U.S. patent application number 15/674566 was filed with the patent office on 2018-02-15 for array of absorbent articles with ear portions.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Urmish Popatlal DALAL, Joerg MUELLER.
Application Number | 20180042786 15/674566 |
Document ID | / |
Family ID | 59677407 |
Filed Date | 2018-02-15 |
United States Patent
Application |
20180042786 |
Kind Code |
A1 |
MUELLER; Joerg ; et
al. |
February 15, 2018 |
ARRAY OF ABSORBENT ARTICLES WITH EAR PORTIONS
Abstract
An array of absorbent articles includes a first absorbent
article comprising a topsheet, a backsheet and an absorbent core
disposed between the topsheet and backsheet, and a first ear
laminate having a first plurality of ultrasonic bonds disposed in a
first elasticized region. The array further includes a second
absorbent article comprising a topsheet, a backsheet and an
absorbent core disposed between the topsheet and backsheet, and a
second ear laminate having a second plurality of ultrasonic bonds
disposed in a second elasticized region. The first ear laminate
differs from the second ear laminate at least in extensibility,
bond pattern, softness and/or tensile strength.
Inventors: |
MUELLER; Joerg; (Karben,
DE) ; DALAL; Urmish Popatlal; (Milford, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
59677407 |
Appl. No.: |
15/674566 |
Filed: |
August 11, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62374286 |
Aug 12, 2016 |
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62419518 |
Nov 9, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F 2013/15357
20130101; A61F 13/49012 20130101; A61F 2013/15406 20130101; A61F
13/5633 20130101; A61F 13/84 20130101; A61F 2013/8497 20130101;
A61F 13/56 20130101; A61F 13/493 20130101; A61F 13/49015 20130101;
A61F 13/15203 20130101 |
International
Class: |
A61F 13/49 20060101
A61F013/49; A61F 13/15 20060101 A61F013/15 |
Claims
1. An array of absorbent articles comprising a first absorbent
article comprising a topsheet, a backsheet and an absorbent core
disposed between the topsheet and backsheet, and a first ear
laminate having a first plurality of ultrasonic bonds disposed in a
first elasticized region; and a second absorbent article comprising
a topsheet, a backsheet and an absorbent core disposed between the
topsheet and backsheet, and a second ear laminate having a second
plurality of ultrasonic bonds disposed in a second elasticized
region; wherein the first ear laminate has an Average Extension at
10 N that is at least 5% greater than the second ear laminate at 10
N.
2. The array of absorbent articles of claim 1 wherein the first
elasticized region comprises an area that is greater than the area
of the second elasticized region.
3. The array of absorbent articles of claim 1 wherein the first ear
laminate comprises a first elastomeric material and the second ear
laminate comprises a second elastomeric material, wherein the first
and second elastomeric materials differ by basis weight, material
type, composition and combinations thereof.
4. The array of absorbent articles of claim 1 wherein a first
package comprises the first absorbent article and a second package
comprises the second absorbent article, and wherein the first and
second packages comprise a common brand name.
5. The array of absorbent articles of claim 1 wherein the first
absorbent article comprises a functional feature and the second
absorbent article is void of said functional feature.
6. The array of absorbent articles of claim 1 wherein the first ear
laminate comprises a primary nonwoven and the second ear laminate
comprises a secondary nonwoven, wherein the primary nonwoven and
the secondary nonwoven differ by one of the group consisting of
layer configuration, fiber composition, calendar bond area or
calendar bond shape, basis weight, and combinations thereof.
7. An array of absorbent articles comprising: a first absorbent
article comprising a topsheet, a backsheet and an absorbent core
disposed between the topsheet and backsheet, and a first ear
laminate having a first plurality of ultrasonic bonds disposed in a
first collective pattern; and a second absorbent article comprising
a topsheet, a backsheet and an absorbent core disposed between the
topsheet and backsheet, and a second ear laminate having a second
plurality of ultrasonic bonds disposed in a second collective
pattern; wherein the first collective pattern differs from the
second collective pattern by average bond spacing, pattern
uniformity, bond size, bond shape, bond orientation, aggregate bond
area, aggregate pattern shape and combinations thereof.
8. The array of claim 7 wherein the first absorbent article and
second absorbent article have different sizes.
9. The array of claim 7 wherein the first pattern corresponds to a
first user characteristic and the second pattern corresponds to
second user characteristic, wherein the first and second user
characteristics are different and are each selected from the group
consisting of: intended wearer gender, intended wearer age and/or
development stage, absorbency needs, fit preferences, and
combinations thereof.
10. The array of claim 7 wherein the first absorbent article
comprises a functional feature and wherein the second absorbent
article is void of said functional feature.
11. The array of absorbent articles of claim 7 wherein a first
package comprises the first absorbent article and a second package
comprises the second absorbent article.
12. An array of absorbent articles comprising: a first absorbent
article comprising a topsheet, a backsheet and an absorbent core
disposed between the topsheet and backsheet, and a first ear
laminate having a first plurality of ultrasonic bonds; and a second
absorbent article comprising a topsheet, a backsheet and an
absorbent core disposed between the topsheet and backsheet, and a
second ear laminate having a second plurality of ultrasonic bonds;
wherein the first ear laminate comprises a TS7 softness value that
is at least 10% less than a TS7 softness value of the second ear
laminate.
13. The array of absorbent articles of claim 12 wherein the first
ear laminate comprises one or more crimped fiber spunbond nonwoven
webs.
14. The array of absorbent articles of claim 12 wherein the first
ear laminate comprises one or more softness additives.
15. The array of absorbent articles of claim 12 wherein the first
ear laminate comprises a carded nonwoven webs.
16. The array of absorbent articles of claim 12 wherein a first
package comprises the first absorbent article and a second package
comprises the second absorbent article, and wherein the first and
second package comprise a common brand name.
17. The array of claim 12 wherein the first absorbent article
comprises a functional feature and wherein the second absorbent
article is void of said functional feature.
18. An array of absorbent articles comprising a first absorbent
article comprising a topsheet, a backsheet and an absorbent core
disposed between the topsheet and backsheet, and a first ear
laminate having a first plurality of ultrasonic bonds; a second
absorbent article comprising a topsheet, a backsheet and an
absorbent core disposed between the topsheet and backsheet, and a
second ear laminate having a second plurality of ultrasonic bonds;
wherein the first ear laminate comprises first Average Load at
Break and the second ear laminate comprises a second Average Load
at Break, wherein the first Average Load at Break is at least 4%
greater than the second Average Load at Break.
19. The array of absorbent articles of claim 18 wherein the first
ear laminate comprises a first garment-facing nonwoven and a first
body-facing nonwoven, wherein at least one of the first
garment-facing and first body-facing nonwovens comprises a basis
weight of about 20 gsm or less.
20. The array of absorbent articles of claim 19 wherein the basis
weight is about 17 gsm or less.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to absorbent articles having
ear portions, in particular stretchable ears.
BACKGROUND OF THE INVENTION
[0002] It has long been known that absorbent articles such as
conventional absorbent articles (e.g., diapers, adult incontinence
articles, feminine hygiene pads) offer the benefit of receiving and
containing urine and/or other bodily exudates (e.g., feces, menses,
mixture of feces and urine, mixture of menses and urine, etc.). To
effectively contain bodily exudates, the article should provide a
snug fit around the waist and legs of a wearer.
[0003] Manufacturers often use extensible areas, such as stretch
side panels (i.e., ears), within the article to help achieve a snug
fit. When worn, the stretch ears extend the article about the hip
and waist of the wearer to anchor the product in use while still
allowing the wearer to move comfortably. A fastening system is
typically joined to the ear to further secure the product about the
wearer. Stretch ears are typically laminates of coverstock
materials (such as nonwovens) and elastomeric materials.
[0004] It has been proposed to create stretch laminates using
ultrasonic bonding. In such instance, a stretched elastomeric
material is combined with a nonwoven via ultrasonic bonding. After
combination, the nonwoven will form corrugations when the laminate
is in a relaxed state. These laminates can produce highly
stretchable ears (depending on the level of stretch imparted in the
elastomeric material) while avoiding the use of glues and
mechanical activation. Further, unlike other forms of lamination,
the elastomeric material need not extend across the entire width of
the laminate. In addition, ultrasonically bonded laminates provide
higher levels of breathability than other stretch laminates.
[0005] While ultrasonically bonded laminates offer a number of
benefits, different executions may be necessary to suit the needs
of individual wearers or different segments of consumers. Indeed,
absorbent articles are typically offered in different sizes,
corresponding to a range of weights for potential wearers. Further,
absorbent articles may be provided different features which may
correspond to performance (e.g., absorbency, leakage protection,
and/or extensibility), comfort (e.g., softness), fit (e.g.,
extensibility) and/or stages of development of potential wearers
(e.g., activity levels, body shape). Manufacturers often provide
multiple product offerings in order to serve different consumer
segments.
[0006] Therefore, there is a need for ultrasonically bonded
laminates that are adapted to different product offerings,
including different sizes, fit, performance and/or comfort
requirements. Further, there is a continued need for stretch ears
having desirable stretch balanced with adequate strength. There is
also a need for stretch ears having improved breathability while
maintaining strength, appropriate stress profiles, stretch
profiles, force profiles and/or other desirable properties.
SUMMARY OF THE INVENTION
[0007] The present invention relates to an array of absorbent
articles having a first absorbent article and a second absorbent
article. The first absorbent article may comprise a topsheet, a
backsheet and an absorbent core disposed between the topsheet and
backsheet, and a first ear laminate having a first plurality of
ultrasonic bonds. The second absorbent article may comprise a
topsheet, a backsheet and an absorbent core disposed between the
topsheet and backsheet, and a second ear laminate having a second
plurality of ultrasonic bonds. The first and second ear laminates
may differ at least in extensibility, bond pattern, softness and/or
tensile strength. In some embodiments, the first ear laminate
comprises an Average Extension at 10 N that is at least 5% greater
than an Average Extension of the second ear laminate at 10 N.
Additionally or alternatively, the first plurality of ultrasonic
bonds may be disposed in a first collective pattern, and the second
plurality of ultrasonic bonds may be disposed in a second
collective pattern. The first and second collective patterns may
differ by average bond spacing, pattern uniformity, bond size, bond
shape, bond orientation, aggregate bond area, aggregate pattern
shape and combinations thereof. In further embodiments, the first
ear laminate may comprise a TS7 softness value that is at least 10%
less than a TS7 softness value of the second ear laminate. The
first ear laminate may further comprise an Average Load at Break
that is at least 4% greater than an Average Load at Break of the
second ear laminate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is schematic plan view of an exemplary absorbent
article according to one nonlimiting embodiment of the present
invention. The absorbent article is shown in a flat, uncontracted
state.
[0009] FIG. 2 is a schematic plan view of an exemplary ear
according to one nonlimiting embodiment of the present
invention.
[0010] FIG. 3 is an exploded perspective view of an exemplary ear
according to a nonlimiting embodiment of the present invention.
[0011] FIG. 4 is a schematic plan view of an exemplary ear
according to one nonlimiting embodiment of the present
invention.
[0012] FIG. 5 is a schematic cross sectional view of the ear in
FIG. 4 taken along the ear's lateral centerline.
[0013] FIG. 6 is a schematic cross sectional view of an exemplary
ear according to another nonlimiting embodiment of the present
invention.
[0014] FIG. 7 is a schematic plan view of an exemplary ear
according to a nonlimiting embodiment of the present invention.
[0015] FIG. 8 is a schematic plan view of an array of absorbent
articles in accordance with a nonlimiting embodiment of the present
invention.
[0016] FIG. 9 is a schematic plan view of exemplary ears in
accordance with a nonlimiting embodiment of the present
invention.
[0017] FIGS. 10-12 are schematic perspective views of packages in
accordance with nonlimiting embodiments of the present
invention.
[0018] FIG. 13 is a schematic perspective view of grips suitable
for use in the Tensile Test Method herein.
[0019] FIG. 14 is a schematic side elevation view of a grip
suitable for use in the Tensile Test Method herein.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0020] "Disposable," in reference to absorbent articles, means that
the absorbent articles are generally not intended to be laundered
or otherwise restored or reused as absorbent articles (i.e., they
are intended to be discarded after a single use and, preferably, to
be recycled, composted or otherwise discarded in an environmentally
compatible manner).
[0021] "Absorbent article" refers to devices which absorb and
contain body exudates 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 exudates discharged from the
body. Exemplary absorbent articles include diapers, training pants,
pull-on pant-type diapers (i.e., a diaper having a pre-formed waist
opening and leg openings such as illustrated in U.S. Pat. No.
6,120,487), refastenable diapers or pant-type diapers, incontinence
briefs and undergarments, diaper holders and liners, feminine
hygiene garments such as panty liners, absorbent inserts, and the
like.
[0022] "Activation" is the mechanical deformation of a plastically
extensible material that results in permanent elongation of the
extensible material in the direction of activation in the X-Y plane
of the material. Activation of a laminate that includes an elastic
material joined to a plastically extensible material typically
results in permanent deformation of the plastic material, while the
elastic material returns substantially to its original dimension.
Activation processes are disclosed in U.S. Pat. Pub. No.
2013/0082418, U.S. Pat. No. 5,167,897 and U.S. Pat. No.
5,993,432.
[0023] "Body-facing" and "garment-facing" refer respectively to the
relative location of an element or a surface of an element or group
of elements. "Body-facing" implies the element or surface is nearer
to the wearer during wear than some other element or surface.
"Garment-facing" implies the element or surface is more remote from
the wearer during wear than some other element or surface (i.e.,
element or surface is proximate to the wearer's garments that may
be worn over the disposable absorbent article).
[0024] "Joined" refers to configurations whereby an element is
directly secured to another element by affixing the element
directly to the other element and to 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.
[0025] "Elastic," "elastomeric," and "elastically extensible" mean
the ability of a material to stretch by at least 100% without
rupture or breakage at a given load, and upon release of the load
the elastic material or component exhibits at least 80% recovery
(i.e., has less than 20% set) in one of the directions as per the
Hysteresis Test described herein. Stretch, sometimes referred to as
strain, percent strain, engineering strain, draw ratio, or
elongation, along with recovery and set may each be determined
according to the Hysteresis Test described in more detail below.
Materials that are not elastic are referred as inelastic.
[0026] "Extensible" means the ability to stretch or elongate,
without rupture or breakage, by at least 50% as per step 5(a) in
the Hysteresis Test herein (replacing the specified 100% strain
with 50% strain).
[0027] "Film" means a sheet-like material wherein the length and
width of the material far exceed the thickness of the material
(e.g., 10.times., 50.times., or even 1000.times. or more). Films
are typically liquid impermeable but may be configured to be
breathable.
[0028] "Laminate" means two or more materials that are bonded to
one another by any suitable method known in the art (e.g., adhesive
bonding, thermal bonding, ultrasonic bonding, or high pressure
bonding using non-heated or heated patterned roll).
[0029] "Lateral" refers to a direction running from a longitudinal
edge to an opposing longitudinal edge of the article and generally
at a right angle to the longitudinal direction. Directions within
45 degrees of the lateral direction are considered to be
"lateral."
[0030] "Longitudinal" refers to a direction running substantially
perpendicular from a waist edge to an opposing waist edge of the
article and generally parallel to the maximum linear dimension of
the article. Directions within 45 degrees of the longitudinal
direction are considered to be "longitudinal."
[0031] "Nonwoven" means a porous, fibrous material made from
continuous (long) filaments (fibers) and/or discontinuous (short)
filaments (fibers) by processes such as, for example, spunbonding,
meltblowing, airlaying, carding, coforming, hydroentangling, and
the like. Nonwovens do not have a woven or knitted filament
pattern. Nonwovens may be liquid permeable or impermeable.
[0032] "Carded fibers" refer to fibers that are of a discrete
length which are sorted, separated, and at least partially aligned
by a carding process. For example, a carded web refers to a web
that is made from fibers which are sent through a combing or
carding unit, which separates or breaks apart and aligns the fibers
in, e.g., the machine direction to form a generally machine
direction-oriented fibrous non-woven web. Carded fibers may or may
not be bonded after being carded.
[0033] "Meltblown fibers" refers to fibers made via a process
whereby a molten material (typically a polymer), is extruded under
pressure through orifices in a spinneret or die. High velocity hot
air impinges upon and entrains the filaments as they exit the die
to form filaments that are elongated and reduced in diameter and
are fractured so that fibers of generally variable but mostly
finite lengths are produced. This differs from a spunbond process
whereby the continuity of the filaments is preserved along their
length. An exemplary meltblown process may be found in U.S. Pat.
No. 3,849,241 to Buntin et al.
[0034] "Spunbond fibers" refers to fibers made via a process
involving extruding a molten thermoplastic material as filaments
from a plurality of fine, typically circular, capillaries of a
spinneret, with the filaments then being attenuated by applying a
draw tension and drawn mechanically or pneumatically (e.g.,
mechanically wrapping the filaments around a draw roll or
entraining the filaments in an air stream). The filaments may be
quenched by an air stream prior to or while being drawn. The
continuity of the filaments is typically preserved in a spunbond
process. The filaments may be deposited on a collecting surface to
form a web of randomly arranged substantially continuous filaments,
which can thereafter be bonded together to form a coherent nonwoven
fabric. Exemplary spunbond process and/or webs formed thereby may
be found in U.S. Pat. Nos. 3,338,992; 3,692,613, 3,802,817;
4,405,297 and 5,665,300.
[0035] "Crimped spunbond fibers" refers to spunbond bi-component
fibers which have a helical crimp or curl. The crimped fibers may
be configured in a side-by side, core-eccentric sheath or other
suitable configuration. The selection of suitable resin
combinations and bi-component fiber configurations can lead to the
helical crimp or curl generated fibers. Where suitable
configurations and/or resin combinations exist, the crimp may occur
spontaneously during the spinning or laydown process, on its own
after web formation. In some instances, the webs may require an
additional step (e.g. heating or mechanical deformation) to induce
the fibers to crimp.
[0036] "Relaxed" means the state of an element, material or
component at rest with substantially no external force acting on
the element, other than gravity.
[0037] A "segment" refers to actual or potential purchasers and/or
wearers having shared characteristics, including but not limited to
common needs, common interests, similar lifestyles, and similar
demographic profiles, which may cause them to respond to a
particular product similarly. Segments may include
purchasers/wearers desiring products having a particular
performance level, residing in a particular geography, and/or
seeking a particular price. By way of nonlimiting example, a first
segment may prioritize high performing absorbent articles with
little regard to their price while a second segment may prioritize
low price absorbent articles and is satisfied with lower
performance standards. A first segment may prioritize one feature
(e.g., softness), while a second segment may prioritize a different
feature (e.g., absorbency). Manufacturers often provide different
product offerings based on purchaser and/or wearer segments.
[0038] "Design element" as used herein means a shape or combination
of shapes that visually create a distinct and discrete component,
regardless of the size or orientation of the component. A design
element may be present in one or more patterns. A design element
may be present one or more times within one pattern. In one
nonlimiting example, the same design element is present twice in
one pattern--the second instance of the design element is smaller
than the first instance. One of skill in the art will recognize
that alternative arrangements are also possible. Design elements
may comprise insignia. Design elements and/or combinations of
design elements may comprise letters, words and/or graphics such as
flowers, butterflies, hearts, character representations and the
like. Design elements may be formed from bonds, including the shape
of one or more bond(s). Design elements and/or combinations of
design elements may comprise instructional indicia providing
guidance or instruction to the caregiver relative to placement
and/or fit of the article about the wearer.
[0039] "Pattern" as used herein means a decorative or distinctive
design, not necessarily repeating or imitative, including but not
limited to the following: clustered, geometric, spotted, helical,
swirl, arrayed, textured, spiral, cycle, contoured, laced,
tessellated, starburst, lobed, blocks, pleated, concave, convex,
braided, tapered, and combinations thereof. In some embodiments,
the pattern includes one or more repeating design elements.
[0040] "Insignia" as used herein means objects, character
representations, words, colors, shapes or other indicia that can be
used to distinguish, identify or represent the manufacturer,
retailer, distributor and/or brand of a product, including but not
limited to trademarks, logos, emblems, symbols, designs, figures,
fonts, lettering, crests or similar identifying marks.
[0041] "Brand name" means a single source identifier, in other
words, a brand name identifies a product and/or service as
exclusively coming from a single commercial source (i.e., company).
An example of a brand name is PAMPERS.RTM., which is also a
trademark. Absorbent articles of the present invention may be
marketed and/or packaged under the same brand name. In addition to
the brand name, a product descriptor (e.g., Extra Absorbent) or
other insignia (e.g., Swaddlers.RTM. may also be associated with
the absorbent article.
[0042] "Bond density" refers to bond frequency and/or aggregate
bond coverage.
[0043] "Bond frequency" refers to the number of bonds per cm.sup.2
as determined by the Bond Dimensions Test Method herein.
[0044] "Aggregate bond coverage" refers to the sum of the bond
areas in a given region as determined by the Bond Dimension Test
Method herein.
Absorbent Article
[0045] FIG. 1 is a plan view of an exemplary, non-limiting
embodiment of an absorbent article 10 of the present invention in a
flat, uncontracted state. The body-facing surface 115 of the
absorbent article 10 is facing the viewer. The absorbent article 10
includes a longitudinal centerline 100 and a lateral centerline
110.
[0046] The absorbent article 10 comprises a chassis 20. The
absorbent article 10 and chassis 20 are shown to have a first waist
region 14, a second waist region 18 opposed to the first waist
region 14, and a crotch region 16 located between the first waist
region 14 and the second waist region 18. The waist regions 14 and
18 generally comprise those portions of the absorbent article 10
which, when worn, encircle the waist of the wearer. The waist
regions 14 and 18 may include elastic members 55 such that they
gather about the waist of the wearer to provide improved fit and
containment. The crotch region 16 is the portion of the absorbent
article 10 which, when the absorbent article 10 is worn, is
generally positioned between the legs of the wearer.
[0047] The outer periphery of the chassis 20 is defined by
longitudinal edges 12 and waist edges (first waist edge 13 in first
waist region 14 and second waist edge 19 in second waist region
18). The chassis 20 may have opposing longitudinal edges 12 that
are oriented generally parallel to the longitudinal centerline 100.
However, for better fit, longitudinal edges 12 may be curved or
angled to produce, for example, an "hourglass" shape article when
viewed in a plan view as shown in FIG. 1. The chassis 20 may have
opposing lateral edges 13, 19 (i.e., the first waist edge 13 and
second waist edge 19) that are oriented generally parallel to the
lateral centerline 110.
[0048] The chassis 20 may comprise a liquid permeable topsheet 24,
a backsheet 26, and an absorbent core 28 between the topsheet 24
and the backsheet 26. The topsheet 24 may be joined to the core 28
and/or the backsheet 26. The backsheet 26 may be joined to the core
28 and/or the topsheet 24. It should be recognized that other
structures, elements, or substrates may be positioned between the
core 28 and the topsheet 24 and/or backsheet 26. In some
embodiments, an acquisition-distribution system 27 is disposed
between the topsheet 26 and the absorbent core 28.
[0049] In certain embodiments, the chassis 20 comprises the main
structure of the absorbent article 10 with other features added to
form the composite absorbent article structure. While the topsheet
24, the backsheet 26, and the absorbent core 28 may be assembled in
a variety of well-known configurations, absorbent article
configurations are described generally in U.S. Pat. Nos. 3,860,003;
5,151,092; 5,221,274; 5,554,145; 5,569,234; 5,580,411; and
6,004,306.
Topsheet:
[0050] The topsheet 24 is generally a portion of the absorbent
article 10 that may be positioned at least in partial contact or
close proximity to a wearer. Suitable topsheets 24 may be
manufactured from a wide range of materials, such as porous foams;
reticulated foams; apertured plastic films; or woven or nonwoven
webs of natural fibers (e.g., wood or cotton fibers), synthetic
fibers (e.g., polyester or polypropylene fibers), or a combination
of natural and synthetic fibers. The topsheet 24 is generally
supple, soft feeling, and non-irritating to a wearer's skin.
Generally, at least a portion of the topsheet 24 is liquid
pervious, permitting liquid to readily penetrate through the
thickness of the topsheet 24. One topsheet 24 useful herein is
available from BBA Fiberweb, Brentwood, Tenn. as supplier code
055SLPV09U. The topsheet 24 may be apertured.
[0051] Any portion of the topsheet 24 may be coated with a lotion
or skin care composition as is known in the art. Non-limiting
examples of suitable lotions include those described in U.S. Pat.
Nos. 5,607,760; 5,609,587; 5,635,191; and 5,643,588. The topsheet
24 may be fully or partially elasticized or may be foreshortened so
as to provide a void space between the topsheet 24 and the core 28.
Exemplary structures including elasticized or foreshortened
topsheets are described in more detail in U.S. Pat. Nos. 4,892,536;
4,990,147; 5,037,416; and 5,269,775.
Absorbent Core:
[0052] The absorbent core 28 may comprise a wide variety of
liquid-absorbent materials commonly used in disposable diapers and
other absorbent articles. Examples of suitable absorbent materials
include comminuted wood pulp, which is generally referred to as air
felt creped cellulose wadding; melt blown polymers, including
co-form; 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 other known absorbent material
or combinations of materials. In one embodiment, at least a portion
of the absorbent core is substantially cellulose free and contains
less than 10% by weight cellulosic fibers, less than 5% cellulosic
fibers, less than 1% cellulosic fibers, no more than an immaterial
amount of cellulosic fibers or no cellulosic fibers. It should be
understood that an immaterial amount of cellulosic material does
not materially affect at least one of the thinness, flexibility,
and absorbency of the portion of the absorbent core that is
substantially cellulose free. Among other benefits, it is believed
that when at least a portion of the absorbent core is substantially
cellulose free, this portion of the absorbent core is significantly
thinner and more flexible than a similar absorbent core that
includes more than 10% by weight of cellulosic fibers. The amount
of absorbent material, such as absorbent particulate polymer
material present in the absorbent core may vary, but in certain
embodiments, is present in the absorbent core in an amount greater
than about 80% by weight of the absorbent core, or greater than
about 85% by weight of the absorbent core, or greater than about
90% by weight of the absorbent core, or greater than about 95% by
weight of the core. In some embodiments, the absorbent core may
comprise one or more channels 29, wherein said channels are
substantially free of absorbent particulate polymer material. The
channels 29 may extend longitudinally or laterally. The absorbent
core may further comprise two or more channels. The channels may be
straight, curvilinear, angled or any workable combination thereof.
In one nonlimiting example, two channels are symmetrically disposed
about the longitudinal axis.
[0053] Exemplary absorbent structures for use as the absorbent core
28 are described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735;
4,888,231; 5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207;
5,397,316, and U.S. patent application Ser. Nos. 13/491,642 and
15/232,901.
Backsheet:
[0054] The backsheet 26 is generally positioned such that it may be
at least a portion of the garment-facing surface of the absorbent
article 10. Backsheet 26 may be designed to prevent the exudates
absorbed by and contained within the absorbent article 10 from
soiling articles that may contact the absorbent article 10, such as
bed sheets and undergarments. In certain embodiments, the backsheet
26 is substantially water-impermeable. Suitable backsheet 26
materials include films such as those manufactured by Tredegar
Industries Inc. of Terre Haute, Ind. and sold under the trade names
X15306, X10962, and X10964. Other suitable backsheet 26 materials
may include breathable materials that permit vapors to escape from
the absorbent article 10 while still preventing exudates from
passing through the backsheet 26. Exemplary breathable materials
may include materials such as woven webs, nonwoven webs, composite
materials such as film-coated nonwoven webs, and microporous films
such as manufactured by Mitsui Toatsu Co., of Japan under the
designation ESPOIR NO and by EXXON Chemical Co., of Bay City, Tex.,
under the designation EXXAIRE. Suitable composite materials
comprising polymer blends are available from Clopay Corporation,
Cincinnati, Ohio under the name HYTREL blend P18-3097. Suitable
breathable backsheets and breathable composite materials are
described in greater detail in PCT App. No. WO 95/16746; U.S. Pat.
No. 5,865,823; U.S. Pat. No. 5,571,096; and U.S. Pat. No.
6,107,537. Other suitable materials and/or manufacturing techniques
may be used to provide a suitable backsheet 26 including, but not
limited to, surface treatments, particular film selections and
processing, particular filament selections and processing, etc.
[0055] Backsheet 26 may also consist of more than one layer. The
backsheet 26 may comprise an outer cover and an inner layer. The
outer cover may be made of a soft, non-woven material. The inner
layer may be made of a substantially liquid-impermeable film, such
as a polymeric film. The outer cover and an inner layer may be
joined together by adhesive or any other suitable material or
method. A particularly suitable outer cover is available from
Corovin GmbH, Peine, Germany as supplier code Al8AH0, and a
particularly suitable inner layer is available from RKW Gronau
GmbH, Gronau, Germany as supplier code PGBR4WPR. While a variety of
backsheet configurations are contemplated herein, it would be
obvious to those skilled in the art that various other
modifications can be made without departing from the spirit and
scope of the invention.
Ears/Fasteners:
[0056] The absorbent article 10 may include one or more ears 30,
including for example front ears 32 disposed in the first waist
region and/or back ears 34 disposed in the second waist region. The
ears 30 may be integral with the chassis or discrete elements
joined to the chassis 20 at a chassis attachment bond 35, which may
join one or more layers of the ear to the chassis. The ears 30 may
be extensible or elastic. The ears 30 may be formed from one or
more nonwoven webs, woven webs, knitted fabrics, polymeric and
elastomeric films, apertured films, sponges, foams, scrims, or
combinations and/or laminates of any the foregoing.
[0057] As illustrated in FIG. 2, ears may include an outboard edge
36 and an inboard edge 38. The outboard edge 36 is the free distal
longitudinal edge of the ear when said ear is joined to the chassis
20. The inboard edge 38 is substantially opposed to the outboard
edge and is joined to or overlapped with the chassis when the ear
is joined to the chassis or is the side defined by a line extending
from longitudinal side 12 in the widest area of the crotch region
and running parallel to the longitudinal centerline in the case of
integral ears. The inboard edge comprises a length, Li. Ears may
further include a first lateral side 40 and an opposing second
lateral side 42, and lateral centerline line 43 which is generally
parallel to the article's lateral centerline 110 when the ear is
joined to the article. An ear may additional comprise a maximum
width, W, extending between the outboard edge and inboard edge and
a maximum length, L, extending between the first and second lateral
sides. In some embodiments, the maximum length is the length of the
inboard edge, Li.
[0058] In some embodiments, the ear 30 may include elastomers, such
that the ear is stretchable. In certain embodiments, the ears 30
may be formed of a stretch laminate such as a nonwoven/elastomeric
material laminate or a nonwoven/elastomeric material/nonwoven
laminate, which also results in the ear being stretchable. The ear
30 may be extensible in the lateral direction. In some embodiments,
the ear is elastic in the lateral direction. In further
embodiments, the ear 30 may extend more in the lateral direction
than in the longitudinal direction. Alternatively, the ear may
extend more in the longitudinal direction than in the lateral
direction.
[0059] In some embodiments, the ear comprises a laminate of a
nonwoven 300 and an elastomeric layer 304. In certain embodiments
illustrated in FIG. 3, an ear comprises a body-facing nonwoven 300,
a garment-facing nonwoven 302 and an elastomeric layer 304. The
elastomeric layer 304 may be sandwiched between the body-facing and
garment-facing nonwovens. Additional layers may be included (e.g.,
additional nonwovens, inelastic materials, elastic or extensible
materials, etc.).
[0060] Any suitable nonwoven may be used in an ear 30. Suitable
nonwovens may comprise a basis weight of at least about 8 gsm, or
about 30 gsm or less, or about 22 gsm or less, or about 20 gsm or
less, or about 17 gsm or less, or from about 10 gsm to about 22
gsm, reciting for said range every 1 increment therein. Typically,
lower basis weight nonwovens reduce an ear's collective strength.
However, the inventors have discovered ears designed according to
the principles herein can obtain high strength despite lower basis
weight nonwovens.
[0061] A nonwoven may comprise meltblown layers, carded layers,
and/or spunbond layers. In a nonlimiting example, a nonwoven
comprises two or more spunbond layers. In further nonlimiting
examples, one or more nonwovens may comprise a SMS configuration.
Alternatively, one or more of the nonwovens in the ear may be void
of meltblown layers. While meltblown layers have been found to
enhance bonding in ears requiring adhesive (given the meltblown
layer's inhibition of the adhesive's diffusion through the porous
nonwoven structure), meltblown layers often lack strength. In some
embodiments, a nonwoven consists essentially of spunbond layers. In
some nonlimiting examples, both the body-facing and the
garment-facing nonwoven comprises at least 2 spunbond layers, or 3
or more spunbond layers. In some embodiments, one or more nonwovens
in the ear laminate comprises crimped spunbond fibers.
[0062] Nonwoven softness is often associated with tactile feel.
Sleek or silky feel is often preferred over rough texture. Various
approaches can be used to deliver silky feel. A nonwoven web can be
made of bi-component or multi-component fibers. One of the
components of the fibers, preferably outer component, is soft
polymer such as polyethylene or elastic polyolefin, polyurethane.
For example, in sheath/core bi-component fiber, sheath can be made
of polyethylene while core can be made of polypropylene.
Alternatively, a nonwoven web can be made of mono-component fiber
with a polymer blend that imparts softness, such as polypropylene
blended with elastomeric polypropylene (VISTAMAXX.RTM. from
Exxon).
[0063] A nonwoven web can be made of fibers comprising elastomeric
polymer, such as elastomeric polyolefins. Additionally or
alternatively, additives can be added to polymer before spinning
fiber. During fiber spinning and subsequent process steps to make
nonwoven web, the additives migrate to fiber surface to provide
silky feel. Amine and Amide based additives are commonly used up to
5% to impart softness.
[0064] In another approach, sleek chemical finish can be coated on
the fibers or nonwoven webs. Chemical finishes based on oil,
silicone, esters, fatty acids, surfactant etc. can be employed.
Softness additives such as anionic, cationic or nonionic can also
be used to improve drape, and touch. Various coating techniques,
like roll coating, screen coating, gravure coating, slot coating,
spray coating, can be used to apply finish.
[0065] In another approach, nonwoven fiber diameter can be reduced
to produce fine fibers and to provide silk like feel. Meltblown
fiber is one technology to reduce fiber diameter to less than 20
microns. Alternatively, nanofibers, having a diameter of less than
1 micron, made from a melt film fibrillation process with a polymer
composition disclosed in U.S. Pat. No. 8,835,709 can be used to
provide softness.
[0066] Bending or pliability of material without any external force
and under its own weight communicates softness. It can be
influenced by variety of factors such as fiber chemistry,
thickness, nonwoven bond pattern. Pliability or drape is linked to
bending stiffness, which is related to inherent elastic modulus and
thickness of material. It has proven to be advantageous for the
nonwoven fabric to have a minimum and a maximum bending stiffness,
since for instance in the use of the nonwoven fabric in contour
matching, as in medical and hygiene articles, too stiff a material
would be undesirable. Polyolefin resin with lower elastic modulus
and/or lower crystallinity enables lower bending stiffness. One can
blend lower elastic modulus materials (elastomer) with traditional
fiber making polyolefin resin to make lower modulus fibers.
Optimizing bonding can also alter the bending stiffness of the web
in the direction desired. Bonds with larger aspect ratio of
longitudinal dimension to lateral dimension provides better drape
in lateral dimension while providing right rigidity and strength
for web handling. Another factor affecting drape is the thickness
of the web. The thicker the web is, the lower is the flexibility or
pliability. Combining right thickness with fiber chemistry or bond
pattern, better drape can be achieved while delivering web
performance suitable for processing.
[0067] Where the ear 30 comprises more than one nonwoven, the
nonwovens may comprise the same basis weight or different basis
weights. Likewise, the nonwovens may comprise the same layer
structure (e.g., SMS) or different layer structures (e.g., SS,
SMS). Further, a nonwoven in the ear may comprise the same or
different features of nonwovens in the backsheet, topsheet, leg
gasketing system and/or waist feature.
[0068] The elastomeric layer 304 comprises one or more elastomeric
materials which provide elasticity to at least a portion of the
layer 304. Nonlimiting examples of elastomeric materials include
film (e.g., polyurethane films, films derived from rubber and/or
other polymeric materials), an elastomeric coating applied to
another substrate (e.g., a hot melt elastomer, an elastomeric
adhesive, printed elastomer or elastomer co-extruded to another
substrate), elastomeric nonwovens, scrims, and the like.
Elastomeric materials can be formed from elastomeric polymers
including polymers comprising styrene derivatives, polyesters,
polyurethanes, polyether amides, polyolefins, combinations thereof
or any suitable known elastomers including but not limited to
co-extruded VISTAMAXX.RTM.. Exemplary elastomers and/or elastomeric
materials are disclosed in U.S. Pat. Nos. 8,618,350; 6,410,129;
7,819,853; 8,795,809; 7,806,883; 6,677,258 and U.S. Pat. Pub. No.
2009/0258210. Commercially available elastomeric materials include
KRATON (styrenic block copolymer; available from the Kraton
Chemical Company, Houston, Tex.), SEPTON (styrenic block copolymer;
available from Kuraray America, Inc., New York, N.Y.), VECTOR
(styrenic block copolymer; available from TSRC Dexco Chemical
Company, Houston, Tex.), ESTANE (polyurethane; available from
Lubrizol, Inc, Ohio), PEBAX (polyether block amide; available from
Arkema Chemicals, Philadelphia, Pa.), HYTREL (polyester; available
from DuPont, Wilmington, Del.), VISTAMAXX (homopolyolefins and
random copolymers, and blends of random copolymers, available from
EXXON Mobile, Spring, Tex.) and VERSIFY (homopolyolefins and random
copolymers, and blends of random copolymers, available from Dow
Chemical Company, Midland, Mich.).
[0069] In nonlimiting examples, the elastomeric layer 304 comprises
a film. The film may comprise a single layer or multiple layers.
The film may be extensible in the lateral direction or may be
elastic in the lateral direction. The film may be preactivated as
disclosed, for example, in U.S. Pat. No. 9,533,067. The elastomeric
layer may comprise a width, Y, as shown for example in FIG. 2. In
some embodiments, Y is less than the width, W, of the ear 30 by at
least about 10 mm. The elastomeric layer may have a longitudinal
dimension that is the same as the ear 30 along with the width of
the elastomeric layer, or a longitudinal dimension that is less
than the longitudinal length of the ear at any point along with the
width of the elastomeric layer. In some embodiments, the
elastomeric layer may have a basis weight of from about 5 to about
150 gsm, or from about 10 to about 100 gsm, or less than about 150
gsm, reciting for each range every 5 gsm increment therein.
[0070] As also illustrated in FIG. 2, the ear 30 may comprise an
elasticized region 306. The elasticized region 306 is generally
defined by the perimeter of the elastomeric material 304. In the
elasticized region 306, the ear is elastically extensible. In some
embodiments, the area of the elasticized region comprises at least
about 20% of, or from about 30% to about 100%, or about 80% or less
of the total area of the ear, reciting for said range every 5%
increment therein. In further embodiments, Y (i.e., the maximum
width of the elastomeric layer) is at least about 20% of, or from
about 25% to about 100%, or from about 35% to about 85%, or about
80% or less of the total width, W, of the ear, reciting for each
range every 5% increment therein.
[0071] The ear may further comprise one or more inelastic regions.
In certain embodiments, the ear 30 comprises a first inelastic
region 308, which extends laterally outward from the inboard edge
38 and is adjacent to the elasticized region 306 at a first
elastomeric edge 307. The ear may further include a second
inelastic region 310, which may extend laterally inward from the
outboard edge 36 and may be adjacent to the elasticized region 306
at a second elastomeric edge 309. The first and second inelastic
regions may be made of the same material(s) or different
materials.
[0072] Turning to FIG. 4, in certain embodiments, the ear 30
comprises a gathered laminate 44, wherein one of the layers is
strained to a greater degree than a remaining layer during
lamination. In this way, the less extensible layer (i.e., the
nonwoven 300, 302) will form gathers when the laminate 44 is in a
relaxed state. In some embodiments, at least a portion of the
elastomeric layer is strained while the nonwoven(s) are in a
relaxed state during lamination. The elastomeric layer may be
stretched one or more directions. Corrugations then form in the
nonwoven layer(s) when the subsequently formed laminate 44 is in a
relaxed state. In nonlimiting examples, the elastomeric layer is
stretched in a direction corresponding with the lateral direction
of the article. In other words, when the ear is joined to the
chassis subsequent to lamination, the ear laminate will be oriented
such that the ear is stretchable in the lateral direction of the
article. In further nonlimiting examples, the ear is also
stretchable in the longitudinal direction.
[0073] The laminate layers may be joined by one or more ultrasonic
bonds 46 as illustrated in FIG. 4. The ultrasonic bonds may join
the nonwoven layers through the elastomeric layer. The
ultrasonically bonded laminate may be formed by the process and/or
equipment disclosed in commonly assigned U.S. Patent App. Nos.
62/374,010 and 62/419,515.
[0074] In some embodiments, the laminate may be void of adhesive.
In some nonlimiting examples, the ear comprises adhesive bond(s)
only at the chassis attachment bond 35 and/or at the fastener
attachment bond 52 (discussed below). The fastener attachment bond
and/or the chassis attachment bond 35 may comprise ultrasonic bonds
and/or may be void of adhesive.
[0075] The absorbent article 10 may also include a fastening system
48. When fastened, the fastening system 48 interconnects the first
waist region 16 and the rear waist region 18 resulting in a waist
circumference that may encircle the wearer during wear of the
absorbent article 10. The fastening system 48 may comprise a
fastening elements 50 such as tape tabs, hook and loop fastening
components, interlocking fasteners such as tabs & slots,
buckles, buttons, snaps, and/or hermaphroditic fastening
components, although any other known fastening means are generally
acceptable. The absorbent article may further comprise a landing
zone to which a fastening element can engage and/or a release tape
that protects the fastening elements from insult prior to use. Some
exemplary surface fastening systems are disclosed in U.S. Pat. Nos.
3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092;
and 5,221,274. An exemplary interlocking fastening system is
disclosed in U.S. Pat. No. 6,432,098. In some embodiments, the
fastening system 48 and/or the element 50 is foldable.
[0076] The fastening system 48 may be joined to any suitable
portion of the article 10 by any suitable means. In some
embodiments, the fastening system is joined to the ear 30 at a
fastener attachment bond 52 as illustrated in FIGS. 4-6. The
fastening system may be joined to the ear between layers. The
fastening system may be joined to the ear on an exterior surface as
shown for example in FIG. 4. The fastening system and/or fastening
elements may be ultrasonically bonded to the ear. The fastening
attachment bond 52 comprises a maximum length, L1, measured
parallel to the longitudinal centerline. The maximum length may be
about 30 mm or less, or about 28 mm or less, or from about 20 mm to
about 35 mm, reciting for said range every 1 mm increment
therein.
[0077] Returning to FIGS. 4-6, the fastening system 48 may be
joined to ear proximate to the outboard edge 36. The fastening
system may be disposed in the second inelastic region 310. In
further embodiments, the fastening system 48 is joined in the
elasticized region 306 of the ear. The inventors have found that
joining the fastening system to the ear in the elasticized region
306 improves the collective strength of the ear/fastening system
combination during use and/or application. Without being bound by
theory, it is believed that breakage in ears formed from
ultrasonically bonded laminates initially occurs in an inelastic
region near the outboard edge 36 as the intact nonwoven resists the
stretching of the elastomeric layer; and therefore, joining the
fastening system within the elasticized region 306 reduces the
stress on the inelastic portion of the ear. In some embodiments,
the fastening system 48 is joined in the elasticized region such
that it overlaps with the elasticized region for a maximum lateral
overlap distance of D as depicted in FIG. 6. In certain nonlimiting
examples, D may be from about 0.05% to about 5%, or about 1% to
about 5% of Y (i.e., the maximum width of the elasticized region),
reciting for each range every 0.02% increment therein.
[0078] In further embodiments, the ear comprises a Length Ratio of
about 3 or less, or about 2.95 or less, or from about 1 to about 3,
or from about 1.75 to about 3, or from about 1 to about 2.5 as
determined by the Tensile Test Method herein, reciting for each
range every 0.05 interval therein. Forming an ear with such Length
Ratios decreases the potential for roping within the ear. Further,
the specified Length Ratios result in increased strength in the
ear.
[0079] The ear may comprise an Average Load at Break of 15 N or
greater, or 20 N or greater, or 25 N or greater, 30 N or greater,
or 40 N or greater, or from about 15 N to about 45 N, or about 25 N
to about 40 N according to the Tensile Test Method herein, reciting
for said range every 1 N increment therein. The specified Average
Load at Break values may be obtained even when garment-facing and
body-facing nonwovens comprise a basis weight of about 17 gsm or
less, or about 14 gsm or less, or about 12 gsm or less, or from
about 8 gsm to about 17 gsm, reciting for said range every 1
increment therein. Once joined to the ear, the fastening system 48
may comprise an Average Load at Break of 24 N or greater, or about
30 N or greater, or from about 17 N to about 40 N, according to the
Tensile Test Method herein, reciting for said range every 1 N
increment therein. The specified Average Load at Break values may
be obtained even when the body-facing and/or garment-facing
nonwovens comprise a basis weight of about 17 gsm or less, or about
14 gsm or less, or about 12 gsm or less, or from about 8 gsm to
about 17 gsm, reciting for said range every 1 gsm increment
therein.
[0080] In other nonlimiting examples, the ultrasonically bonded ear
laminate comprises an Average Extension at 5 N of about or 10 mm
about or greater, or about 15 mm or greater, from about 10 mm to
about 25 mm according to the Tensile Test Method herein; and/or an
Average Extension at 10 N of about 35 mm or greater, about 40 mm or
greater, or about 45 mm or greater, or from about 35 mm to about 50
mm according to the Tensile Test Method herein.
[0081] In certain embodiments, the ear may comprise an Air
Permeability Value of at least about 1 m.sup.3/m.sup.2/min, or from
about 2 m.sup.3/m.sup.2/min to about 125 m.sup.3/m.sup.2/min, or
from about 5 m.sup.3/m.sup.2/min to about 50 m.sup.3/m.sup.2/min
according to the Air Permeability Test Method herein, reciting for
each range every 1 m.sup.3/m.sup.2/min increment therein.
[0082] The ear may comprise one or more bond patterns 400. A
pattern may be comprised of a plurality of ultrasonic bonds 46.
Where the ear comprises multiple bond patterns as in FIG. 7, two or
more patterns 400a, 400b may be the same and/or two or more
patterns may be different. Patterns may be disposed in different
regions of the ear, for example a first bonding region 402 may at
least partially overlay an inelastic region which may comprise a
different pattern than a second bonding region 404 at least
partially overlapping the elasticized region. Other portions of the
ear or fastener may comprise different bonding regions, which may
comprise patterns 400c, 400d, 400e. The bonding regions may
comprise different bond densities, or two or more of the regions
may comprise the same bond density while having different bond
patterns. In nonlimiting examples, two bonding regions have the
same bond density and the two bond patterns differ by the design
elements; average spacing between bonds within the patterns;
uniformity within the patterns; the sizes, shapes and/or
orientation of the bonds within the patterns; the aggregate bond
area within the patterns; and/or the collective pattern shape
(i.e., the perimeter of the pattern). Additionally or
alternatively, two bond patterns may be provided with distinct
visual characteristics, including but not limited to insignia,
instructional indicia, garment-like patterns and/or other design
elements which distinguish one bonding region from one another. In
other embodiments, bonding regions comprise substantially the same
bond pattern. In some embodiments, bond patterns in different
bonding regions but may match, meaning the patterns may comprise
substantially similar design elements, which may be rotated,
mirrored, reduced in size, enlarged in size and/or altered in
aspect ratio between the patterns. Further, where the ear comprises
multiple bond patterns and bonding regions, said patterns and
regions collectively comprise a collective bond pattern 4000.
Leg Gasketing System
[0083] Returning to FIG. 1, the absorbent article 10 may comprise a
leg gasketing system 70 attached to the chassis 20, which may
comprise one or more cuffs 71. The leg gasketing system may
comprise a pair of barrier leg cuffs 72. Each barrier leg cuff may
be formed by a piece of material which is bonded to the absorbent
article so it may extend upwards from a wearer-facing surface of
the absorbent article and provide improved containment of fluids
and other body exudates approximately at the junction of the torso
and legs of the wearer. The barrier leg cuffs are delimited by a
proximal edge joined directly or indirectly to the topsheet 24
and/or the backsheet 26 and a free terminal edge 75, which is
intended to contact and form a seal with the wearer's skin. In some
embodiments, the free terminal edge 75 comprises a folded edge. The
barrier leg cuffs 72 extend at least partially between the front
waist edge 13 and the rear waist edge 19 of the absorbent article
on opposite sides of the longitudinal centerline 100 and are at
least present in the crotch region. The barrier leg cuffs may be
joined at the proximal edge with the chassis of the article by a
bond which may be made by gluing, fusion bonding, or a combination
of other suitable bonding processes.
[0084] The barrier leg cuffs may be integral with the topsheet 24
or the backsheet 26 or may be a separate material joined to the
article's chassis. Each barrier leg cuff 72 may comprise one, two
or more elastic elements 55 close to the free terminal edge 75 to
provide a better seal.
[0085] In addition to the barrier leg cuffs 72, the article may
comprise gasketing cuffs 76, which are joined to the chassis of the
absorbent article, in particular to the topsheet 24 and/or the
backsheet 26 and are placed externally relative to the barrier leg
cuffs 72. The gasketing cuffs 76 may provide a better seal around
the thighs of the wearer. A gasketing cuff may comprise a proximal
edge and a free terminal edge 77. The free terminal edge 77 may
comprise a folded edge. Each gasketing cuff may comprise one or
more elastic elements 55 in the chassis of the absorbent article
between the topsheet 24 and backsheet 26 in the area of the leg
openings. All, or a portion of, the barrier leg cuffs and/or
gasketing cuffs may be treated with a lotion or another skin care
composition.
[0086] In further embodiments, the leg gasketing system comprises
barrier leg cuffs that are integral with gasketing cuffs. Suitable
leg gasketing systems which may be part of the absorbent article
are disclosed in U.S. Pat. App. No. 62/134,622, 14/077,708; U.S.
Pat. Nos. 8,939,957; 3, 860,003; 7,435,243; 8,062,279.
Elastic Waist Feature
[0087] The absorbent article 10 may comprise at least one elastic
waist feature 80 that helps to provide improved fit and
containment, as shown in FIG. 1. The elastic waist feature 80 is
generally intended to expand and contract to dynamically fit the
wearer's waist. Elasticized waist features include waistbands,
waist cuffs having pockets formed from a portion of the waist
feature 80 that is unattached from the chassis 20, and waist panels
designed to fit securely about the abdomen of the wearer.
Nonlimiting examples of elasticized waist features are disclosed in
U.S. patent application Ser. Nos. 13/490,543; 14/533,472; and
62/134,622. Waist features 80 may be joined to the chassis 20 in
the first waist region 14 and/or in the second waist region 16. The
waist feature can be used in conjunction with the ear 30 to provide
desirable stretch and flexibility for proper fit of the article on
the wearer.
Array of Absorbent Articles
[0088] The present invention includes an array 450 of two or more
absorbent articles 10a, 10b, 10c as exemplified in FIG. 8.
Absorbent articles in the array may be manufactured and/or
distributed by a single manufacturer, under a common brand name
and/or under a common tradename or trademark. In certain
embodiments, the array comprises absorbent articles of different
sizes. Additionally or alternatively, the array may comprise
absorbent articles suited for different wearer and/or purchaser
segments. Each absorbent article may comprise a topsheet, a
backsheet, an absorbent core between said topsheet and backsheet,
and an ear comprising a laminate; each component having any of the
features described above relating to the respective components. Two
or more ears within the array may comprise ultrasonically bonded
ear laminates, each comprising a plurality of ultrasonic bonds,
and/or two or more ears may comprise a gathered laminate. Absorbent
articles in the array may further comprise other features 350 such
as fasteners, waist features, wetness indicators and/or leg
cuffs.
[0089] In certain embodiments, the array comprises a first
absorbent article 10a having a first ear laminate 30a and a second
absorbent article 10b having a second ear laminate 30b. Both of the
first and second ear laminates may each comprise an ultrasonically
bonded ear laminate. The first and second ear laminate may each
comprise a gathered laminate. Each of the first and second ear
laminate may comprise a laminate of a nonwoven layer and an
elastomeric layer, as discussed above. The first ear laminate may
comprise a first garment-facing nonwoven, a first body-facing
nonwoven and a first elastomeric material disposed between said
nonwovens. Likewise, the second ear laminate may comprise a second
garment facing nonwoven, a second body-facing nonwoven, and a
second elastomeric material disposed between said second nonwovens.
In some embodiments, the first and second ear laminates are each
disposed in the respective second waist regions of the first and
second absorbent article; each comprising a back ear.
[0090] The first and second ear laminates may differ. Nonlimiting
examples of differences between the ear laminates include
differences in extensibility, bond pattern, softness, tensile
strength, component materials (e.g., nonwoven or film materials),
shape, size, position of the ear on the chassis and combinations
thereof. In nonlimiting examples, the first ear laminate and second
ear laminate are different sizes. The first ear laminate may
comprise a first maximum length, L.sub.F, and the second ear
laminate may comprise a second maximum length, L.sub.S, which may
be different than the first maximum length. In nonlimiting
examples, the first maximum length may be at least about 6%
greater, or at least about 10% greater, or at least about 12%
greater, or at least about 15% greater, or from about 5% to about
50% greater than the second maximum length, reciting for said range
every 1% increment therein. In additional nonlimiting examples, the
first ear laminate comprises a first area (which is the
two-dimensional area of the first ear) and the second ear laminate
comprises a second area (i.e., the two-dimensional area of the
second ear). The first area may be at least about 6% greater, or at
least about 10% greater, or at least about 15% greater, or from
about 5% to about 50% greater than the second area. Additionally or
alternatively, the width of two ear laminates may differ. It is
contemplated that the length of the first ear laminate may be
greater than the length of the second ear laminate, and the width
of the first ear laminate may be less than the width of the second
ear laminate or vice versa.
[0091] In an embodiment, the first ear laminate 30a is more
extensible than the second ear laminate. For example, the first ear
laminate may comprise an Average Extension at 10 N that is at least
about 5% greater, or about 10% greater, or about 20% greater, or
from about 5% to about 30% greater than the Average Extension of
the second ear laminate at 10 N, reciting for said range every 5%
increment therein. In other embodiments, the first ear laminate may
comprise an Average Extension at 5 N that is at least about 5%
greater, or about 10% greater, or about 20% greater, or from about
5% to about 30% greater than the Average Extension of the second
ear laminate at 5N, reciting for said range every 5% increment
therein. Extensibility at 10 N and 5N can be determined by the
Tensile Test Method herein.
[0092] In certain embodiments, extensibility differences may be
provided by differences in the elasticized regions of the ear
laminates. In nonlimiting examples, the first ear laminate
comprises a first elasticized region 306.sub.F and the second ear
laminate comprises a second elasticized region 306.sub.S, where the
second elasticized region comprises one or more dimensions that are
different than the first elasticized region. The first elasticized
region may comprise a first elasticized area (i.e., the two
dimensional area of 306.sub.F) and the second elasticized region
may comprise a second elasticized area (i.e., the two dimensional
area of 306.sub.S), wherein the first elasticized area may be
greater than the second elasticized area. In nonlimiting examples,
the first elasticized area is at least about 5%, or least about
10%, or from about 5% to about 30% greater than the second
elasticized area. In further nonlimiting examples, the maximum
width, Y.sub.F, of the first elasticized region may be greater than
the maximum width of the second elasticized region, Y.sub.S.
Additionally or alternatively, the first elasticized region may
comprise a first elastomeric material 304.sub.F, and the second
elasticized region may comprise a second elastomeric material
304.sub.S. The first and second elastomeric material may be
different. For example, the elastomeric materials may differ by
basis weight, type of elastic material (e.g., film versus elastic
strands), the composition or base materials forming the elastomeric
material (e.g. polyurethane films, styrenic film materials, etc.)
and combinations thereof. In nonlimiting examples, the first and
second ear laminate comprise gathered laminates and the first
elastomeric material is strained to a greater degree during
lamination than the second elastomeric material. The first
elastomeric material may be strained by at least about 5% more, or
at least about 10% more, or from about 5% to about 30% more than
the second elastomeric material during the respective first and
second ear laminations. In some nonlimiting examples, both the
first and the second elastomeric materials comprise film, although
the films may differ.
[0093] In further nonlimiting examples, the characteristics of one
or more nonwovens in the ear laminate may contribute to
extensibility and other properties. As stated above, the first ear
laminate may comprise a first garment-facing nonwoven and/or a
first body-facing nonwoven, and the second ear laminate may
comprise a second garment-facing nonwoven and/or a second
body-facing nonwoven. One or both of the first garment-facing and
first body-facing nonwovens may comprise a primary nonwoven 360.
Likewise, one or both of the second garment-facing and second
body-facing nonwovens may comprise a secondary nonwoven 370. The
primary nonwoven may differ from the secondary nonwoven by one of
the group consisting of basis weight, layer configuration (e.g.,
SMS, carded, SS), fiber composition, fiber configurations (e.g.,
mono-component or bi-component), fiber denier, fiber diameter,
calendar bond area, calendar bond shape, and combinations thereof.
These factors may result in differences in extensibility and/or
differences in softness.
[0094] The first ear laminate and the second ear laminate will each
comprise TS7 and TS750 values determinable by the Softness Test
Method herein. Lower TS7 and TS750 values indicate greater
softness, which is highly desirable in absorbent articles. Wearers
and caregivers may find absorbent articles with high TS7 and TS750
values uncomfortable and/or scratchy or otherwise undesirable. In
some embodiments, the first ear laminate may comprise a different
TS7 value and/or a different TS750 value than the second ear
laminate. In nonlimiting examples, the TS7 value of the first ear
laminate is lower than the TS7 value of the second ear laminate by
least about 10%, or about 15%, or at least about 20%, or from about
5% to about 25%, reciting for said range every 1% increment
therein. Additionally or alternatively, the TS750 value of the
first ear laminate may be less than the TS750 value of the second
ear laminate by least about 10%, or about 15%, or at least about
20%, or from about 5% to about 25%, reciting for said range every
1% increment therein. The TS7 and/or TS750 values may be affected
by the type of nonwoven materials and/or elastomeric materials used
in the ear laminates. In nonlimiting examples, the ear laminate
comprising a low TS7 or TS750 value may comprise a nonwoven having
layers comprising nanofibers, meltblown fibers, crimped spunbond
fibers, carded fibers, softness additives, bi-component fibers,
fibers derived from elastomeric polyolefins and combinations
thereof.
[0095] The first and second ear laminates may further differ in
breathability. In some embodiments, the first ear laminate
comprises a first Air Permeability Value and the second ear
laminate may comprise a second Air Permeability Value. The first
Air Permeability Value may be greater than the second Air
Permeability Value by at least about 5%, or at least about 10%, or
at least about 20%, or at least about 50%, or from about 5% to
about 75%, reciting for said range every 10% increment therein. In
nonlimiting examples, the air permeability may be affected by the
number of bonds, bond arrangements, and/or bond sizes. In further
nonlimiting examples, the array may further comprise an ear
laminate that is substantially non-breathable.
[0096] Turning to FIG. 9, the first and second ear laminates may
comprise different bond patterns or different combinations of bond
patterns. The first ear laminate may comprise a first collective
bond pattern 4000a, which is the combination of the various bond
patterns and arrangements within the ear. The second ear laminate
may comprise a second collective bond pattern 4000b. The first and
second collective bond patterns may differ by the design elements;
average spacing between bonds within the patterns; uniformity
within the patterns; the sizes, shapes and/or orientation of the
bonds within the patterns; the aggregate bond area within the
patterns; bond density in one or more bond regions; the collective
pattern shapes (i.e., the perimeters of the collective patterns);
space between multiple patterns; arrangements of patterns; the
number of different patterns; the randomness of bonds and
combinations thereof. Differences in bond patterns may result in
changes in breathability, extensibility, modulus, tensile strength
and/or aesthetic design. In nonlimiting examples, one or more
patterns on the first ear laminate matches one or more patterns on
the second ear laminate. Additionally or alternatively, patterns on
an ear laminate may match patterns on other components of the
absorbent article, such as the patterns visible when viewing the
topsheet, patterns visible when viewing the backsheet, patterns on
fastening systems and/or patterns on leg cuffs. The first and/or
second collective pattern may comprise instructional indicia,
graphics, and/or insignia. The first collective pattern and/or the
second collective pattern may correspond to a user characteristic
such as the intended gender of the wearer, intended age and/or
development stage, absorbency needs, fit preferences and
combinations thereof. The first and second collective patterns may
correspond to different user characteristics (e.g., different ages,
different absorbency needs).
[0097] The first and second ear laminates may further comprise
different tensile strength, as determined by the Average Load at
Break in the Tensile Test Method herein. In some embodiments, the
first ear laminate comprises a first Average Load at Break and the
second ear laminate comprises a second Average Load at Break. The
first Average Load at Break may be at least about 4% greater, or at
least about 10% greater, or at least about 15% greater, or from
about 4% to about 25% greater than the second Average Load at
Break, reciting for said range every 1% increment therein. The ear
laminates may comprise nonwovens having a basis weight of about 30
gsm or less, or about 22 gsm or less, or about 17 gsm or less, or
about 14 gsm or less, or about 12 gsm or less, or from about 8 gsm
to about 30 gsm, or from about 10 to about 17 gsm, reciting for
each range every 1 gsm increment therein.
[0098] For the avoidance of doubt, except where property values are
reported in percentage or ratios, percent differences for a given
property can be calculated by utilizing the respective test method
to determine the property values, then using the following
formula:
.DELTA. Property = Property for First Ear - Property for Second Ear
Property for Second Ear .times. 100 % ##EQU00001##
[0099] Where property values are reported in percentages or ratios
(e.g., Aggregate Bond Coverage), the relative difference between
the properties of two laminates is calculated by subtracting the
property values:
.DELTA.Property that is reported in %=Property of First
Ear-Property of Second Ear
[0100] Differences in ear laminates within the array may correspond
to different purchaser/wearer preferences. Returning to FIG. 8, in
some embodiments, a property of an ear laminate may be paired with
additional functional features 350 in the absorbent article to
further meet the purchaser/wearer's preferences. For example, a
first ear laminate may comprise greater breathability, softness,
extensibility and/or tensile strength, and the first absorbent
article may further comprise an additional feature functional
feature 350 including but not limited to channels 29, apertured
topsheets, enhanced superabsorbent materials or greater absorbency,
softer or higher performing leg cuffs (i.e., less leakage), waist
features, wetness indicators, secondary fastening systems, and
combinations thereof. In nonlimiting examples, the second absorbent
article may be void of a functional feature 350 that is present in
the first absorbent article, as shown for example in FIG. 8 where
the first absorbent article comprises a waist feature 80 and the
second absorbent article is void of a waist feature. It is also
contemplated that two absorbent articles may comprise functional
features that perform similar tasks but are different. For example,
the first absorbent article and second absorbent article may each
comprise channels 29 but said channels may be shaped
differently.
[0101] Further, the array 450 may comprise additional absorbent
articles, such as a third absorbent article 10c having a third ear
laminate 30c. The third ear laminate 30c may comprise any of the
features described above, which may be the same as or different
from features of the first and second ear laminates.
[0102] In some embodiments, the first and second absorbent article
are disposed in a single package 1000 as shown in FIG. 10. In other
embodiments, the first and second absorbent articles are disposed
in different packages 1000a, 1000b as shown in FIG. 11. Each
package 1000a, 1000b may comprise a plurality of absorbent
articles. In nonlimiting examples, the first package 1000a
comprises a plurality of first absorbent articles, each of the
plurality having a first ear laminate. In further nonlimiting
examples, the second package 1000b comprises a plurality of second
absorbent articles, each of the plurality having a second ear
laminate. The packages may be marketed and/or sold under the same
brand name and/or tradename.
[0103] 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.
[0104] 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.
[0105] FIG. 12 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.
Combinations
[0106] Various combinations may be obtained and fall within the
scope of this invention. For instance, the first ear laminate may
be softer than the second ear laminate, but the second ear laminate
may be more breathable. Each property can be independently varied
between ear laminates. [0107] A. An array of absorbent articles
comprising: [0108] a first absorbent article comprising a topsheet,
a backsheet and an absorbent core disposed between the topsheet and
backsheet, and a first ear laminate having a first plurality of
ultrasonic bonds disposed in a first elasticized region; and [0109]
a second absorbent article comprising a topsheet, a backsheet and
an absorbent core disposed between the topsheet and backsheet, and
a second ear laminate having a second plurality of ultrasonic bonds
disposed in a second elasticized region; [0110] wherein the first
and second ear laminate differ in extensibility, bond pattern,
softness and/or Average Load at Break. [0111] B. The array of
absorbent articles according to paragraph A wherein the absorbent
articles are offered under a common brand name. [0112] C. The array
of absorbent articles according to paragraphs A or B wherein the
first ear laminate has an Average Extension at 10 N that is at
least 5% greater than an Average Extension of the second ear
laminate at 10 N. [0113] D. The array of absorbent articles
according to any of the preceding paragraphs wherein the first
elasticized region comprises an area that is greater than the area
of the second elasticized region. [0114] E. The array of absorbent
articles according to any of the preceding paragraphs wherein the
first ear laminate comprises a first film and the second ear
laminate comprises a second film, wherein the first film is
strained by at least 5% more than the second film when the laminate
is fully extended. [0115] F. The array of absorbent articles of any
of the preceding paragraphs wherein the first ear laminate
comprises a primary nonwoven and the second ear laminate comprises
a secondary nonwoven, wherein the primary nonwoven and the
secondary nonwoven differ by one of the group consisting of layer
configuration, fiber composition, calendar bond area or calendar
bond shape, basis weight, and combinations thereof. [0116] G. The
array of absorbent articles according to any of the preceding
paragraphs wherein the first plurality of ultrasonic bonds is
disposed in a first collective pattern; and the second plurality of
ultrasonic bonds is disposed in a second collective pattern;
wherein the first collective pattern differs from the second
collective pattern by average bond spacing, pattern uniformity,
bond size, bond shape, bond orientation, aggregate bond area,
aggregate pattern shape and combinations thereof. [0117] H. The
array according to paragraph G wherein the first collective pattern
corresponds to a first user characteristic and the second pattern
corresponds to second user characteristic, wherein the first and
second user characteristics are different and are each selected
from the group consisting of: intended wearer gender, intended
wearer age and/or development stage, absorbency needs, fit
preferences, and combinations thereof. [0118] I. The array of
absorbent articles according to any of the preceding paragraphs
wherein the first ear laminate comprises a TS7 softness value that
is at least 10% less than a TS7 softness value of the second ear
laminate. [0119] J. The array of absorbent articles of any of the
preceding paragraphs wherein the first ear laminate comprises one
of the group consisting of a crimped fiber spunbond nonwoven web, a
meltblown nonwoven web, a softness additive, a carded nonwoven web,
and combinations thereof. [0120] K. The array of absorbent articles
according to any of the preceding paragraphs wherein the first ear
laminate comprises first Average Load at Break and the second ear
laminate comprises a second Average Load at Break, wherein the
first Average Load at Break is at least 4% greater, or at least 10%
greater, than the second Average Load at Break. [0121] L. The array
of absorbent articles according to any of the preceding paragraphs
wherein the first ear laminate comprises a first garment-facing
nonwoven and a first body-facing nonwoven, wherein at least one of
the first garment-facing and first body-facing nonwovens comprises
a basis weight of about 20 gsm or less. [0122] M. The array of
absorbent articles according to paragraph L wherein the basis
weight is about 17 gsm or less. [0123] N. The array of absorbent
articles according to any of the preceding paragraphs wherein the
first absorbent article and second absorbent article are different
sizes. [0124] O. The array of absorbent articles according to any
of the preceding paragraphs wherein a single package comprises the
first and second absorbent articles. [0125] P. The array of
absorbent articles according to any of paragraphs A-N wherein a
first package comprises the first absorbent article and a second
package comprises the second absorbent article, wherein each
package comprises the common brand name. [0126] Q. The array of
absorbent articles according to any of the preceding paragraphs
wherein the first absorbent article comprises a functional feature
and the second absorbent article is void of said functional
feature. [0127] R. The array of absorbent articles according to any
of the preceding paragraphs wherein the first ear laminate
comprises a first elastomeric material and the second ear laminate
comprises a second elastomeric material, wherein the first and
second elastomeric materials differ by basis weight, material type,
composition and combinations thereof
Test Methods
Tensile Test Method
[0128] The Tensile Test is used to measure the strength of a
specimen at a relatively high strain rate that represents product
application. The method uses a suitable tensile tester such as an
MTS 810, available from MTS Systems Corp., Eden Prairie Minn., or
equivalent, equipped with a servo-hydraulic actuator capable of
speeds exceeding 5 m/s after 28 mm of travel, and approaching 6 m/s
after 40 mm of travel. The tensile tester is fitted with a 50 lb.
force transducer (e.g., available from Kistler North America,
Amherst, N.Y. as product code 9712 B50 (50 lb)), and a signal
conditioner with a dual mode amplifier (e.g., available from
Kistler North America as product code 5010). Grips shown in the
FIGS. 13 and 14 should be used to secure the specimens during
tensile testing. (FIG. 14 is a side view of one of the grips in
FIG. 13 with a material 505 to prevent slippage.) The opposing
grips 500 may have the same width or different widths as
specified.
[0129] (a) Grips
[0130] The line grips 500 are selected to provide a well-defined
gauge and avoid undue slippage. The specimen is positioned such
that it has minimal slack between the grips. The apexes 507 of the
grips 500 are ground to give good gage definition while avoiding
damage or cutting of the specimen. The apexes are ground to provide
a radius in the range of 0.5-1.0 mm. A portion of one or both grips
500 may be configured to include a material 505 that reduces the
tendency of a specimen to slip, (e.g., a piece of urethane or
neoprene rubber having a Shore A hardness of between 50 and 70) as
shown in FIG. 14. Six inches wide top and bottom grips are used to
clamp the specimen unless specified otherwise.
[0131] (b) Tensile Test of Specimen from Absorbent Article
[0132] Ears are generally bonded to chassis via thermal or adhesive
or similar bonding. Ears should be separated from the chassis in a
way that ears are not damaged and performance of the ear is not
altered. If the chassis bond is too strong (i.e., ears will be
damaged upon removal), then the portion of the chassis joined to
the ear should be cut within the chassis material but without
damaging the ear. Folded fastening systems (e.g., release tapes
covering fastening elements) should be unfolded.
[0133] The specimen is clamped in the top grip at a first grip
location G1 which is inboard edge 52a of the fastener attachment
bond 52 (see FIGS. 4-5). The grip line G1 is kept parallel to the
longitudinal centerline of the product. If the fastener attachment
bond is angled, the specimen is gripped at the center of the bond
region and grip line is kept parallel to the longitudinal
centerline of the product at the center. The width of the top grip
should be equal to the maximum length of the fastener attachment
bond 52 (L1) measured parallel to the longitudinal centerline of
the article. If, at the G1 position, the length of the specimen is
the same as the maximum length of the fastener attachment bond,
then any grip width greater than the specimen length at G1 can be
used. The specimen is mounted and hung from the top grip. The
opposing edge 38 of the specimen is mounted in the bottom grip in
relaxed condition. The bottom grip location G2 is adjusted so the
specimen is gripped at the outboard edge 35b of the chassis bond.
If the chassis bond is curvilinear, the specimen is gripped at the
outboard edge of the outermost bond. The bottom grip is greater
than the length of the ear at the second grip location, G2. The top
and bottom grips are parallel to each other.
[0134] The specimen is tested as follows: The vertical distance
(perpendicular to the grip line) from the first grip location, G1,
to second grip location, G2, is measured to 0.1 mm using ruler and
is used as gage length for the test. The specimen is tested at a
test speed that provides 9.1 sec.sup.-1 strain rate with the gage
length selected for the specimen. Test speed in mm/second is
calculated by multiplying 9.1 sec.sup.-1 by the gage length in mm.
Before testing, 5 mm of slack is put between the grips.
[0135] Each specimen is pulled to break. During testing, one of the
grips is kept stationary and the opposing grip is moved. The force
and actuator displacement data generated during the test are
recorded using a MOOG SmarTEST ONE STO03014-205 standalone
controller, with the data acquisition frequency set at 1 kHz. The
resulting load data may be expressed as load at break in Newton.
The Extension (mm) at 5 N and at 10 N are also recorded. Total of
five (5) specimens are run for example. The Average Load at Break
and standard deviation, the Average Extension at 5N and standard
deviation, and the Average Extension at 10 N and standard deviation
of at least 4 specimens are recorded. If, standard deviation
recorded is higher than 5%, a new set of five specimens is run.
[0136] (c) Length Ratio
[0137] Per the earlier steps, the grips are positioned at a first
grip location and a second grip location. The ratio of the length
of the specimen at the second grip position (L2) to the maximum
length of bond (L1) is Length Ratio. The respective lengths are
measured to 0.1 mm accuracy using the ruler.
Basis Weight Test Method
[0138] Each specimen is weighed to within .+-.0.1 milligram using a
digital balance. Specimen length and width are measured using
digital Vernier calipers or equivalent to within .+-.0.1 mm. All
testing is conducted at 22.+-.2.degree. C. and 50.+-.10% relative
humidity. Basis weight is calculated using equation below.
Basis Weight ( g m 2 ) = ( Weight of the specimen in grams ) (
Length of the specimen in meter ) ( Width of the specimen in meter
) ##EQU00002##
[0139] For calculating the basis weight of a substrate, a total 8
rectilinear specimens at least 10 mm.times.25 mm are used.
[0140] The average basis weight and standard deviation are
recorded.
[0141] Nonwoven specimens from ears are obtained as follows. The
specimen should be taken from a region having no additional
material (i.e., only nonwoven). Each nonwoven layer is separated
from the other layers of the ear without damaging or tearing the
nonwoven layer. If one continuous nonwoven covers outboard and
inboard inelastic regions of the ear, said nonwoven is separated
from the inelastic regions and used as the specimen. If the
nonwoven layer is inseparable from other ear layers, the specimen
is collected from the outboard inelastic region of the ear. If the
outboard inelastic region is smaller than the prescribed specimen
dimensions or has additional material (other than nonwoven layers),
and if the inboard inelastic region has identical nonwovens as the
outboard inelastic region, then the specimen (either nonwoven layer
or the combination of nonwoven layers) is collected from the
inboard inelastic region. If the nonwoven layers in the inelastic
region are identical and/or inseparable, then the calculated basis
weight of the specimen is divided by the number of nonwoven layers
to get the individual nonwoven basis weight.
Hysteresis Test Method
[0142] The Hysteresis Test can be used to various specified strain
values. The Hysteresis Test utilizes a commercial tensile tester
(e.g., from Instron Engineering Corp. (Canton, Mass.), SINTECH-MTS
Systems Corporation (Eden Prairie, Minn.) or equivalent) interfaced
with a computer. The computer is used to control the test speed and
other test parameters and for collecting, calculating, and
reporting the data. The tests are performed under laboratory
conditions of 23.degree. C..+-.2.degree. C. and relative humidity
of 50%.+-.2%. The specimens are conditioned for 24 hours prior to
testing.
[0143] The specimen is cut with a dimension of 10 mm in the
intended stretch direction of the ear.times.25.4 mm in the
direction perpendicular to the intended stretch direction of the
ear. A specimen is collected from either an inelastic region or
from an elastic region.
[0144] Test Protocol
[0145] 1. Select the appropriate grips and load cell. The grips
must have flat surfaces and must be wide enough to grasp the
specimen along its full width. Also, the grips should provide
adequate force and suitable surface to ensure that the specimen
does not slip during testing. The load cell is selected so that the
tensile response from the specimen tested is between 25% and 75% of
the capacity of the load cell used.
[0146] 2. Calibrate the tester according to the manufacturer's
instructions.
[0147] 3. Set the distance between the grips (gauge length) at 7
mm.
[0148] 4. Place the specimen in the flat surfaces of the grips such
that the uniform width lies along a direction perpendicular to the
gauge length direction. Secure the specimen in the upper grip, let
the specimen hang slack, then close the lower grip. Set the slack
preload at 5 gram/force. This means that the data collection starts
when the slack is removed (at a constant crosshead speed of 13
mm/min) with a force of 5 gram force. Strain is calculated based on
the adjusted gauge length (1.), which is the length of the specimen
in between the grips of the tensile tester at a force of 5 gram
force. This adjusted gauge length is taken as the initial specimen
length, and it corresponds to a strain of 0%. Percent strain at any
point in the test is defined as the change in length relative to
the adjusted gauge length, divided by the adjusted gauge length,
multiplied by 100.
[0149] 5(a) First cycle loading: Pull the specimen to the 100%
strain at a constant cross head speed of 70 mm/min. Report the
stretched specimen length between the grips as l.sub.max.
[0150] 5(b) First cycle unloading: Hold the specimen at the 100%
strain for 30 seconds and then return the crosshead to its starting
position (0% strain or initial sample length, l.sub.ini) at a
constant cross head speed of 70 mm/min. Hold the specimen in the
unstrained state for 1 minute.
[0151] 5(c) Second cycle loading: Pull the specimen to the 100%
strain at a constant cross head speed of 70 mm/min.
[0152] 5(d) Second cycle unload: Next, hold the specimen at the
100% strain for 30 seconds and then return the crosshead to its
starting position (i.e. 0% strain) at a constant cross head speed
of 70 mm/min.
[0153] A computer data system records the force exerted on the
sample during the test as a function of applied strain. From the
resulting data generated, the following quantities are
reported.
[0154] i. Length of specimen between the grips at a slack preload
of 5 gram-force (l.sub.ini) to the nearest 0.001 mm.
[0155] ii. Length of specimen between the grips on first cycle at
the 100% strain (l.sub.max) to the nearest 0.001 mm.
[0156] iii. Length of specimen between the grips at a second cycle
load force of 7 gram-force (l.sub.ext) to the nearest 0.001 mm.
[0157] iv. % Set, which is defined as
(l.sub.ext-l.sub.ini)/(l.sub.max-l.sub.ini)*100% to the nearest
0.01%. The testing is repeated for six separate samples and the
average and standard deviation reported.
Air Permeability Test
[0158] The air permeability of an ear laminate or substrate (e.g.,
film, nonwoven, or article component) is determined by measuring
the flow rate of standard conditioned air through a test specimen
driven by a specified pressure drop. This test is particularly
suited to materials having relatively high permeability to gases,
such as nonwovens, apertured ear laminates and the like. ASTM D737
is used, modified as follows.
[0159] A TexTest FX 3300 instrument or equivalent is used,
available from Textest AG, Switzerland, or from Advanced Testing
Instruments ATI in Spartanburg S.C., USA. The procedures described
in the Operating Instructions for the TEXTEST FX 3300 Air
Permeability Tester manual for the Air Tightness Test and the
Function and Calibration Check are followed. If a different
instrument is used, similar provisions for air tightness and
calibration are made according to the manufacturer's
instructions.
[0160] The specimen is tested while in a relaxed state.
[0161] The test pressure drop is set to 125 Pascal and the 38.3
cm.sup.2 area test head (model FX 3300-5) or equivalent is used.
The result is recorded to three significant digits. The average of
5 specimens is calculated and reported as the Air Permeability
Value (m.sup.3/m.sup.2/min).
Bond Dimension Test Method
[0162] The Bond Dimension Test is used to measure bond density of a
laminate in the various bonding regions. For purposes of this
method, a bond is the intentional joining of two or more layers and
is the deformed area caused during the bonding process (e.g., the
reduced caliper at the site of bonding). It is recognized that in
some cases, the deformed area may include one or more
apertures.
[0163] Specimen Collection [0164] 1. Uniform pattern regions: To
measure bond density of the bonding region having a uniform
pattern, a square specimen of 1 cm.sup.2 area is cut from the
patterned bonded region of the laminate. Care should be taken to
avoid collecting specimen from an adjacent region, if it is
different. If specimen collection size of 1 cm.sup.2 square is
larger than the patterned region, the specimen is collected in the
rectangle shape having a 1 cm.sup.2 area: the shorter dimension of
the patterned region forms one side of the rectangle and the other
is selected such a way that rectangle area is 1 cm.sup.2. [0165] 2.
Other regions: To measure bond density of a bonding region without
a uniform pattern, identify the plurality of bonds of interest and
outline the resulting periphery. The specimen is collected by
cutting along the periphery. [0166] 3. To the extent bonding
regions are not identifiable, the ear may be segmented into three
longitudinally extending regions: The first region has a width
corresponding to the maximum width between the proximate edge of
the ear and edge of the chassis bond closest to the distal edge of
the ear. The second region has a width corresponding to the maximum
width between the distal edge and the edge of the fastener
attachment bond closest to the proximate edge of the ear. The third
region has a width that extends between the first and second
regions. Each region extends longitudinally for the length of the
ear in their respective regions and the lengths may vary in the
same manner as the ear's length varies in their respective
regions.
[0167] Bond Frequency: Bond density by bond frequency is calculated
by counting number of bonds on the specimen and dividing the number
of bonds by the specimen's area. To the extent that specimen
collection creates a partial bond within the specimen area, the
partial bond is counted as a fraction equal to the fraction of the
area of the bond included within the specimen relative to the area
of the whole bond (i.e., the bond prior to cutting the specimen).
Bond dimensions are measured to accuracy of 0.01 mm using a
microscope and/or imaging software. The dimensions for each bond
are used to calculate the bond area as per the mathematical area
formula for the given shape of the bond. A total of five specimens
are used, and an average bond density by bond frequency is
calculated.
[0168] Aggregate Bond Coverage: Bond density by aggregate bond
coverage is calculated by summing the bond areas for each bond in
the specimen and dividing it by the specimen's area. Bond
dimensions are measured to accuracy of 0.01 mm using a microscope
and/or imaging software. The dimensions for each bond are used to
calculate the bond area as per the mathematical area formula for
the given shape of the bond. The area of partial bonds inside the
specimen are also measured. All bond areas within the specimen are
added to calculate aggregate bond area for the specimen and then
the aggregate bond area is divided by the area of the specimen to
determine aggregate bond coverage. A total of five specimen are
used and an average bond density by aggregate bond coverage is
calculated.
Softness Test Method
[0169] TS7 and TS750 values are measured using an EMTEC Tissue
Softness Analyzer ("Emtec TSA") (Emtec Electronic GmbH, Leipzig,
Germany) interfaced with a computer running Emtec TSA software
(version 3.19 or equivalent). According to Emtec, the TS7 value
correlates with the real material softness, while the TS750 value
correlates with the felt smoothness/roughness of the material. The
Emtec TSA comprises a rotor with vertical blades which rotate on
the test sample at a defined and calibrated rotational speed (set
by manufacturer) and contact force of 100 mN. Contact between the
vertical blades and the test piece creates vibrations, which create
sound that is recorded by a microphone within the instrument. The
recorded sound file is then analyzed by the Emtec TSA software. TS7
and TS750 values are reported in db V.sup.2 rms
Sample Preparation
[0170] Test samples are prepared by cutting square or circular
samples from a finished product. Test samples are cut to a length
and width (or diameter if circular) of about 90 mm, and no greater
than about 120 mm, in dimension. If the finished product has a
discrete section of elasticized region (i.e. elasticized region is
shorter in one or more dimensions than nonwoven facing-layers), a
set of rectilinear specimens 76 mm.+-.3 mm long in the primary
stretch direction, and 100 mm.+-.3 mm wide in the perpendicular
direction is cut from the product part, with the elasticized region
centered in the rectilinear specimen. Test samples are selected to
avoid creases or folds within the testing region. Prepare 8
substantially similar replicate samples for testing. Equilibrate
all samples at TAPPI standard temperature and relative humidity
conditions (23.degree. C..+-.2 C..degree. and 50%.+-.2%) for at
least 1 hour prior to conducting the TSA testing, which is also
conducted under TAPPI conditions.
In-Bag Stack Height Test
[0171] The in-bag stack height of a package of absorbent articles
is determined as follows:
Equipment
[0172] 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
[0173] Absorbent article packages are equilibrated at
23.+-.2.degree. C. and 50.+-.5% relative humidity prior to
measurement.
[0174] 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. 12). 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.
[0175] 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."
[0176] Every document cited herein, including any cross referenced
or related patent or application and any patent application or
patent to which this application claims priority or benefit
thereof, is hereby incorporated herein by reference in its entirety
unless expressly excluded or otherwise limited. The citation of any
document is not an admission that it is prior art with respect to
any invention disclosed or claimed herein or that it alone, or in
any combination with any other reference or references, teaches,
suggests or discloses any such invention. Further, to the extent
that any meaning or definition of a term in this document conflicts
with any meaning or definition of the same term in a document
incorporated by reference, the meaning or definition assigned to
that term in this document shall govern.
[0177] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *