second layer 7004, the third
layer may have a different path length or the same path length as
the first layer 7002 or the second layer 7004.
[0261] In an instance, both the first and second layers 7002 and
7004 may each have a plurality of apertures or patterned apertures.
At least some of the apertures in the first layer 7002 may at least
partially, or fully, align with at least some of the apertures in
the second layer 7004. In other instances, all of, or most of, the
apertures may align or at least partially align. In such
configurations, portions of, or all of, perimeters of at least some
apertures in the first layer 7002 may be bonded (e.g., mechanically
or adhesively) to portions of, or all of, perimeters of at least
some apertures in the second layer 7004. In other configurations,
the first and second layers 7002 and 7004 may be joined by a
plurality of and/or a pattern of mechanical or adhesive bonds.
[0262] The first layer 7002 may be formed of a different material
than the second layer 7004 and/or the third layer 7010. In an
example, the first layer 7002 may be formed of a first nonwoven
material and the second and/or third layers 7004, 7010 may be
formed of a different nonwoven material or other material, such as
a film, for example.
[0263] The patterned apertures in any of the layers may have the
Absolute Feret Angles, the Average Absolute Feret Angles, the
Interaperture Distances, Effective Aperture Areas, and/or the
Average Interaperture Distances described herein. Further, any of
the layers may have the Effective Open Areas specified herein, such
as in the range of about 5% to about 50%.
[0264] Absorbent articles may comprise one or more of these
pre-strained laminates. Example absorbent articles, as described
above, may comprise a liquid permeable topsheet, a liquid
impermeable backsheet, and outer cover nonwoven material, and an
absorbent core, among other features. The pre-strained laminates
may be used as topsheets, outer covers, outer cover nonwoven
material/backsheet laminates, portions of garment-facing surfaces
of the absorbent articles, portions of wearer-facing surfaces of
the absorbent articles, portions of belts, hip areas, waist areas,
and/or portions of barrier leg cuffs, for example. These
pre-strained laminates may also be used in cleaning substrates,
dusting substrates, wipes, medical substrates, and/or any other
suitable products or consumer products, for example.
[0265] Some examples of pre-strained laminates are illustrated
below.
[0266] The materials used in Charts 1 and 2 are specified
below.
[0267] Material A: 25 gsm spunbond nonwoven material comprising
50/50 PE/PP sheath/core bicomponent fibers having an average fiber
size of 2.8 denier per filament, available from Fitesa Nonwovens in
Washougal, Wash.
[0268] Material B: 24 gsm carded, through-air bonded nonwoven
material comprising 2.0 dpf PE/PET fibers, available from Xiamen
Yanjan Industries, Inc.
[0269] In all instances in Charts 1 and 2 below, Layer 2 was
pre-strained in the machine direction by the % shown and then the
two layers were overbonded together, using the overbonding process
described herein with respect to FIG. 16. The pre-strain force was
applied by decreasing the speed of an infeed roll by 0% (i.e., no
pre-strain), 5%, 10%, or 15% (according to the Charts) relative to
the speed of the rolls 112 and 114 of FIG. 16. The pre-strain in
Layer 2 was then released. Examples without the overbonds ruptured
are Examples 1-8 and FIGS. 64-67. Examples with the overbonds
ruptures are Examples 9-16 and FIGS. 68-71. In the latter, the
overbonds were ruptured to form apertures in both layers using the
steps and equipment 132 and 132' described herein with respect to
FIG. 15 (with additional details described in view of FIGS. 23-29).
For Examples 9-16, the depth of engagement (see e.g., FIG. 24) was
0.065 inches and the line speed was 1,000 feet per minute.
[0270] As the amount of pre-strain on Layer 2 increases, the
caliper of the resultant pre-strained laminate may also increase,
by an amount than is greater than the increase in basis weight
would predict. The example substrates of FIGS. 65, 67, 69, and 71
with a pre-strained layer show significant puckering or
three-dimensionality as compared to the non-pre-strained examples
of FIGS. 64, 66, 68, and 70.
TABLE-US-00001 CHART 1 Overbond Only, No Apertures Total Layer
Basis Normalized 2 % Weight Caliper Layer (pre- Pre- Caliper (BW)
(Caliper/ Example # 1 strain) Strain (mm) (gsm) BW) 1 (FIG. 64) A A
0 0.45 51.8 0.009 2 A A 5 0.66 56.0 0.012 3 (FIG. 65) A A 10 1.01
61.6 0.016 4 A A 15 1.38 69.0 0.020 5 (FIG. 66) B A 0 0.57 49.3
0.012 6 B A 5 0.89 52.7 0.017 7 (FIG. 67) B A 10 1.31 62.6 0.021 8
B A 15 1.53 68.5 0.022
TABLE-US-00002 CHART 2 Overbond and Apertures Layer 2 % Caliper
Example # Layer 1 (pre-strain) Pre-Strain (mm) 9 (FIG. 68) A A 0
0.66 10 A A 5 0.69 11 (FIG. 69) A A 10 0.70 12 A A 15 0.76 13 (FIG.
70) B A 0 0.81 14 B A 5 0.92 15 (FIG. 71) B A 10 0.95 16 B A 15
1.01
[0271] Various method of producing pre-strained laminates will now
be discussed. For example, two non-apertured layers may be
provided. One layer may be pre-strained in the CD or MD direction.
The layers may then be overbonded (see e.g., FIG. 16 for
overbonding and associated disclosure) to join them together, or
joined together and then overbonded. The pre-strain force may then
be released to create a plurality of three-dimensional features in
the non-pre-strained layer or in both layers. Optionally, at least
some of, most of, or all of the overbonds may then be ruptured to
create apertures in the first and second layers. Such rupturing may
be done by stretching the first and second layers in the CD or MD
direction (see e.g., FIGS. 23-29 for example overbond rupturing).
In some instances, the pre-strain force may not be released until
the apertures are ruptured. At least a third layer may also be
combined into the laminate. The at least third layer may be
apertured or non-apertured, pre-strained, or non-pre-strained. At
least one of the layers may be formed of a different material than
the remaining layers (e.g., film/nonwoven, first nonwoven/second
nonwoven, or first film/second film).
[0272] In an instance, one apertured layer may be combined with one
non-apertured layer, or two apertured layers may be combined, using
mechanical or adhesive bonding. The apertures may be formed in the
layer or layers using any suitable aperturing technique, such as
needle punching, for example. Either of the layers may be
pre-strained prior to joining the layers. Upon release of the
pre-strain force, three-dimensional features may be formed in the
layer that was not pre-strained, or in both layers. At least a
third layer may also be combined into the laminate. The at least
third layer may be apertured or non-apertured, pre-strained or
non-pre-strained. At least one of the layers may be formed of a
different material than the remaining layers (e.g., film/nonwoven,
first nonwoven/second nonwoven, or first film/second film).
[0273] In an instance, one overbonded layer may be combined with
one non-apertured or apertured layer, or two overbonded layers may
be combined, using mechanical or adhesive bonding. Either of the
layers may be pre-strained prior to joining the layers. Upon
release of the pre-strain force, three-dimensional features may be
formed in the layer that was not pre-strained, or in both layers.
At least a third layer may also be combined into a laminate. The at
least third layer may be overbonded or non-overbonded, apertured or
non-apertured, pre-strained or non-pre-strained. At least one of
the layers may be formed of a different material than the remaining
layers (e.g., film/nonwoven, first nonwoven/second nonwoven, or
first film/second film).
[0274] In an instance, a method of forming a three-dimensional
laminate for an absorbent article is provided. The method may
comprise providing a first layer and a second layer (and optionally
additional layers). The first and second layers may be the same or
different. For example, the layers may comprise the same nonwoven
materials, the same film materials, two different nonwoven
materials, two different film materials, or a film material and a
nonwoven material. In some instances, any of these layers may be
apertured or non-apertured, overbonded or non-overbonded. The
apertures patterns or overbonds patterns may be homogeneous or
non-homogeneous. The method may comprise applying a pre-strain
force to the first or second layers. The pre-strain force may be
applied in any suitable direction, such as substantially in the
machine direction or substantially in the cross-machine direction,
for example. The layers may then be joined by adhesive or
mechanical bonding, or other suitable methods of joining layers. If
at least one of the first or second layers is not apertured or
overbonded, the joining step may comprise an overbonding step (see
e.g., FIG. 16 for overbonding as associated disclosure) or
embossing. The first and second layers may be joined to each other
while the first or second layer remains in a pre-strained state or
condition. Suitable adhesives, patterned adhesive, pigmented
patterned adhesives, pigmented printed inks, or printed inks may be
applied to the first or second layers pre joining or post-joining,
if desired. If an overbonding step is used, the layers,
post-joining, may be stretched in a suitable direction, such as
substantially in the cross-machine direction or substantially in
the machine direction to at least partially rupture, or fully
rupture at least some of, most of, or all of the overbonds to
thereby at least partially form, or form apertures in the layers
(see e.g., FIGS. 23-29 for such rupturing). The pre-strain force
may then be released to form a plurality of three-dimensional
features in the laminate. The plurality of three-dimensional
features may be formed in the non-pre-strained layer or in both of
the layers (including the pre-strained layer).
[0275] Any of the laminates with at least one layer pre-strained
may be free of elastic strands or elastic films.
[0276] The methods may comprise applying a pre-strain force to one
of the layers (pre-layer joining) in a substantially machine
direction, a machine direction, or other direction. The pre-strain
force causes the layer being pre-strained to elongate in the
direction the pre-strain force is being applied by at least 5%, at
least 10%, at least 15%, at least 20%, in the range of about 5% to
about 40%, or in the range of about 5% to about 20%, specifically
reciting all 0.1% increments within the specified ranges and all
ranges formed therein or thereby. The pre-strain force may be
applied by supplying a continuous web of pre-strained laminate
where an infeed roll is rotating at a slower speed than overbonding
rolls or an output roll.
[0277] If a layer, or more than one layer, of the pre-strained
laminate has a plurality of overbonds, the overbonds may comprise a
first overbond, a second overbond, and at least a third overbond.
The first, second, and at least third overbonds may all be
different in size, shape, feret angle, and/or orientation.
Alternatively, at least two of the first, second, and third
overbonds may be different in size, shape, feret angle, and/or
orientation.
[0278] One or more layers of a laminate (pre-strained layer or no
pre-strained layer) may have a first overbond having a central
longitudinal axis extending in a first direction, a second overbond
having a central longitudinal axis extending in a second direction,
and a third overbond having a central longitudinal axis extending
in a third direction. At least two of, or all of the first, second,
and third directions may be different. At least two of, or all of,
the first, second, and third directions may be at least about 5
degrees, at least about 10 degrees, at least about 15 degrees, at
least about 20 degrees, apart from each other. In other instances,
at least two of, or all of, the first, second, and third directions
may be different from each other in the range of about 5 degrees to
about 40 degrees, about 5 degrees to about 30 degrees, or about 10
degrees to about 25 degrees, specifically reciting all 0.1 degree
increments within the specified ranges and all ranges formed
therein or thereby. More than three overbonds having central
longitudinal axes may also be provided. The central longitudinal
axes of the more than three overbonds may also extend in different
directions than the first, second, and third central longitudinal
axes, as described in this paragraph.
[0279] Another method of forming a three-dimensional laminate for
an absorbent article is provided. The method may comprise providing
a first layer and providing a separate, second layer. The layers
may be the same or different in material, basis weight, and/or
properties, for example. The method may comprise applying a
pre-strain force to the first layer or to the second layer and
overbonding the first layer and the second layer while the first
layer or the second layer is in a pre-strained condition to join
the first layer and the second layer. The method may further
comprise releasing the pre-strain force to form the
three-dimensional laminate and three-dimensional features in the
non-pre-strained layer. Before or after the pre-strain force is
released, the method may comprise stretching the first and second
layers to cause at least some of, most of, or all of the overbonds
to at least partially rupture and at least partially form, or form,
apertures in the first and second layers. This stretching may be
substantially (e.g., +/-1 degree, +/-3 degrees, or +/-5 degrees) in
the cross-machine direction, while the pre-strain force may be
substantially in the machine direction (e.g., +/-1 degree, +/-3
degrees, or +/-5 degrees). In other instances, the stretching may
be substantially in the machine direction, while the pre-strain
force may be substantially in the cross-machine direction.
[0280] Another method of forming a three-dimensional laminate for
an absorbent article is provided. The method may comprise providing
a nonwoven first layer and providing a separate, nonwoven second
layer. The method may comprise applying a pre-strain force
substantially in the machine direction to the first nonwoven layer
or to the second nonwoven layer and overbonding the first layer and
the second layer while the first layer or the second layer is in a
pre-strained condition to join the first layer and the second
layer. The method may comprise stretching the first and second
nonwoven layers in a substantially cross-machine direction to cause
at least some of, most of, or all of the overbonds to at least
partially rupture and at least partially form, or form apertures in
the first and second nonwoven layers. The method may comprise
releasing the pre-strain force to form the three-dimensional
laminate and form three-dimensional features in the
non-pre-strained layer. The three-dimensional laminate may be free
of elastic strands or elastic films.
Garment-Facing Layer/Garment-Facing Laminate
[0281] Absorbent article of the present disclosure may comprise a
garment-facing layer or garment facing laminates comprising at
least one apertured or patterned apertured layer. The absorbent
articles may comprise a liquid permeable topsheet on a
wearer-facing side of the absorbent article and a garment-facing
laminate or a garment-facing layer on a garment-facing side of the
absorbent article. The garment-facing laminate may comprise a first
layer or a first nonwoven layer and a second layer joined to the
nonwoven layer. The first layer or the first nonwoven layer may
comprise a plurality of apertures. In some instances, at least 3,
at least 5, or at least 10 of the apertures in a repeat unit have
one or more of a different size, a different shape, or a different
Absolute Feret Angle, according to the Aperture Test herein. At
least 3, at least 5, or at least 10 of the plurality of apertures
in the first nonwoven layer may be non-homogeneous apertures within
the repeat unit. The garment-facing layer may only comprise a
single layer having the features of the first layer or first
nonwoven layer of the garment-facing laminate. The absorbent
article may comprise an absorbent core that is disposed at least
partially intermediate the liquid permeable topsheet and the
garment-facing laminate or the garment-facing layer. Either of the
first or second layers of the garment-facing laminate may be
pre-strained as described herein to create three-dimensional
features in the non-pre-strained layer or in both layers. The first
or second layer that is pre-strained may be free of apertures.
[0282] The second layer of the garment-facing laminate may be a
second nonwoven layer. The second nonwoven layer may be positioned
on the outermost surface of the garment-facing surface or
intermediate the first nonwoven layer and a liquid impermeable
backsheet. If the second nonwoven layer is positioned on the
outermost surface, the first nonwoven layer comprising the
apertures or patterned apertures may be visible through the second
nonwoven layer. In an instance, the second nonwoven layer may
comprise apertures or patterned apertures, as the patterned
apertured are described herein. The second nonwoven layer may also
be non-apertured. In other instances, the second layer of the
garment-facing laminate may comprise a liquid impermeable backsheet
film. A patterned adhesive, a pigmented patterned adhesive, a
printed ink, or a pigmented printed ink (together "indicia") may be
on the backsheet film such that this indicia is visible through the
first and/or second layers and/or through the apertures or the
patterned apertures in one of the layers. This indicia may also be
on the first nonwoven layer or the second nonwoven layer in other
instances. In an instance, a first portion of the indicia may be on
the first nonwoven layer and a second portion of the indicia may be
on the second layer.
[0283] The first nonwoven layer may be joined to the second layer
or the second nonwoven layer by a patterned of mechanical or
adhesive bonds. In other instances, the first nonwoven layer may be
joined to the second layer or the second nonwoven layer by a
patterned adhesive or a pigmented patterned adhesive. The patterned
adhesive or pigmented patterned adhesive may have a first color
that is different than the color of the first nonwoven layer or the
second layer or the nonwoven layer. For example, the adhesive may
be teal, while the first and second layers are white. The first and
second layers may also have colors that are different.
[0284] FIGS. 72-75 illustrate example layering of garment-facing
laminates. In the example of FIG. 72, a first layer 8002 may be a
liquid impermeable backsheet, a second layer 8004 may be a
material, such as a nonwoven material, that is apertured or
non-apertured, and a third layer 8006 may be a material, such as a
nonwoven material, that is apertured or non-apertured. If any of
the layers are non-apertured, they may comprise embossments or
overbonds. One or more of layers 8002, 8004, and 8006 may be
pre-strained prior to being joined to the other layers. In some
instances, the first layer 8002 may also be a nonwoven material.
Any or all of the layers may be apertured or have patterned
apertures. In some instances, especially in cases where the first
layer 8002 is a liquid impervious backsheet film, the second layer
8004 and/or the third layer 8006 may be apertured or have patterned
apertures. In other instances, only one of the second layer 8004
and the third layers 8006 may have apertures or patterned
apertures, with the other layer being non-apertured. In an
instance, it may be desirable to have only the second layer 8004
have apertures or patterned apertures with the third layer 8006
being non-apertured to provide an absorbent article with a smooth
garment-facing surface. Layer 8006 may form a portion of a
garment-facing surface of an absorbent article.
[0285] FIG. 73 illustrates the garment-facing laminate of FIG. 72,
but with an indicia 8008 positioned on one of the layers; in the
example, the first layer 8002 or the second layer 8004. The indicia
8008 may also be positioned intermediate the first and second
layers 8002 and 8004. The indicia 8008 may be a patterned adhesive,
a pigmented patterned adhesive, a printed ink, and/or a pigmented
printed ink, for example. As shown in the example of FIG. 74, a
first indicia 8008 may be positioned on the first and second layers
8002 and 8004, or may be positioned intermediate the first and
second layers 8002 and 8004. A second indicia 8008' may be
positioned on the second and third layers 8004 and 8006, or may be
positioned intermediate the second and third layers 8004 and 8006.
The second indicia 8008' may be a patterned adhesive, a pigmented
patterned adhesive, a printed ink, and/or a pigmented printed ink.
In some instances, only the second indicia may be provided. The
first indicia 8008 may be the same as or different than the second
indicia 8008'. In FIGS. 73 and 74, the first, second, and third
layers 8002, 8004, and 8006 may be the same as described with
respect to FIG. 72. If two or more nonwoven materials are provided
as two or more of the layers, the nonwoven materials may be the
same or different (i.e., different in basis weight, material,
methods of manufacture, properties, effective open area). The third
layer 8006 may form a portion of a garment-facing surface of an
absorbent article.
[0286] FIG. 75 illustrates a two layer garment-facing laminate. The
first layer 8002 and the second layer 8004 may be the same or
different. At least one of the layers may be a nonwoven material.
In some instances, the first layer 8002 may comprise a liquid
impermeable backsheet, while the second layer 8004 may comprise a
garment-facing surface of an absorbent article. In such an
instance, the first layer 8002 may be non-apertured, while the
second layer 8004 may be apertured, have patterned apertures, or
comprise a plurality of overbonds or embossments. Either of the
first and second layers 8002 and 8004 may be pre-strained prior to
being joined together to create a three-dimensional laminate. An
indicia may be positioned on the first or second layers 8002 or
8004, or may be placed intermediate the first and second layers
8002 or 8004. The indicia may be the same as described above with
respect to FIG. 73.
[0287] The plurality of apertures, patterned apertures, overbonds,
or embossments in the first nonwoven layer or the second layer or
second nonwoven layer may have a first pattern in a first area and
a second, different pattern in a second, different area. The first
area may comprise one or more of a waist region, a hip region, a
belt portion, a crotch region, a front region, a back region,
and/or a buttocks region. The second area may comprise a different
one or more of the waist region, the hip region, the belt portion,
the crotch region, the front region, the back region, and/or the
buttocks region. The first pattern may different from the second,
different pattern in size and shape, shape and frequency, or size
and frequency, for example.
[0288] Referring to FIGS. 76 and 77, example garment-facing
laminates or garment-facing layers on an absorbent article 8010 are
illustrated. The garment-facing laminates or layers may be the same
as described above in construction, but may have different zones.
The absorbent articles 8010 may have a first zone 8012, a second
zone 8014, and a third zone 8016. The first and second zones 8012,
8014 may form waist or hip portions (or front or rear regions) of
the absorbent article 8010, while the third zone 8016 may form a
crotch and/or buttocks portion of the absorbent article 8010. Any
suitable number of zones may also be provided in a garment-facing
laminate or layer. At least some of the zones 8012, 8014, 8016 may
have apertures or patterned apertures. In some instances, two or
more of the zones 8012, 8014, and 8016, or portions thereof, may
have apertures or patterned apertures. In still other instances,
one or more zones may have apertures and other zones may have
patterned apertures. In yet other instances, one more zones may
have overbonds that are not ruptured or may have overbonds that are
partially ruptured, as will be described in further detail below.
One or more of the zones may comprise embossments. The apertures or
patterned apertures may be the same or different in different
zones. In an instance, the first and second zones 8012 and 8014 may
have the same pattern of apertures or patterned apertures,
overbonds, or embossments, while the third zones 8016 may have a
different pattern of apertures or patterned apertures, overbonds,
or embossments. Any of the zones may also comprise indicia as
described herein. The indicia may be the same or different in
various zones.
[0289] FIG. 78 illustrates an example absorbent article 8010' with
a first zone 8012', a second zone 8014', a third zone 8016', and
fourth zone 8018. Any of the first, second, third, and fourth zones
8012', 8014', 8016', and 8018 may be apertured, have patterned
apertures, and/or comprise overbonds and/or embossments. The
apertures, patterned apertures, overbonds, and/or embossments may
be the same or different in the various zones. In an instance, at
least two zones may have the same pattern of apertures, patterned
apertures, overbonds and/or embossments. Any of the zones may also
comprise indicia as described herein. In an instance, the first and
second zones 8012' and 8014' may have the same pattern of
apertures, patterned apertures, embossments, and/or overbonds,
while the third zone 8016' or the fourth zone 8018 may have a
different pattern of apertures, patterned apertures, embossments,
and/or overbonds.
[0290] FIG. 79 is another example of an absorbent article 8020 with
zones in a garment-facing layer or laminate. A first zone 8022 and
a second zone 8024 comprise a plurality of apertures 8026 or
patterned apertures, while a third zone 8029 comprises a pattern of
unopened overbonds 8028 or embossments. Stated another way, the
first zone 8022 and the second zone 8024 comprise a plurality of
ruptured overbonds 8026, while the third zone 8029 comprises a
plurality of unruptured overbonds 8028. To create such a structure,
a material may be overbonded and then certain regions (e.g., the
first and second zones 8022 and 8024) may be stretched (e.g., in
the cross-machine direction) to at least partially, or fully,
rupture the overbonds, with other regions not being stretched
(e.g., the third zone 8029). In such a configuration, the
garment-facing layer or laminate may signify that the waist, hip,
or belt portions (i.e., the first and second zones 8022 and 8024
(with apertures or patterned apertures)) are breathable, while the
third zone 8029 (with only overbonds or embossing) is designed for
absorbency and/or performance. Ruptured overbonds (or apertures)
and unruptured overbonds may be positioned in any suitable
zones.
[0291] FIG. 80 is a photograph of a nonwoven material or laminate
with ruptured overbonds forming apertures in a first section (or
zone) 8030 (left side) and unruptured overbonds in a second section
8032 (or zone) (right side). FIG. 80 also illustrates a third,
transition section 8034 positioned intermediate the first section
8030 and the second section 8032. In the third, transition section
8034, at least some of the overbonds are partially ruptured. Such a
material may be used as a portion of the garment-facing laminate of
FIG. 79.
[0292] FIG. 81 is a photograph of a nonwoven laminate with
overbonds or embossments in a first section 8036. The first section
(or zone) 8036 may also have a layer that was pre-strained prior to
being joined to another layer, thereby producing the
three-dimensional features. A second section (or zone) 8038 may
comprise a plurality of apertures or a plurality of patterned
apertures with or without a pre-strained layer. The first section
8036 may represent a first zone in a garment-facing laminate and
the second section 8038 may represent a second zone in the
garment-facing laminate.
[0293] An absorbent article may comprise a liquid permeable
topsheet on a wearer-facing side of the absorbent article and a
garment-facing laminate on a garment-facing side of the absorbent
article. The garment-facing laminate may comprise a first layer or
a first nonwoven layer and a second layer or a second nonwoven
layer joined to the first layer when the first layer or the second
layer is in a pre-strained condition and when the other of the
first layer or the first nonwoven layer or the second layer or the
second nonwoven layer is in a non-pre-strained condition to form a
three-dimensional material. Details of the pre-strained layers and
laminates comprising a pre-strained layer are described above. The
first nonwoven layer may comprise a plurality of apertures or a
plurality of patterned apertures as described herein. At least 3,
at least 5, or at least 10 of the apertures may be nonhomogeneous
apertures. The second layer may comprise a film or may comprise a
backsheet film. The laminate may comprise one or more patterned
adhesives and/or printed inks, as described herein. The absorbent
article may comprise an absorbent core is disposed at least
partially intermediate the liquid permeable topsheet and the
garment-facing laminate.
[0294] An absorbent article may comprise a liquid permeable
topsheet on a wearer-facing side of the absorbent article and a
garment-facing layer on a garment-facing side of the absorbent
article. The garment-facing layer may comprise a nonwoven material.
The garment-facing layer may comprise a first zone comprising a
plurality of overbonds and a second zone comprising a plurality of
apertures or patterned apertures. The second zone may at least
partially form a waist region, hip region, or belt portion, of the
absorbent article and the second zone may at least partially form a
crotch region of the absorbent article. At least 3, at least 5, or
at least 10 of the plurality of apertures in a repeat unit may have
a different size, a different shape, and/or a different Absolute
Feret Angle, according to the Aperture Test herein. The absorbent
article may comprise a liquid impermeable backsheet and an
absorbent core is disposed at least partially intermediate the
liquid permeable topsheet and the backsheet.
[0295] FIG. 82 is an example patterned apertured web 9000 with
patterned apertures 9002 in a central region 9004 thereof and with
embossed areas 9006 in outer portions 9008 thereof. The patterned
apertured web 9000 may be used in a feminine hygiene product, as a
topsheet, for example, or may be used in other absorbent
articles.
[0296] FIG. 83 is another example patterned apertured web 9010.
Moire Effect Laminates and Methods for Making the Same
[0297] The present disclosure also envisions laminates that provide
a moire effect. The moire effect is a visual image that is evident
when one pattern in a first material is superimposed over another
pattern in a second material while one pattern is displaced or
moved relative to the other pattern. More than two materials may
also be used, optionally with additional patterns. Providing the
moire effect in various layers of consumer products or absorbent
articles is highly consumer desired because of the interesting
appearance of the product or article. In an absorbent article
context, providing the moire effect may provide the consumer with
the impressions of depth, absorbency, quality, improved wicking,
and/or and air flow.
[0298] Some examples of patterned apertured nonwoven materials
providing the moire effect are illustrated in FIGS. 84-87. In FIG.
84, a first layer 1100 is in a first position relative to the
second layer 1102. The first layer 1100 has a plurality of
patterned apertures 1104 (as described herein) and the second layer
1102 has a plurality of uniformly spaced and homogeneous apertures
1106. FIG. 85 illustrates the first layer 1100 in a second position
relative to the second layer 1102. FIG. 86 illustrates the first
layer 1100 in a third position relative to the second layer 1102.
FIG. 87 illustrates the first layer 1100 in a fourth position
relative to the second layer 1102. When viewing FIGS. 84-87
together, the moire effect is illustrated. This may be accomplished
by having non-bonded spans between the first and second layers 1100
and 1102. By having non-bonded spans in the first and second
layers, the first and second layers may move relative to each
other, even when the first and second layers are at least
intermittently joined together into a laminate. Even if the first
and second layers do not move relative to each other, the moire
effect may appear as the viewer moves relative to the laminate.
FIGS. 84-87 are merely examples of the moire effect, and further
forms are discussed below.
[0299] A moire effect laminate may have two or more layers. A first
layer may comprise a nonwoven, a cellulosic material, a coform
material, a woven, a film, any other suitable material, or
combinations thereof. A second layer may also comprise a nonwoven,
a cellulosic material, a coform material, a woven a film, any other
suitable material, or combinations thereof. The first layer or the
second layer may comprise apertures (uniform and homogenous) or
patterned apertures as described herein. In other instances, only
one of the layers may comprise apertures or patterned apertures. In
still other instances, neither of the layers may comprise apertures
or patterned apertures.
[0300] One of the layers may comprise a plurality of lower opacity
zones in a pattern positioned within a higher opacity zone. Stated
another way, a material having a first opacity (higher opacity) may
have certain zones that have a reduced opacity (lower opacity). The
lower opacity zones should have an area of at least about 1
mm.sup.2' at least about 2 mm.sup.2, at least about 3 mm.sup.2, at
least about 4 mm.sup.2, at least about 5 mm.sup.2, at least about 6
mm.sup.2, at least about 7 mm.sup.2, at least about 8 mm.sup.2, or
in the range of about 1 mm.sup.2 to about 20 mm.sup.2, about 1
mm.sup.2 to about 15 mm.sup.2, about 2 mm.sup.2 to about 10
mm.sup.2, specifically reciting all 0.1 mm.sup.2 increments within
the specified ranges and all ranges formed therein or thereby.
These lower opacity zones, in some instances, may be at least
partially, or fully, formed by apertures. The lower opacity zones
positioned within a higher opacity zone may enable viewing a
portion of a pattern behind the material with the lower opacity
zones. Stated another way, the lower opacity zones essentially
create "windows" in the material, thereby allowing a pattern behind
the material to be at least partially visible.
[0301] The higher opacity zone may have an opacity of at least
about 1.1 times, at least about 1.5 times, at least about 2 times,
at least about 2.5 times, or at least about 3 times greater than
the opacity of the lower opacity zones, according to the Opacity
Test herein. Alternatively, the higher opacity zone may have an
opacity in the range of about 1.1 times to about 5 times greater
than the lower opacity zones, according to the Opacity Test herein,
specifically reciting all 0.1 increments within the specified range
and all ranges formed therein. Also, the higher opacity zone may
have an opacity that is at least about 3 percentage points, at
least about 5 percentage points, at least about 10 percentage
points, at least about 15 percentage points, at least about 20
percentage points, or at least about 25 percentage points greater
than an opacity of the lower opacity zones, according to the
Opacity Test herein. Alternatively, the higher opacity zone may
have an opacity that is in the range of about 3 percentage points
to about 20 percentage points greater than the opacity of the lower
opacity zones, specifically reciting all 0.1 percentage point
increments within the specified ranges an all ranges formed
therein, according to the Opacity Test herein. If the lower opacity
zones are apertures, their opacity would be 0% or about 0%, or
about 0% to 5%, specifically reciting all 0.1% increments within
the specified range and all ranges formed therein, according to the
Opacity Test herein.
[0302] The higher opacity zone may have a light transmission of at
least about 1.1 times, at least about 1.5 times, at least about 2
times, at least about 2.5 times, or at least about 3 times less
than the light transmission of the lower opacity zones, according
to the Light Transmission Test herein. Alternatively, the higher
opacity zone may have a light transmission in the range of about
1.1 times to about 5 times less than the lower opacity zones,
according to the Light Transmission Test herein, specifically
reciting all 0.1 increments within the specified range and all
ranges formed therein. Also, the higher opacity zone may have a
light transmission that is at least about 3 percentage points, at
least about 5 percentage points, at least about 10 percentage
points, at least about 15 percentage points, at least about 20
percentage points, or at least about 25 percentage points less than
a light transmission of the lower opacity zones, according to the
Light Transmission Test herein. Alternatively, the higher opacity
zone may have a light transmission that is in the range of about 3
percentage points to about 20 percentage points less than the light
transmission of the lower opacity zones, according to the Light
Transmission Test herein. If the lower opacity zones are apertures,
their light transmission would be about 95-100%, specifically
reciting all 0.1% increments within the specified range and all
ranges formed therein, according to the Light Transmission Test
herein.
[0303] The layers of the moire effect laminate may comprise the
same materials or different materials. By different, the layers
could be different in basis weight, opacity, fiber composition,
fiber type, fiber size, method of production, caliper, and/or
color, for example. In some instances, a first layer may be a
nonwoven material and a second layer may be a different type of
nonwoven material or a film.
[0304] In some instances, a first pattern in a first layer of a
moire effect laminate may be a printed pattern, a patterned
adhesive, a pattern of homogeneous and uniform apertures, patterned
apertures (as described herein), lower opacity zones positioned in
a higher opacity zone, and/or a pattern of embossments. Likewise, a
second pattern in a second layer of a moire effect laminate may be
a printed pattern, a patterned adhesive, a pattern of homogeneous
and uniform apertures, patterned apertures, lower opacity zones
positioned in a higher opacity zone, a pattern of embossments, or
combinations thereof. The first and second patterns, in the first
and second layers, respectively, may be the same or different, in
size, scale, shape, area, color, and/or orientation, for example.
As a further example, a first pattern in a first layer may comprise
patterned apertures and a second pattern in a second layer may
comprise a printed pattern or a patterned adhesive. As another
example, a first pattern in a first layer may comprise lower
opacity zones positioned within a higher opacity zone and a second
pattern in a second layer may comprise a printed pattern or a
patterned adhesive. As still another example, a first pattern in a
first layer may comprise lower opacity zones positioned within a
higher opacity zone, apertures, or patterned apertures and a second
pattern in a second layer may comprise apertures, patterned
apertures, and/or a pattern of embossments. The first layer may be
the layer facing the viewer, but the second layer could be as
well.
[0305] As referenced above, the color of the layers in a moire
effect laminate may be the same or different. As an example, a
first layer may be white and a second layer may be blue. As another
example, a first layer may be light blue and a second layer may be
dark blue. Any of the layers may be the same or a different color
as the patterns of printed ink or patterned adhesive.
[0306] In an instance, a first layer of a moire effect laminate may
comprise a garment-facing nonwoven layer and a second layer may
comprise a backsheet film or other film. The garment-facing
nonwoven layer may have apertures, patterned apertures (as
described herein), or lower opacity zones within a higher opacity
zone. These apertures, patterned apertures, or lower opacity zones
may form the first pattern in the first layer. The first layer may
comprise one or more substrates as a laminate. The second layer
comprising the backsheet film or other film may comprise a second
pattern comprising apertures, patterned apertures, printed inks,
patterned adhesives, and/or patterns of embossments. The second
pattern may be at least partially visible through the first pattern
in the first layer.
[0307] The first layer of the moire effect laminate may be
intermittently joined or bonded to the second layer of the moire
effect laminate (or additional layers) using any suitable type of
joining or bonding. Examples of suitable joining or bonding include
ultrasonic bonding or joining, adhesive bonding or joining,
mechanically bonding or joining, interpenetration of one layer into
another layer, mechanical entanglement, and/or thermal joining or
bonding, for example. The bonds or joined portions may be placed at
least about 15 mm, at least about 20 mm, at least about 25 m, at
least about 30 mm, at least about 35 mm, at least about 40 mm, at
least about 45 mm, or at least about 50 mm apart. In other
instances, the bonds or joined portions may be positioned in the
range of about 15 mm to about 150 mm apart, about 20 mm to about
140 mm apart, about 20 mm to about 120 mm apart, about 30 mm to
about 100 mm apart, specifically reciting all 0.1 mm increments
within the above-referenced ranges and all ranges formed therein or
thereby. In larger products, the bonds or joined portions may be
positioned in the range of about 25 mm to about 1000 mm apart,
about 100 mm to about 750 mm apart, or about 100 mm to about 500 mm
apart, specifically reciting all 0.1 mm increments within the
above-referenced ranges and all ranges formed therein or
thereby.
[0308] Referring to FIGS. 88-90, example bonds or joined portions
1108 are illustrated in simplistic views for ease in understanding.
The bonds or joined portions 1108 may be between the first and
second layers (or additional layers) of a moire effect laminate. In
FIGS. 88-90, an example absorbent article 1110 is illustrated with
a garment-facing surface (or first layer) removed to show the
locations of the bonds or joined portions, although the bonding or
joining concept applies to any moire effect laminate, regardless of
where used in an absorbent article or another consumer product. For
example, the moire effect laminates could be used as topsheets,
topsheets and acquisition layers, topsheets and distribution
layers, waist bands, outer covers, leg cuffs, belts, fastening
systems, wipes, or as any other component of consumer products or
absorbent articles that have natural movement when in use (e.g.,
ears). The bonds or joined portions 1108 may be discrete (see FIG.
88), linear and continuous (see FIGS. 89 and 90), discontinuous and
linear, or discontinuous, for example. In various instances, the
bonds or joined portions may form any suitable or desired
patterns.
[0309] In view of the bond or joined portion spacing described
above, again referring to FIGS. 88-90, non-joined spans 1112 may
exist intermediate the bonds or joined portions 1108 in a moire
effect laminate. These non-joined spans 1112 are areas where the
first layer is not joined or bonded to the second layer (or an
additional layer, if provided in a moire effect laminate). They can
also be referred to as non-bonded spans. The non-bonded spans may
extend in any suitable direction between the bonds or joined
portions. The first and second layers within the non-joined spans
1112 may be moveable relative to each other, even if just slightly
to allow for the moire effect. The non-joined spans may have
distances in the range of at least about 15 mm, at least about 20
mm, at least about 25 mm, at least about 30 mm, at least about 35
mm, at least about 40 mm, at least about 45 mm, or at least about
50 mm, for example. In other instances, the non-joined spans may be
positioned in the range of about 15 mm to about 150 mm apart, about
20 mm to about 140 mm apart, about 20 mm to about 120 mm apart,
about 30 mm to about 100 mm apart, specifically reciting all 0.1 mm
increments within the above-referenced ranges and all ranges formed
therein or thereby. In larger products, the non-joined spans may be
positioned in the range of about 25 mm to about 1000 mm apart,
about 100 mm to about 750 mm apart, or about 100 mm to about 500 mm
apart, specifically reciting all 0.1 mm increments within the
above-referenced ranges and all ranges formed therein or
thereby.
[0310] In some instances, a path length in a non-joined or
non-bonded span may be greater, less, the same, or different in one
of the layers of a moire effect laminate relative to another one of
the layers. Referring to FIG. 91, a first layer 1100 may have a
greater path length, P1, than a path length P2, of the second layer
1102 in a non-joined span 1112. Path length is the distance
traveled when moving over a surface from one bond or joined portion
1108 to another. As can be seen, the distance traveled would be
greater for the first layer 1100 than the second layer 1102. Stated
another way, the first layer 1100 is longer than the second layer
1102 in the non-joined span. The opposite may also be true with the
path length of the second layer 1102 being greater than the first
layer 1100. Providing a laminate with two layers, where the two
layers have different path lengths may be provided by pre-straining
one layer before joining it to another non-pre-strained layer, as
described in greater detail herein. By providing this path length
differential, a moire effect laminate may provide three dimensional
features in at least one layer, while also increasing the visual
significance of the moire effect as one layer is allowed to move
more relative to another layer within the non-joined or non-bonded
span 1112. In the example of FIG. 91, the first layer 1100 may have
apertures, patterned apertures, or lower opacity zones in a first
pattern and the second layer 1102 may have a printed pattern, a
printed ink, a patterned adhesive, apertures, and/or patterned
apertures that are at least partially visible through the
apertures, patterned apertures, or lower opacity zones in the first
layer. The path length of a first layer may be at least about 0.5%,
about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 4%,
about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or in
the range of about 0.5% to about 40% greater than or different than
the path length of a second layer in a moire effect laminate,
specifically reciting all 0.1% increments with the specified range
and all ranges formed therein.
[0311] Even without a different path length between the layers in
the non-joined spans, the first and second layers within the
non-joined span may still be able to move relative to each other.
This allows the moire effect to be observed. Movement between the
first and second layers in the non-bonded span or span may be
caused by movement of a wearer of an absorbent article and/or
movement of the consumer product that the moire laminate is part
of.
[0312] FIG. 92 illustrates an example of a first layer 1100 of a
moire effect laminate having a first pattern 1004. The first
pattern may comprise apertures, patterned apertures, or lower
opacity zones positioned within a higher opacity zone. FIG. 93
illustrates an example of a second layer 1102 of a moire effect
laminate having a second pattern 1106. The second pattern 1106 may
comprise apertures, patterned apertures, printed inks, patterned
adhesives, and/or embossments, for example. FIG. 94 illustrates the
first layer 1100 in a first position relative to the second layer
1102 in a non-joined span. FIG. 95 illustrates the first layer 1100
in a second position relative to the second layer 1102 in the same
non-joined span. As can be seen, a first portion of the second
pattern 1106 is visible through the first pattern 1104 when the
first layer 1100 is in the first position and a second portion of
the second pattern 1106 is visible through the first pattern 1104
when the first layer 1102 is in the second position. The first
pattern 1104 and the second pattern 1106 may be the same size and
shape.
[0313] FIG. 96 illustrates an example of another first layer 1100
of a moire effect laminate having a first pattern 1104. The first
pattern may comprise apertures, patterned apertures, or lower
opacity zones positioned within a higher opacity zone. FIG. 97
illustrates an example of a second layer 1102 of a moire effect
laminate having a second pattern 1106. The second pattern 1106 may
comprise apertures, patterned apertures, printed inks, patterned
adhesives, and/or embossments, for example. FIG. 98 illustrates the
first layer 1100 in a first position relative to the second layer
1102 in a non-joined span. FIG. 99 illustrates the first layer 1100
in a second position relative to the second layer 1102 in the same
non-joined span. As can be seen, a first portion of the second
pattern 1106 is visible through the first pattern 1104 when the
first layer 1100 is in the first position and a second portion of
the second pattern 1106 is visible through the first pattern 1104
when the first layer 1102 is in the second position. The first
pattern 1104 and the second pattern 1106 may be a different size
and shape.
[0314] FIG. 100 illustrates a cross-sectional illustration of a
portion of a non-joined span of a moire effect laminate, wherein
the first layer 1100 is in a first position relative to the second
layer 1102, and wherein a first portion of the second pattern 1106
is visible through the first pattern 1104. In such an example, the
first pattern 1104 is a plurality of apertures or patterned
apertures and the second pattern 1106 is a plurality of apertures
or patterned apertures.
[0315] FIG. 101 illustrates another cross-sectional illustration of
the portion of the non-joined span of the moire effect laminate of
FIG. 100, wherein the first layer 1100 has been moved into a second
position relative to the second layer 1102, and wherein a second
portion of the second pattern 1106 is visible through the first
pattern 1004.
[0316] FIG. 102 illustrates a cross-sectional illustration of a
portion of a non-joined span of a moire effect laminate, wherein
the first layer 1100 is in a first position relative to the second
layer 1102, and wherein a first portion of the second pattern 1106
is visible through the first pattern 1104. In such an example, the
first pattern 1104 is a plurality of lower opacity zones in a
higher opacity zone and the second pattern 1106 is a plurality of
apertures or patterned apertures.
[0317] FIG. 103 illustrates another cross-sectional illustration of
the portion of the non-joined span of the moire effect laminate of
FIG. 101, wherein the first layer 1100 has been moved into a second
position relative to the second layer 1102, and wherein a second
portion of the second pattern 1106 is visible through the first
pattern 1004.
[0318] Any of the moire effect laminates disclosed herein may have
a pattern formed by patterned apertures having any parameters of
the patterned apertures set forth herein, such as Interaperture
Distance and Average Absolute Feret Angle, for example.
[0319] A method of producing moire effect laminate is provided. The
method may comprise providing a first layer, a first nonwoven
layer, or a first film layer, comprising a plurality of lower
opacity zones positioned within a higher opacity zone (opacity
differences are discussed above). The lower opacity zones may
comprise or be apertures. The plurality of lower opacity zones may
form a first pattern. The method may comprise providing a second
layer, a second nonwoven layer, or a second film layer, comprising
a second pattern and positioning the first layer in a face-to-face
relationship with the second layer. The method may comprise
intermittently joining the first layer to the second layer to form
at least one non-joined span of the first and second layers such
that at least a portion of the first layer is moveable relative to
a portion of the second layer within the non-joined span. The
non-joined span may have a dimension of at least 20 mm (or any of
the dimensions set forth above for the non-joined or non-bonded
spans). Portions of the second pattern may be aligned, or partially
aligned, with portions of the first pattern in the non-joined span.
A portion of the second pattern and a portion of the first pattern
may be present in the non-joined span. The first pattern may be the
same or different than the second pattern in size, shape, and/or
orientation, for example. A first path length in the first layer of
the non-joined span may be different than, greater than, or less
than a second path length in the second layer of the non-joined
span by any of the percentages disclosed above.
[0320] A method of producing an optical interference pattern in an
absorbent article is provided. The method may comprise providing a
first layer (nonwoven or film) as a first component of the
absorbent article. The first layer may comprise a plurality of
lower opacity zones positioned within a higher opacity zone
(differences in opacity are described above). The plurality of
lower opacity zones may form a first pattern. The lower opacity
zones may comprise apertures. The method may comprise providing a
second layer (nonwoven or film) as a second component of the
absorbent article. The second layer may comprise a second pattern.
The first layer, or a portion thereof, may be in a face-to-face
relationship with the second layer, or a portion thereof, and is
intermittently joined to the second layer to thereby form at least
one non-joined span. The method may comprise allowing a portion of
the first layer, in the non-joined span, to move relative to a
portion of the second layer, in the non-joined span, to produce the
optical interference pattern. A first portion of the second
pattern, in the non-joined span, may be visible through a portion
of the first pattern, in the non-joined span, when the portion of
the first layer is in a first position relative to the portion of
the second layer. A second portion of the second pattern, in the
non-joined span, may be visible through the portion of the first
pattern, in the non-joined span, when the portion of the first
layer is in a second position relative to the portion of the second
layer. The first component of the absorbent article may be a
topsheet, an acquisition layer, or any other suitable component.
The second component of the absorbent article may be a secondary
topsheet, an acquisition layer, a backsheet, or any other suitable
component.
Zonal Patterned Apertured Webs
[0321] Referring to FIGS. 104-107, aspects of zonal patterned
apertured webs are illustrated. The various zones are represented
as Z1, Z2, etc. to signify zone 1, zone 2 etc. Although the zonal
patterned apertured web are illustrated as either a garment-facing
layer or laminate or wearer-facing layer or laminate in FIGS.
104-107, it will be understood that zonal patterned apertured web,
whether comprising one layer or multiple layers, may also be used
for any portion of an absorbent article or other consumer product.
For example, a zonal patterned apertured web may be used as part of
an ear panel, a wipe, and/or a barrier leg cuff. The zonal
patterned apertured webs may have one or more layers that is
pre-strained and joined to non-pre-strained layers, as described
herein.
[0322] Referring to FIG. 104, a first zone, Z1, represents a front
portion of an absorbent article while a second zone, Z2, represents
a rear portion of an absorbent article. The first and second zones
are formed in a patterned apertured web that may be a single layer
or multiple layers. The patterned apertured web 1300 may comprise a
plurality of first arrays forming the first zone, Z1. At least some
of the first arrays may comprise a first plurality of land areas
and a first plurality of apertures. At least some of the first
plurality of land areas surround at least some of the first
plurality of apertures. The first zone, Z1, may have a plurality of
Interaperture Distances, according to the Aperture Test herein. The
Interaperture Distances of the first zone, Z1, may have a first
distribution having a first mean and a first median. The first mean
may be greater than, less than, or different than the first median
by at least 4% or other percentage, such as 8%, for example. The
first arrays in the first zone, Z1, may have an Effective Open
Area, according to the Aperture Test herein, in the range of about
5% to about 50%, also including any other ranges specified herein.
An example of first arrays that may form the first zone, Z1, is
illustrated in FIG. 1, along with land areas 14 and apertures 12.
Any of the other patterned apertured webs of the present disclosure
may also form all of or part of the first zone, Z1.
[0323] A plurality of second, different arrays may form the second
zone, Z2, in the patterned apertured web 1300. At least some of the
second arrays may comprise a second plurality of land areas and a
second plurality of apertures. At least some of the second land
areas may surround at least some of the second plurality of
apertures. The second zone, Z2, may have a plurality of
Interaperture Distances, according to the Aperture Test herein. The
Interaperture Distances of the second zone, Z2, may have a second
distribution having a second mean and a second median. The second
mean may be greater than, less than, or different than the second
median by at least 4% or other percentage, such as 8%, for example.
The second arrays in the second zone, Z2, may have an Effective
Open Area, according to the Aperture Test herein, of about 5% to
about 50%, also including any other ranges specified herein. An
example of second arrays that may form the second zone, Z2, is
illustrated in FIG. 2, along with land areas 14 and apertures 12.
Any of the other patterned apertured webs of the present disclosure
may also form all of or part of the second zone, Z2.
[0324] The patterned apertured web in either of the zones, Z1 or
Z2, may comprise one or more layers or may only comprise a single
layer. The layer or layers may comprise films, nonwoven material or
any of the other materials specified herein. In a multi-layer
patterned apertured web, the layers may comprise the same materials
or different materials, with at least one of the layers having
patterned apertures. The layers may have the same or different
colors. The first plurality of apertures in the first zone, Z1, may
be the same as or different than the plurality of apertures in the
second zone, Z2. The first plurality of apertures in the first
array or the second plurality of apertures in the second array may
form a substantially continuous pattern, a discrete pattern, or a
linear pattern. The first plurality of land areas in the first
array or the second plurality of land area in the second array may
form a substantially continuous pattern, a discrete pattern, or a
linear pattern.
[0325] The first zone, Z1, or the second zone, Z2, may indicate the
correct orientation of the absorbent article on a wearer. The
patterned apertured web 1300 may comprise a
polyethylene/polypropylene bicomponent spunbond material,
nanofibers, and/or crimped fibers.
[0326] A patterned apertured web (single or multi-layer) may
comprise a plurality of first arrays forming a first zone, Z1, in
the patterned apertured web 1300. At least some of the first arrays
may comprise a first plurality of land areas and a first plurality
of non-homogeneous apertures. At least some of the first plurality
of land areas may surround at least some of the first plurality of
apertures. The first plurality of apertures may have an Average
Absolute Feret Angle of greater than about 20 degrees (or other
degrees as set forth herein), according to the Aperture Test
herein. The first arrays may have an Effective Open Area, according
to the Aperture Test herein, in the range of about 5% to about 50%
(or other percentages or ranges specified herein). A plurality of
second, different arrays may form a second zone, Z2, in the
patterned aperture web. At least some of the second arrays may
comprise second plurality of land areas and a second plurality of
non-homogeneous apertures, wherein at least some of the second
plurality of land areas surround at least some of the second
plurality of apertures. The second arrays may have an Effective
Open Area, according to the Aperture Test, of about 5% to about 50%
(or other percentages or ranges specified herein). The second
plurality of apertures may also have an Average Absolute Feret
Angle of greater than about 20 degrees, according to the Aperture
Test herein.
[0327] A patterned apertured web (whether single or multi-layer)
may comprise a plurality of first arrays forming a first zone, Z1,
in the patterned apertured web. At least some of the first arrays
may comprise a first plurality of land areas having a width greater
than at least 5 mm, at least 8 mm, or at least 10 mm and a first
plurality of apertures. At least some of the first plurality of
land areas may surround at least some of the first plurality of
apertures. The first zone, Z1, may have a plurality of
Interaperture Distances, according to the Aperture Test herein,
wherein the Interaperture Distance of the first zone, Z1, may have
a first distribution having a first mean and a first median. The
first mean may be greater than, less than, or different than the
first median by at least 4% or at least 8%. The first arrays may
have an Effective Open Area, according to the Aperture Test, in the
range of about 5% to about 50% (or other percentages or ranges
specified herein). A plurality of second arrays may form second
zone, Z2, in the patterned apertured web 1300. At least some of the
second arrays may comprise a second plurality of land areas having
a width greater than at least 5 mm, at least 8 mm, or at least 10
mm and a second plurality of apertures. At least some of the second
plurality of land areas may surround at least some of the second
plurality of apertures. The second zone, Z2, may have a plurality
of Interaperture Distances, according to the Aperture Test herein.
The Interaperture Distances of the second zone, Z2, may have a
second distribution having a second mean and a second median. The
second mean may be greater than, less than, or different than the
second median by at least 4% or at least 8% or in the range of
about 4% to about 25%. The second arrays may have an Effective Open
Area in the range of about 5% to about 50% (or other percentages or
ranges specified herein).
[0328] A patterned apertured web may comprise a layer comprising a
plurality of apertures and a plurality of land areas. The plurality
of apertures may comprise a first set of apertures and a second set
of apertures. The first set of apertures may have Interaperture
Distances, according to the Aperture Test herein. The Interaperture
Distances of the first set of apertures may have a first
distribution having a first mean and a first median. The first mean
may be greater than, less than or different than, the first median.
The second set of apertures may have Interaperture Distances,
according to the Aperture Test herein. The Interaperture Distances
of the second set of apertures may have a second distribution
having a second mean and a second median. The second mean may be
greater than, less than, or different than the second median. The
first and second sets of apertures may have different patterns. The
patterned apertured web 1300 may comprise a third set of apertures.
The third set of apertures may be different than the first and
second sets of apertures. The third set of apertures may have
Interaperture Distances, according to the Aperture Test herein. The
e Interaperture Distances of the third set of apertures may have a
third distribution having a third mean and a third median. The
third mean may be greater than, less than or different than the
third median. The patterned apertured web 1300 may have one or more
layers. One or more of the layers may be apertured. In other
instances, one or more of the layer may not be apertured. A first
layer of the patterned apertured web may be apertured and a second
layer of the patterned apertured web may not be apertured. In other
instances, a first layer of a patterned apertured web may be
apertured and a second layer of the patterned apertured web may be
apertured. The layers may have a different in hydrophilicity as
described herein. A portion of, or all of, the first layer or a
portion of, or all of, the second layer may comprise a
polyethylene/polypropylene bicomponent spunbond material,
nanofibers, and/or crimped fibers.
[0329] Referring to FIG. 105, a patterned apertured web 1301 may
have a first zone, Z1, and a second zone, Z2. The first and second
zones, Z1 and Z2, may have any of the features described above with
respect to the patterned apertured web 1300 and FIG. 104. The same
applies to the patterned apertured web 1302 of FIG. 106. In FIG.
106, the first zone, Z1, may be a first patterned apertured web,
and the second zone, Z2, may be a second patterned apertured web.
The first patterned apertured web may surround the second patterned
apertured web or the second patterned apertured web may be a patch
placed on or joined to the first patterned apertured web.
[0330] Referring to FIG. 107, a patterned apertured web 1303 may
have a first zone, Z1, a second zone, Z2, a third zone, Z3, and a
fourth zone, Z4. The first, second, third, and fourth zones, Z1-Z4,
may have any of the features described above with respect to the
patterned apertured web 1300 and FIG. 104.
[0331] At least some of the zones of FIGS. 104-107 may not have
patterned apertures or apertures in some instances.
Packages
[0332] The absorbent articles of the present disclosure may be
placed into packages. The packages may comprise polymeric films
and/or other materials. Graphics and/or indicia relating to
properties of the absorbent articles may be formed on, printed on,
positioned on, and/or placed on outer portions of the packages.
Each package may comprise a plurality of absorbent articles. The
absorbent articles may be packed under compression so as to reduce
the size of the packages, while still providing an adequate amount
of absorbent articles per package. By packaging the absorbent
articles under compression, caregivers can easily handle and store
the packages, while also providing distribution savings to
manufacturers owing to the size of the packages.
[0333] Accordingly, packages of the absorbent articles of the
present disclosure may have an In-Bag Stack Height of less than
about 110 mm, less than about 105 mm, less than about 100 mm, less
than about 95 mm, less than about 90 mm, less than about 85 mm,
less than about 80 mm, less than about 78 mm, less than about 76
mm, less than about 74 mm, less than about 72 mm, or less than
about 70 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 110 mm, from about 70 mm to about 105 mm, from about 70 mm to
about 100 mm, from about 70 mm to about 95 mm, from about 70 mm to
about 90 mm, from about 70 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.
[0334] FIG. 108 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.
Materials/Laminates Comprising Overbonds
[0335] Materials and/or laminates comprising overbonds are also
within the scope of the present disclosure. The materials may be
single self-sustaining webs, while the laminates may be one or more
single self-sustaining webs that are joined together. In a laminate
context, only one layer may comprise overbonds or all layers may
comprise overbonds. If overbonds are provided in more than one
layer of a laminate, they may have the same patterns or different
patterns. Any of the layers of the laminate may be pre-strained.
The webs may be films, nonwovens, any other suitable materials,
and/or any other materials described herein. The overbonds may be
arranged in any suitable patterns, such as the patterns of FIGS.
19-23, 31, 53, and 55-60, for example. The overbonds may be applied
at a nonwoven supplier or nonwoven manufacture (without performing
the cross-machine directional stretching step(s)) or may be applied
at a site where the cross-machine directional stretching step(s)
is/are also conducted. Examples of the cross-machine direction
stretching steps are described herein with references to FIGS. 16
and 24-30. The overbonded materials and/or laminates may be used to
produce the patterned apertured webs of the present disclosure.
Test Methods
Basis Weight Test
[0336] Basis weight of the patterned apertured webs may be
determined by several available techniques, but a simple
representative technique involves taking an absorbent article or
other consumer product, removing any elastic which may be present
and stretching the absorbent article or other consumer product to
its full length. A punch die having an area of 45.6 cm.sup.2 is
then used to cut a piece of the patterned apertured web (e.g.,
topsheet, outer cover) from the approximate center of the absorbent
article or other consumer product in a location which avoids to the
greatest extent possible any adhesive which may be used to fasten
the patterned apertured web to any other layers which may be
present and removing the patterned apertured web from other layers
(using cryogenic spray, such as Cyto-Freeze, Control Company,
Houston, Tex., if needed). The sample is then weighed and dividing
by the area of the punch die yields the basis weight of the
patterned apertured web. Results are reported as a mean of 5
samples to the nearest 0.1 cm.sup.2.
Aperture Test
[0337] Aperture dimensions, Effective Aperture Area, % Effective
Open Area, Interaperture Distance measurements, among other
measurements, are obtained from specimen images acquired using a
flatbed scanner. The scanner is capable of scanning in reflectance
mode at a resolution of 6400 dpi and 8 bit grayscale (a suitable
scanner is an Epson Perfection V750 Pro from Epson America Inc.,
Long Beach Calif. or equivalent). The scanner is interfaced with a
computer running an image analysis program (a suitable program is
ImageJ v. 1.47 or equivalent, National Institute of Health, USA).
The specimen images are distance calibrated against an acquired
image of a ruler certified by NIST. A steel frame is used to mount
the specimen, which is then backed with a black glass tile (P/N
11-0050-30, available from HunterLab, Reston, Va.) prior to
acquiring the specimen image. The resulting image is then
thresheld, separating open aperture regions from specimen material
regions, and analyzed using the image analysis program. All testing
is performed in a conditioned room maintained at about
23.+-.2.degree. C. and about 50.+-.2% relative humidity.
Sample Preparation:
[0338] To obtain a specimen, tape an absorbent article to a rigid
flat surface in a planar configuration. Any leg elastics may be cut
to facilitate laying the article flat. A rectilinear steel frame
(100 mm square, 1.5 mm thick with an opening 60 mm square) is used
to mount the specimen. Take the steel frame and place double-sided
adhesive tape on the bottom surface surrounding the interior
opening. Remove the release paper of the tape, and adhere the steel
frame to the apertured layer of the article. Align the frame so
that it is parallel and perpendicular to a machine direction (MD)
and a cross direction (CD) of the apertured layer. Using a razor
blade excise the apertured layer from the underlying layers of the
article around the outer perimeter of the frame. Carefully remove
the specimen such that its longitudinal and lateral extension is
maintained to avoid distortion of the apertures. A cryogenic spray
(such as Cyto-Freeze, Control Company, Houston Tex.) may be used to
remove the specimen from the underlying layers if necessary. Five
replicates obtained from five substantially similar articles are
prepared for analysis. If the apertured layer of interest is too
small to accommodate the steel frame, reduce the frame dimensions
accordingly to accomplish the goals of removal of the specimen
without distortion of the apertures while leaving an opening of
sufficient size to allow for scanning a significant portion of the
apertured layer. An apertured or patterned apertured substrate raw
material is prepared for testing by extending or activating it
under the same process conditions, and to the same extent, as it
would be for use on the absorbent article, and then in its extended
state adhering it to the steel frame as described above for
testing. Condition the samples at about 23.degree. C..+-.2
C..degree. and about 50%.+-.2% relative humidity for 2 hours prior
to testing.
Image Acquisition:
[0339] Place the ruler on the scanner bed, oriented parallel to
sides of the scanner glass, and close the lid. Acquire a
calibration image of the ruler in reflectance mode at a resolution
of 6400 dpi (approximately 252 pixels per mm) and 8 bit grayscale,
with the field of view corresponding to the dimensions of an
interior of the steel frame. Save the calibration image as an
uncompressed TIFF format file. Lift the lid and remove the ruler.
After obtaining the calibration image, all specimens are scanned
under the same conditions and measured based on the same
calibration file. Next, place the framed specimen onto the center
of the scanner bed, lying flat, with the outward facing surface of
the specimen facing the scanner's glass surface. Orient the
specimen so that sides of the frame are aligned parallel with and
perpendicular to the sides of the scanner's glass surface, so that
the resulting specimen image will have the MD vertically running
from top to bottom. Place the black glass tile on top of the frame
covering the specimen, close the lid and acquire a scanned image.
Scan the remaining four replicates in like fashion. If necessary,
crop all images to a rectangular field of view circumscribing the
apertured region, and resave the files.
% Effective Open Area Calculation:
[0340] Open the calibration image file in the image analysis
program and perform a linear distance calibration using the imaged
ruler. This distance calibration scale will be applied to all
subsequent specimen images prior to analysis. Open a specimen image
in the image analysis program and set the distance scale. View the
8 bit histogram (0 to 255, with one bin per GL) and identify the
gray level (GL) value for the minimum population located between
the dark pixel peak of the aperture holes and the lighter pixel
peak of the specimen material. Threshold the image at the minimum
gray level value to generate a binary image. In the binary image
the apertures appear as black, with a GL value of 255, and specimen
as white, with a GL value of 0.
[0341] Using the image analysis program, analyze each of the
discrete aperture regions. Measure and record all of the individual
aperture areas to the nearest 0.01 mm.sup.2, including partial
apertures along the edges of the image. Discard any apertures with
an area less than 0.3 mm.sup.2 as "non-effective". Sum the
remaining aperture areas (including whole and partial apertures),
divide by the total area included in the image and multiply by 100.
Record this value as the % effective open area to the nearest
0.01%.
[0342] In like fashion, analyze the remaining four specimen images.
Calculate and report the average % effective open area values to
the nearest 0.01% for the five replicates.
Effective Aperture Dimension Measurements:
[0343] Open the calibration image (containing the ruler) file in
the image analysis program. Resize the resolution of the original
image from 6400 dpi to 640 dpi (approximately 25.2 pixels per mm)
using a bicubic interpolation. Perform a linear distance
calibration using the imaged ruler. This distance calibration scale
will be applied to all subsequent specimen images prior to
analysis. Open a specimen image in the image analysis program.
Resize the resolution of the original image from 6400 dpi to 640
dpi (approximately 25.2 pixels per mm) using a bicubic
interpolation. Set the distance scale. View the 8 bit histogram (0
to 255, with one bin per GL) and identify the gray level (GL) value
for the minimum population located between the dark pixel peak of
the aperture holes and the lighter pixel peak of the specimen
material. Threshold the image at the minimum gray level value to
generate a binary image. In the binary image, the apertures appear
as black, with a GL value of 255, and specimen as white, with a GL
value of 0. Next, two morphological operations are performed on the
binary image. First, a closing (a dilation operation followed by an
erosion operation, iterations=1, pixel count=1), which removes
stray fibers within an aperture hole. Second, an opening (an
erosion operation followed by a dilation operation, iterations=1,
pixel count=1), which removes isolated black pixels. Pad the edges
of the image during the erosion step to ensure that black boundary
pixels are maintained during the operation. Lastly, fill any
remaining voids enclosed within the black aperture regions.
[0344] Using the image analysis program, analyze each of the
discrete aperture regions. During the analysis exclude measurements
of partial apertures along the edges of the image, so that only
whole apertures are measured. Measure and record all of the
individual effective aperture areas, perimeters, feret diameters
(length of the apertures) along with its corresponding angle of
orientation in degrees from 0 to 180, and minimum feret diameters
(width of the apertures). Record the measurements for each of the
individual elements areas to the nearest 0.01 mm.sup.2, the
perimeters and feret diameters (length and width), to the nearest
0.01 mm, and angles to the nearest 0.01 degree. Discard any
apertures with an area less than 0.3 mm.sup.2 as "non-effective".
Record the number of remaining apertures, divide by the area of the
image and record as the Aperture Density value. The angle of
orientation for an aperture aligned with the MD (vertical in the
image) will have an angle of 90 degrees. Apertures with a positive
slope, increasing from left to right, will have an angle between
zero and 90 degrees. Apertures with a negative slope, decreasing
from left to right, will have an angle between 90 and 180 degrees.
Using the individual aperture angles calculate an Absolute Feret
Angle by subtracting 90 degrees from the original angle of
orientation and taking its absolute value. In addition to these
measurements, calculate an Aspect Ratio value for each individual
aperture by dividing the aperture length by its width. Repeat this
analysis for each of the remaining four replicate images. Calculate
and report the statistical mean and standard deviation for each of
the effective aperture dimension, the Absolute Feret Angle, and the
Aspect Ratio measurements using all of the aperture values recorded
from the replicates. Record the average of the individual Absolute
Feret Angle measurements as the Average Absolute Feret Angle value.
Calculate and report the % relative standard deviation (RSD) for
each of the aperture dimension, the Absolute Feret Angle, and the
Aspect Ratio measurements by dividing the standard deviation by the
mean and multiplying by 100.
Inter-Aperture Distance Measurements:
[0345] The mean, standard deviation, median, and maximum distance
between the apertures can be measured by further analyzing the
binary image that was analyzed for the aperture dimension
measurements. First, obtain a duplicate copy of the resized binary
image following the morphological operations, and using the image
analysis program, perform a Voronoi operation. This generates an
image of cells bounded by lines of pixels having equal distance to
the borders of the two nearest pattern apertures, where the pixel
values are outputs from a Euclidian distance map (EDM) of the
binary image. An EDM is generated when each interaperture pixel in
the binary image is replaced with a value equal to that pixel's
distance from the nearest pattern aperture. Next, remove the
background zeros to enable statistical analysis of the distance
values. This is accomplished by using the image calculator to
divide the Voronoi cell image by itself to generate a 32-bit
floating point image where all of the cell lines have a value of
one, and the remaining parts of the image are identified as Not a
Number (NaN). Lastly, using the image calculator, multiply this
image by the original Voronoi cell image to generate a 32-bit
floating point image where the distance values along the cell lines
remain, and all of the zero values have been replaced with NaN.
Next, convert the pixel distance values into actual inter-aperture
distances by multiplying the values in the image by the pixel
resolution of the image (approximately 0.04 mm per pixel), and then
multiply the image again by 2 since the values represent the
midpoint distance between apertures. Measure and record the mean,
standard deviation, median and maximum inter-aperture distances for
the image to the nearest 0.01 mm. Repeat this procedure for all
replicate images. Calculate the % relative standard deviation (RSD)
for the interaperture distance by dividing the standard deviation
by the mean and multiplying by 100.
Opacity Test
[0346] Opacity by contrast ratio measurements are made using a
0.degree./45.degree. spectrophotometer suitable for making standard
CIE L*a*b* color measurements (e.g., Hunterlab Labscan XE
spectrophotometer, Hunter Associates Laboratory Inc., Reston Va. or
equivalent). The diameter of the instrument's measurement port
should be chosen such that only the region of interest is included
within the measurement port. Analyses are performed in a room
controlled at about 23.degree. C..+-.2 C..degree. and 50%.+-.2%
relative humidity. Samples are conditioned at the same condition
for 2 hours before testing.
[0347] Calibrate the instrument per the vender instructions using
the standard black and white tiles provided by the vendor. Set the
spectrophotometer to use the CIE XYZ color space, with a D65
standard illumination and 10.degree. observer. If the specimen is a
layer of an article, use cryogenic spray and scissors to carefully
excise the specimen from the article for testing, otherwise obtain
the specimen from a representative sample of material of sufficient
size for testing. Place the specimen flat against the instrument
with the outward facing surface toward the spectrophotometer's
measurement port and the region of interest within the port. Ensure
that no tears, holes or apertures are within the measurement port.
Place the white standard tile onto the opposing surface of the
specimen such that it completely covers the measurement port. Take
a reading for XYZ and record to 0.01 units. Without moving the
specimen, remove the white plate and replace it with the black
standard plate. Take a second reading for XYZ and record to 0.01
units. Repeat this procedure at a corresponding site for a total of
ten (10) replicate specimens.
[0348] Opacity is calculated by dividing the Y value measured using
the black tile as backing, divided by the Y value measured using
the white tile as backing, then multiplying the ratio by 100.
Record the opacity value to the nearest 0.01%. Calculate opacity
for the 10 replicates and report the average opacity to the nearest
0.01%.
Light Transmission Test
[0349] The light transmission test measures the average amount of
light transmitted through specific regions of a specimen. A
calibrated light transmission image is obtained using a flatbed
scanner. A binary mask is generated to separate discrete aperture
regions from the surrounding land area. The binary mask is then
registered to the light transmission image, and used to exclude the
apertures from the land area in the light transmission image. This
enables the average light transmission value for the land area to
be calculated.
Sample Preparation:
[0350] To obtain a specimen, tape the absorbent article to a rigid
flat surface in a planar configuration. Any leg elastics may be cut
to facilitate laying the article flat. A rectilinear steel frame
(100 mm square, 1.5 mm thick with an opening 60 mm square) is used
to mount the specimen. Take the steel frame and place double-sided
adhesive tape on the bottom surface surrounding the interior
opening. Remove the release paper of the tape, and adhere the steel
frame to the apertured layer of the article. Align the frame so
that it is parallel and perpendicular to the machine direction (MD)
and cross direction (CD) of the apertured layer. Using a razor
blade excise the apertured layer from the underlying layers of the
article around the outer perimeter of the frame. Carefully remove
the specimen such that its longitudinal and lateral extension is
maintained to avoid distortion of the apertures. A cryogenic spray
(such as Cyto-Freeze, Control Company, Houston Tex.) can be used to
remove the specimen from the underlying layers if necessary. Five
replicates obtained from five substantially similar articles are
prepared for analysis. If the aperture layer of interest is too
small to accommodate the steel frame, reduce the frame dimensions
accordingly to accomplish the goals of removal of the specimen
without distortion of the apertures while leaving an opening of
sufficient size to allow for scanning a significant portion of the
apertured layer. An apertured substrate raw material is prepared
for testing by extending or activating it under the same process
conditions, and to the same extent, as it would be for use on the
absorbent article, and then in its extended state adhering it to
the steel frame as described above for testing. Condition the
samples at about 23.degree. C..+-.2 C..degree. and about 50%.+-.2%
relative humidity for 2 hours prior to testing.
Light Transmission Image
[0351] The light transmission measurement is based on the CIE
L*a*b* color system (CIELAB). A flatbed scanner capable of scanning
a minimum of 24 bit color at 800 dpi and has manual control of
color management (a suitable scanner is an Epson Perfection V750
Pro from Epson America Inc., Long Beach Calif. or equivalent) is
used to acquire images. The scanner is interfaced with a computer
running color management software (suitable color management
software is MonacoEZColor available from X-Rite Grand Rapids, Mich.
or equivalent). The scanner is calibrated against a color
transparency target and corresponding reference file compliant with
ANSI method IT8.7/1-1993 using the color management software to
construct a calibrated color profile. The resulting calibrated
scanner profile is used to color correct an image from a test
specimen within an image analysis program that supports sampling in
CIE L*a*b* (a suitable program is Photoshop S4 available from Adobe
Systems Inc., San Jose, Calif. or equivalent). All testing is
performed in a conditioned room maintained at about 23.+-.2.degree.
C. and about 50.+-.2% relative humidity.
[0352] Turn on the scanner for 30 minutes prior to calibration.
Deselect any automatic color correction or color management options
that may be included in the scanner software. If the automatic
color management cannot be disabled, the scanner is not appropriate
for this application. Place the IT8 target face down onto the
scanner glass, close the scanner lid, acquire an image at 200 dpi
and 24 bit color and remove the IT8 target. Open the image file on
the computer with the color management software. Follow the
recommended steps within the color management software to create
and export a calibrated color profile. These steps may include,
ensuring that the scanned image is oriented and cropped correctly.
The calibrated color profile must be compatible with the image
analysis program. The color management software uses the acquired
image to compare with the included reference file to create and
export the calibrated color profile. After the profile is created
the scan resolution (dpi) for test specimens can be changed, but
all other settings must be kept constant while imaging
specimens.
[0353] Open the scanner lid and place the specimen flat against the
scanner glass with the outward facing surface facing the glass.
Acquire and import a scan of the specimen region within the
interior of the frame into the image analysis software at 24 bit
color and at 800 dpi in transparency mode. If necessary, crop image
to a rectangular field of view circumscribing the apertured region.
Transparency mode illuminates the specimen from one side with the
sensor capturing the image from the opposite side. Assign the
calibrated color profile to the image and change the color space
mode to L*a*b* Color corresponding to the CIE L*a*b* standard. This
produces a color corrected image for analysis. Save this color
corrected image in an uncompressed format, such as a TIFF file.
Land Area Mask
[0354] The boundaries of the apertured areas and land area are
identified by thresholding the L* channel image to generate a
binary image, separating apertured areas from the surrounding land
area. This binary image will then be used as a mask on the
corresponding light transmission image to measure the average Light
Transmission Value of only the land area.
[0355] To do this, first open the color corrected light
transmission image in the image analysis software. To generate the
land area mask, first separate the L*, a* and b* channels, and
select only the L* channel for analysis. The L* channel represents
the "Lightness" of the image and has values that range from 0-100.
Threshold the L* channel image at a value of 90 to generate a
binary image.
[0356] By thresholding at the level described above, a binary mask
image is produced with the discrete aperture areas assigned one
value, and the surrounding land area assigned a different value.
For example, the discrete aperture areas could appear black, and
the surrounding land area could appear white. Save this binary mask
image in an uncompressed format, such as a TIFF file.
Analysis of Light Transmission Image
[0357] Open both the color corrected light transmission image and
the corresponding binary mask image in the image analysis software.
To analyze the specimen light transmission image, first separate
the L*, a* and b* channels, and select only the L* channel for
analysis. Register the light transmission image and the binary mask
image to each other. Use the binary mask to exclude the apertures
from the light transmission image, and calculate an average L*
value (Light Transmission Value) for the remaining surrounding land
area. Record this value as the Land Area Light Transmission Value
to the nearest 0.1 units. In like fashion, repeat this procedure on
all of the replicate specimens. Calculate and report the average of
the five individual Land Area Light Transmission Values to the
nearest 0.1 units.
In-Bag Stack Height Test
[0358] The in-bag stack height of a package of absorbent articles
is determined as follows:
Equipment
[0359] 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
[0360] Absorbent article packages are equilibrated at
23.+-.2.degree. C. and 50.+-.5% relative humidity prior to
measurement.
[0361] 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. 108). 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.
[0362] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm".
[0363] All documents cited herein, including any cross referenced
or related patent, patent publication, or patent application, is
hereby incorporated by reference in its entirety unless expressly
excluded or otherwise limited. The citation of any document is not
an admission that it is prior art with respect to any invention
disclosed or claimed herein or that it alone, or in any combination
with any other reference or references, teaches, suggests, or
discloses any such invention. Further, to the extent that any
meaning or definition of a term in this document conflicts with any
meaning or definition of the same term in a document incorporated
by reference, the meaning or definition assigned to that term in
this document shall govern.
[0364] While particular forms of the present disclosure have been
illustrated and described, those of skill in the art will recognize
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 the present
disclosure.
* * * * *