U.S. patent application number 16/186755 was filed with the patent office on 2019-03-14 for patterned apertured webs and methods for making the same.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Kelyn Anne Arora, Amanda Margaret Bicking, Jennifer Lynn Dusold, Timothy Ian Mullane, Stephanie Michelle Niezgoda, Jill Marlene Orr, Margaret Elizabeth Porter, Jennifer Rodic, Donald Carroll Roe, John Brian Strube, Ann Cecilia Tapp, Rachael Eden Walther.
Application Number | 20190076305 16/186755 |
Document ID | / |
Family ID | 54541245 |
Filed Date | 2019-03-14 |
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United States Patent
Application |
20190076305 |
Kind Code |
A1 |
Arora; Kelyn Anne ; et
al. |
March 14, 2019 |
PATTERNED APERTURED WEBS AND METHODS FOR MAKING THE SAME
Abstract
A disposable absorbent article having a topsheet, a backsheet,
and an absorbent core disposed therebetween is described. The
topsheet includes a plurality of apertures arranged in a first zone
and a first plurality of structures which are disposed adjacent to
the first plurality of apertures. The plurality of apertures have
an Effective Aperture Area of from between 0.5 mm.sup.2 to about 8
mm.sup.2 as measured by the Aperture/Feret Angle test as described
herein, and the topsheet has a top layer and a lower layer, wherein
the top layer is more hydrophobic than the lower layer.
Inventors: |
Arora; Kelyn Anne;
(Cincinnati, OH) ; Dusold; Jennifer Lynn;
(Cincinnati, OH) ; Mullane; Timothy Ian; (Union,
KY) ; Orr; Jill Marlene; (Liberty Township, OH)
; Porter; Margaret Elizabeth; (Cincinnati, OH) ;
Rodic; Jennifer; (Cincinnati, OH) ; Roe; Donald
Carroll; (West Chester, OH) ; Tapp; Ann Cecilia;
(West Chester, OH) ; Walther; Rachael Eden;
(Union, KY) ; Niezgoda; Stephanie Michelle;
(Cincinnati, OH) ; Strube; John Brian; (Okeana,
OH) ; Bicking; Amanda Margaret; (Cincinnati,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
54541245 |
Appl. No.: |
16/186755 |
Filed: |
November 12, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14933001 |
Nov 5, 2015 |
|
|
|
16186755 |
|
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|
|
62177405 |
Mar 13, 2015 |
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62076043 |
Nov 6, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 428/24331 20150115;
Y10T 428/24612 20150115; A61F 2013/51092 20130101; A61F 13/51476
20130101; A61F 2013/5127 20130101; A61F 2013/51078 20130101; A61F
2013/51178 20130101; A61F 13/5123 20130101; A61F 13/51478 20130101;
A61F 13/515 20130101; A61F 2013/51147 20130101; B32B 3/30 20130101;
A61F 13/512 20130101; A61F 13/5126 20130101; D10B 2509/026
20130101; A61F 13/511 20130101; A61F 13/51104 20130101; B32B
2250/20 20130101; A61F 2013/51186 20130101; A61F 13/51305 20130101;
B32B 2250/03 20130101; A61F 2013/51322 20130101; A61F 2013/51165
20130101; A61F 2013/5128 20130101; B32B 5/26 20130101; Y10T
428/24314 20150115; B32B 2555/02 20130101; B44F 99/00 20130101;
D04H 3/14 20130101; A61F 13/551 20130101; Y10T 428/24793 20150115;
A61F 2013/8497 20130101; B32B 5/022 20130101; Y10T 442/60 20150401;
A61F 2013/15715 20130101; A61F 2013/51182 20130101; B32B 2250/04
20130101; B32B 2250/242 20130101; Y10T 428/24826 20150115; B32B
5/142 20130101; B32B 2307/726 20130101; Y10T 428/24322 20150115;
A61F 2013/51486 20130101; A61F 13/5116 20130101; D04H 1/56
20130101; B32B 3/26 20130101; A61F 13/51121 20130101; A61F
2013/51377 20130101; B32B 3/06 20130101; B32B 3/266 20130101; B32B
7/05 20190101; A61F 13/51394 20130101; D04H 3/147 20130101; A61F
13/15699 20130101; A61F 13/51484 20130101; B32B 2555/00 20130101;
Y10T 442/66 20150401 |
International
Class: |
A61F 13/512 20060101
A61F013/512; A61F 13/511 20060101 A61F013/511; A61F 13/513 20060101
A61F013/513; B32B 3/26 20060101 B32B003/26; B32B 5/14 20060101
B32B005/14; B32B 5/02 20060101 B32B005/02 |
Claims
1. A disposable absorbent article comprising a longitudinal axis
and a lateral axis generally perpendicular to the longitudinal
axis, a pair of side edges extending generally parallel to the
longitudinal axis and a pair of end edges joining said pair of side
edges on opposite ends of the disposable absorbent article, the
disposable absorbent article further comprising: a topsheet
comprising a web having a length generally parallel to the
longitudinal axis and a width generally parallel to the lateral
axis, a plurality of apertures arranged in a first zone, a first
plurality of structures which are disposed adjacent to the first
plurality of apertures, wherein the plurality of apertures have an
Effective Aperture Area of from between 0.5 mm.sup.2 to about 8
mm.sup.2 as measured by the Aperture/Feret Angle test as described
herein, and wherein the topsheet comprises a top layer and a lower
layer, wherein the top layer is more hydrophobic than the lower
layer; a backsheet; and an absorbent core disposed between the
topsheet and the backsheet.
2. The disposable absorbent article of claim 1, wherein the top
layer has a basis weight of between 10 gsm and 30 gsm.
3. The disposable absorbent article of claim 1, wherein the lower
layer has a basis weight of between 10 gsm and 30 gsm.
Description
FIELD
[0001] The present disclosure generally relates to apertured webs
and methods for making the same. The apertured webs are
particularly suited for use in disposable absorbent articles, such
as diapers, adult incontinence products, training pants, feminine
hygiene products, wipes, dusting substrates, cleaning substrates,
and any other suitable consumer products.
BACKGROUND
[0002] Apertured webs are sometimes useful in disposable absorbent
products and other consumer products. These apertured webs
typically have uniformly sized and shaped circular or ovate
apertures throughout their area. The circular or ovate apertures
are also typically uniformly spaced in the cross machine direction
and in the machine direction with respect to each other. These
uniform aperture patterns provide webs that have the same amount of
fluid penetration and/or absorbency throughout their area owing to
the uniform circular or ovate aperture designs. Furthermore, land
areas (i.e., non-apertured portions) in these apertured webs
typically have the same size, shape, orientation, and spacing with
respect to each other. While such uniform apertured webs may be
desirable in some applications, other applications would benefit
from aperture patterns that combine a plurality of apertures into
arrays and that create non-uniformly sized, shaped, and/or spaced
land areas. Additionally, other features in conjunction with or
independent from aperture patterns would be beneficial.
SUMMARY
[0003] Apertured webs of the present invention may be utilized in
any suitable disposable absorbent article. In some forms of the
present invention, the apertured webs may have non-uniformly sized,
shaped, and/or spaced (CD or MD) land areas at least partially
surrounding arrays of apertures. Each of the apertures may have the
same or different size, space, orientation, and/or spacing relative
to another aperture within the array. The apertures may be
configured in a patterned fashion disclosed herein or maybe
similarly spaced from adjacent apertures.
[0004] The present disclosure also provides laminates comprising
one or more of the apertured webs or one or more of the apertured
webs and one or more non-apertured materials (e.g., films,
nonwovens, wovens). In the laminates, colored layers or materials
may be positioned intermediate the one or more apertured webs or
the one or more apertured webs and the one or more non-apertured
materials. The colored layers or material may also be positioned
under the apertured webs or laminates having at least one apertured
web. The colored layers or materials may comprise colored
adhesives, inks, or other colored materials, such as nonwovens, for
example. The colored layers or materials may be apertured or
non-apertured, patterned, or non-patterned. In some forms, the
apertured web may comprise a plurality of apertures which are
arranged in a pattern or may comprise uniform rows/columns of
apertures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] While the specification concludes with claims particularly
pointing out and distinctly claiming the subject matter which is
regarded as forming the present invention, it is believed that the
invention will be better understood from the following description
which is taken in conjunction with the accompanying drawings in
which the designations are used to designate substantially
identical elements and in which:
[0006] FIGS. 1-4 are photographs of portions of example single
layer apertured webs in accordance with the present disclosure;
[0007] FIG. 5 is a schematic representation of a cross-sectional
view of a apertured web having two layers, with one layer being
apertured and the other layer being non-apertured in accordance
with the present disclosure;
[0008] FIG. 6 is a schematic representation of a cross-sectional
view of a apertured web having two layers, with both layers being
apertured and with the apertures in the layers being aligned in
accordance with the present disclosure;
[0009] FIG. 7 is a schematic representation of a cross-sectional
view of a apertured web having two layers, with both layers being
apertured and with the apertures in one layer being fully
overlapped by land areas in the other layer in accordance with the
present disclosure;
[0010] FIG. 8 is a schematic representation of a cross-sectional
view of a apertured web having two layers, with both layers being
apertured and with the apertures in one layer being partially
overlapped by land areas in the other layer in accordance with the
present disclosure;
[0011] FIG. 9 is a schematic representation of a cross-sectional
view of a apertured web having two layers, with a first apertured
layer and a second non-apertured layer and with printing or ink on
one of the layers in accordance with the present disclosure;
[0012] FIG. 10 is a schematic representation of a cross-sectional
view of a apertured web having two layers, with a first apertured
layer and a second non-apertured layer and with a colored adhesive
on one of the layers or positioned intermediate the layers in
accordance with the present disclosure;
[0013] FIG. 11 is a schematic representation of an example process
for producing the apertured webs of the present disclosure in
accordance with the present disclosure;
[0014] FIG. 12 is a perspective view of a web weakening arrangement
of FIG. 11 in accordance with the present disclosure;
[0015] FIG. 13 is a photograph of an exemplary roller that can be
used as roller 110 in the weakening arrangement of FIG. 12 in
accordance with the present disclosure;
[0016] FIG. 14 is a photograph of an example apertured web produced
using the roller of FIG. 13 in the weakening arrangement in
accordance with the present disclosure;
[0017] FIG. 15 is a photograph of an example apertured web produced
using a weakening arrangement in accordance with the present
disclosure;
[0018] FIG. 16 is a photograph of an example apertured web produced
using a weakening arrangement in accordance with the present
disclosure;
[0019] FIG. 17 is a perspective view of an incremental stretching
system of the process of FIG. 11 in accordance with the present
disclosure;
[0020] FIG. 18 is an enlarged view showing the details of teeth of
the incremental stretching system of FIG. 17 in accordance with the
present disclosure;
[0021] FIG. 19 is a perspective view of an example cross machine
directional tensioning apparatus of the process of FIG. 11 in
accordance with the present disclosure;
[0022] FIG. 20 is a schematic representation of a front view of an
example cross machine directional tensioning apparatus with outer
longitudinal portions in an unexpanded and non-angled position
relative to a middle portion in accordance with the present
disclosure;
[0023] FIG. 21 is a schematic representation of a front view of the
cross machine directional tensioning apparatus of FIG. 20 with the
outer longitudinal portions in a longitudinally expanded position
relative to the middle portion in accordance with the present
disclosure;
[0024] FIG. 22 is a schematic representation of a front view of the
cross machine directional tensioning apparatus of FIG. 20 with the
outer longitudinal portions in an angled and expanded position
relative to the middle portion in accordance with the present
disclosure;
[0025] FIG. 23 is a schematic representation of a front view of a
cross machine directional tensioning apparatus with outer
longitudinal portions fixed in an angled position relative to a
middle portion in accordance with the present disclosure;
[0026] FIG. 24 is an example overbond bond pattern for the roller
110 of FIG. 13 in accordance with the present disclosure;
[0027] FIG. 25 is a photograph of an example apertured web produced
using the overbond pattern of FIG. 24 and having been subjected to
a 25% cross directional stretch using the equipment illustrated in
FIG. 20 in accordance with the present disclosure;
[0028] FIG. 26 is a photograph of an example apertured web produced
using the overbond pattern of FIG. 24 and having been subjected to
a 35% cross directional stretch using the equipment illustrated in
FIG. 20 in accordance with the present disclosure;
[0029] FIG. 27 is a photograph of an example apertured web produced
using the overbond pattern of FIG. 24 and having been subjected to
a 45% cross directional stretch using the equipment illustrated in
FIG. 20 in accordance with the present disclosure;
[0030] FIG. 28 is a photograph of an example apertured web produced
using the overbond pattern of FIG. 24 and having been subjected to
a 55% cross directional stretch using the equipment illustrated in
FIG. 20 in accordance with the present disclosure;
[0031] FIG. 29 is a plan view of an example disposable absorbent
article having portions cut away to reveal underlying structure
that may comprise one or more apertured webs, the inner surface of
the absorbent article is facing the viewer in accordance with the
present disclosure;
[0032] FIG. 30 is a top view of an example absorbent core of an
absorbent article with some layers partially removed, wherein the
absorbent core comprises one or more channels in accordance with
the present disclosure;
[0033] FIG. 31 is a cross-sectional view of the absorbent core
taken about line 37--37 of FIG. 30 in accordance with the present
disclosure;
[0034] FIG. 32 is a cross-sectional view of the absorbent core
taken about line 38--38 of FIG. 30 in accordance with the present
disclosure;
[0035] FIG. 33 is a top view of an absorbent article of the present
disclosure, having portions cut away to reveal underlying
structure, that is a sanitary napkin in accordance with the present
disclosure;
[0036] FIG. 34 is a top view of a patterned adhesive applied to a
substrate for an absorbent article in accordance with the present
disclosure;
[0037] FIG. 35 is a top view of another patterned adhesive applied
to a substrate for an absorbent article in accordance with the
present disclosure;
[0038] FIG. 36 is a photograph of a portion of a apertured web
comprising fused portions surrounding the apertures in accordance
with the present disclosure;
[0039] FIG. 37 is a side view of a package of absorbent articles in
accordance with the present disclosure. The outer surface is
illustrated as transparent for purposes of clarity;
[0040] FIGS. 38A-38B illustrate schematic illustrations of examples
of apertured webs of the present disclosure, with structures formed
thereon;
[0041] FIG. 39 is a depiction of a coordinate system for the
apertured webs of the present invention;
[0042] FIGS. 40-53 are photographs of apertured webs constructed in
accordance with the present invention;
[0043] FIGS. 54-58 represents a schematic illustration of a
disposable absorbent article comprising a plurality of zones in
accordance with the present invention;
[0044] FIGS. 59-65 represent schematic illustrations of feminine
care articles constructed in accordance with the present invention
and including the apertured webs described herein;
[0045] FIGS. 66-69 represent schematic illustrations of bond
patterns for materials of the present invention;
[0046] FIGS. 70-71 are schematic illustrations showing overbond
patterns on a web in accordance with the preset invention;
[0047] FIGS. 72-81 are photographs of apertured webs in accordance
with the present disclosure;
[0048] FIGS. 82-88 are illustrations showing overbonds, patterned
adhesive and combination of overbonds and patterned adhesive,
respectively; and
[0049] FIG. 89 is a cross sectional view of a disposable absorbent
article or a portion thereof, constructed in accordance with the
present invention.
DETAILED DESCRIPTION
[0050] Various non-limiting forms of the present disclosure will
now be described to provide an overall understanding of the
principles of the structure, function, manufacture, and use of the
apertured webs and methods for making the same disclosed herein.
One or more examples of these non-limiting forms are illustrated in
the accompanying drawings. Those of ordinary skill in the art will
understand that the apertured webs and methods for making the same
specifically described herein and illustrated in the accompanying
drawings are non-limiting example forms and that the scope of the
various non-limiting forms of the present disclosure are defined
solely by the claims. The features illustrated or described in
connection with one non-limiting form may be combined with the
features of other non-limiting forms. Such modifications and
variations are intended to be included within the scope of the
present disclosure.
[0051] As used herein, the term "nonwoven material" is used in its
normal sense and specifically, refers to a web that has a structure
of individual fibers or threads which are interlaid, but not in any
regular, repeating manner. Nonwoven materials have been, in the
past, formed by a variety of processes, such as, for example,
meltblowing processes, spunbonding processes and bonded carded web
processes.
[0052] As used herein, the term "microfibers", refers to small
diameter fibers having an average diameter not greater than about
100 microns.
[0053] As used herein, the term "nanofibers", refers to very small
diameter fibers having an average diameter less than about 1
micron.
[0054] As used herein, the term "meltblown fibers", refers to
fibers formed by extruding a molten thermoplastic material through
a plurality of fine, usually circular, die capillaries as molten
threads or filaments into a high velocity gas (e.g., air) stream
which attenuates the filaments of molten thermoplastic material to
reduce their diameter, which may be to a microfiber diameter.
Thereafter, the meltblown fibers are carded by the high velocity
gas stream and are deposited on a collecting surface to form a web
of randomly dispersed meltblown fibers.
[0055] As used herein, the term "spunbonded fibers", refers to
small diameter fibers which are formed by extruding a molten
thermoplastic material as filaments from a plurality of fine,
usually circular, capillaries of a spinneret with the diameter of
the extruded filaments then being rapidly reduced as by, for
example, eductive drawing or other well-known spunbonding
mechanisms.
[0056] As used herein, the term "polymer" generally includes, but
is not limited to, homopolymers, copolymers, such as, for example,
block, graft, random, and alternating copolymers, terpolymer, etc.,
and blends and modifications thereof. Furthermore, unless otherwise
specifically limited, the term "polymer" shall include all possible
geometrical configurations of the material. These configurations
include, but are not limited to, isotactic, syndiotactic and random
symmetries.
[0057] As used herein, the terms "join", "joined", "joining",
"bond", "bonded", "bonding", "attach", "attached", or "attaching"
encompasses configurations whereby an element is directly secured
to another element by affixing the element directly to the other
element, and configurations whereby an element is indirectly
secured to another element by affixing the element to intermediate
member(s) which in turn are affixed to the other element.
[0058] As used herein, the term "elastic" refers to any material
that, upon application of a biasing force, can stretch to an
elongated length of at least about 110% of its relaxed, original
length (i.e., can stretch to 10 percent), without rupture or
breakage, and upon release of the applied force, recovers at least
about 40% of its elongation. For example, a material that has an
initial length of 100 mm can extend at least to 110 mm, and upon
removal of the force would retract to a length of 106 mm (40%
recovery). "Elastic" may refer to a single material, or it may
refer to a combination of materials making up a laminate or a
macrostructure in an article. An elastic material may be
incorporated into a laminate or macrostructure which is not
elastic, or which is less elastic than one or more of the elastic
materials of the laminate or macrostructure.
[0059] As used herein, the term "nonelastic" refers to any material
which does not fall within the definition of "elastic" above.
[0060] As used herein, the term "extensible" refers to any material
which, upon application of a biasing force, is elongatable by at
least about 10 percent, at least about 20, or at least about
percent 50 percent, without experiencing catastrophic failure.
Recovery of the strain is not required for a material to be
considered extensible.
[0061] As used herein, the term "melt-stabilized" refers to
portions of a nonwoven material which have been subjected to
localized heating and/or localized pressure to substantially
consolidate the fibers of the nonwoven material into a stabilized
film-like form.
[0062] As used herein, the term "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 bodily exudates discharged from the body. The term
absorbent article includes, but is not limited to, diapers, pants,
training pants, adult incontinence products, sanitary napkins,
tampons, wipes, and liners. The term "absorbent article" also
encompasses cleaning or dusting pads or substrates that have some
absorbency.
[0063] The term "machine direction" (MD) is used herein to refer to
the primary direction of material, strip of substrate, or article
flow through a process.
[0064] The term "cross direction" (CD) is used herein to refer to a
direction that is generally perpendicular to the machine
direction.
[0065] As used herein, the term "aperture aspect ratio" is the
ratio of the major axis to the minor axis of a single aperture.
Apertured Webs
[0066] The apertured webs of the present disclosure provide many
benefits over conventional apertured topsheets, as will be
described herein. Examples of apertured webs 10 are illustrated in
FIGS. 1-4, 14-16, and 72-81. As illustrated, the apertured webs 10
may take on a number of configurations. The apertures are labeled
12 and the land areas (non-apertured areas) are labeled 14. A
number of additional example apertured web configurations are
illustrated in subsequent figures.
[0067] The apertured webs of the present disclosure may comprise a
single apertured layer (see FIGS. 1-4) or more than one layer), for
example, two or three layers. In such constructions, not all layers
are required to be apertured. As such, webs of the present
invention may comprise a single layer or may be constructed as a
laminate. The term "layer" means a self-sustaining web (e.g., a
nonwoven or a film) and not a non-self-sustaining web (e.g., a spun
layer of an SMMS nonwoven). Thus, a
Spunbond-Meltblown-Meltblown-Spunbond (SMMS) nonwoven material
would be considered a single layer for purposes of this disclosure,
much like a film would be considered a single layer.
[0068] The apertured web may comprise one or more non-apertured
layers that have not been put through an aperturing process, but
merely have openings (if any) created in the formation of the
material (e.g., pores in nonwovens). If two apertured layers are
provided in an apertured web, each layer may have the same
aperturing pattern or a different aperturing pattern. However, as
noted previously, in some forms, the apertured web may comprise a
single layer.
[0069] For those forms where the apertured webs comprise multiple
layers, each layer may comprise a plurality of substrates, e.g.
SMMS. Other suitable substrates include spunbonded "S"; meltblown
"M"; spunlace "SL"; carded "C"; and fine fiber substrates "N".
Suitable substrate combinations include SMS, SNS, SMNS and the
like. Spunbonded, meltblown, and carded nonwovens are well known in
the art. Fine fiber substrates include fibers with average
diameters less than one micron or 1000 nanometers.
[0070] Referring to FIG. 5, a schematic illustration of an example
cross-sectional view of an apertured web 10 is illustrated. The
apertured web 10 may comprise an apertured layer 16 and a
non-apertured layer 18. The apertured layer 16 may comprise any of
the various aperture patterns disclosed herein. The aperture layer
16 may be combined with, bonded to, or joined to the non-apertured
layer 18 to form a laminate. The apertured layer 16 may have
apertures and land areas at least partially surrounding the
apertures.
[0071] If both or all layers of an multi-layer apertured web are
apertured, the apertures may be aligned or overlapping, not aligned
or not overlapping, or partially aligned or partially overlapping
in the Z-direction. For instance, the apertures in one layer may be
100% aligned or overlapping in the Z-direction with the apertures
in a second layer thus forming apertures through both layers of the
apertured web. In other instances, the apertures may be less than
100% aligned or overlapping in the Z-direction. Stated another way,
the apertures in one layer may be offset in the CD, MD, or other
direction or different patterns of apertures may be formed in each
layer to create the misalignment of the apertures. In such
instances, the area of the apertures in one layer may overlap the
area of the apertures in another layer, in the Z-direction, by 10%
to 90%, 10% to 100%, 25%, 50%, or 75%, for example, specifically
reciting all 0.5% increments within the specified ranges and all
ranges formed therein or thereby.
[0072] In instances where more than one layer of an apertured web
includes apertures, the apertures may be coincident in the
Z-direction, i.e., penetrate through both layers. In a form, this
may be achieved by forming the apertures after bonding, joining
and/or laminating the two or more layers together. Alternatively,
the apertures in one layer may have a different pattern, size,
and/or shape from the apertures in a second layer and/or may be
oriented in a different direction. In a form, this may be achieved
by forming the apertures in each of the layers prior to combining
the two or layers into a laminated structure. In absorbent article
forms comprising an apertured web having an apertured layer and a
non-apertured layer, the apertured layer may be oriented on the
wearer-facing side of the apertured web or on the garment-facing
side of the apertured web. In still other forms, the apertured
layer may be positioned intermediate two non-apertured layers.
[0073] Any of the layers of the apertured web described herein may
be hydrophilic or hydrophobic. In some instances, all of the layers
may be hydrophilic or may all be hydrophobic. In still other
instances, all of, or some of, the layers may be hydrophilic to
different extents or hydrophobic to different extents. In a form, a
first layer of an apertured web may have the same or a different
hydrophilicity as another layer of the same apertured web. At least
one of the layers comprises apertures. As an example, a
wearer-facing layer of an apertured web may be hydrophobic to help
keep the wearer feeling dry and fresh while a garment-facing layer
of the apertured web may be hydrophilic to help wick fluid into the
apertures and into an absorbent core. For those instances where a
single layer apertured web is utilized, constituent substrates of
the single layer may have differing hydrophilic/hydrophobic
properties. For those instances where the apertured web comprises a
plurality of layers, a constituent substrate of a first layer may
have differing hydrophilic/hydrophobic properties from a
constituent substrate of a second layer.
[0074] In an instance, again referring to FIG. 5, the apertured
layer 16 may have a different color than the non-apertured layer
18, such that the apertures in the layer 16 are easily visible or
more readily apparent to a user. The aperture pattern in the
apertured layer 16 may also form indicia ("apertured indicia") that
may indicate the correct orientation of an absorbent article
comprising the apertured web 10 on a wearer. Such apertured indicia
may include any object or shape that has a commonly understood
vertical orientation, such as a heart shape, a face, a building, a
letter or numeral, a car, for example. This may also apply to other
apertured webs described herein, regardless of how many apertured
or non-apertured layers are provided.
[0075] Any of the apertured webs described herein may have
gradients of color to indicate which side of the product comprising
the web is the top and which side is the bottom.
[0076] The layers of the apertured web of the present disclosure
may have the same basis weight or a different basis weight. In an
instance, again referring to FIG. 5, the layer 16 may have a higher
basis weight than the layer 18. This may provide better softness on
a surface of the layer 16 (e.g., a topsheet contacting a wearer's
skin), while also providing enhanced fluid penetration owing to the
apertures in the layer 16.
[0077] The basis weight of a apertured web may in the range of
about 10 gsm to about 200 gsm, about 10 gsm to about 100 gsm, about
10 gsm to about 50 gsm, or about 10 gsm to about 40 gsm,
specifically reciting all 0.1 gsm increments within the
above-specified range and all ranged formed therein or thereby.
Basis weight is measured according to the Basis Weight Method
herein. The predominant fiber orientation of the fibers in the
layers of multi-layered apertured webs may be the same or
different. In an instance, a predominant fiber orientation may be
about 45 degrees to about 135 degrees, for example, off-axis
relative to a machine direction, while another layer may have a
predominant fiber orientation substantially along a machine
direction or +/-about 10 to about 20 degrees from the machine
direction. Providing different layers in an apertured web with
different predominant fiber orientations may provide increased
strength and resistance to tearing of the apertured web when the
two or more layers are joined or bonded together.
[0078] Referring to FIG. 6, a schematic illustration of an example
cross-sectional view of another apertured web 10 is illustrated.
The apertured web 10 may comprise a first apertured layer 20 and a
second apertured layer 22. Apertures of the first apertured layer
20 in FIG. 6 may be 80%, 85%, 90%, 95%, 80% to 100%, or 100%
aligned, in the Z-direction (indicated by arrow Z), with apertures
the second apertured layer 22, specifically reciting all 0.5%
increments within the specified range and all ranges formed
therein. The first apertured layer 20 may be combined with, bonded
to, or joined to the second patterned aperture layer 22 to form a
laminated apertured web. The apertured web 10 of FIG. 6, or any of
the other apertured webs of the present disclosure, may comprise a
third layer 21 (or more than three layers) that may be
non-apertured or apertured. The second apertured layer 22 may be
combined with, bonded to, or joined to the third non-apertured
layer 21. Again referring to FIG. 6, the apertures in the second
apertured layer 22 may be smaller than (e.g., 10% less area, 20%
less area, 30% less area etc.) the apertures in the first apertured
layer 20. Such a feature may allow BM penetration through the first
layer 20 while also providing adequate liquid bodily exudate fluid
strikethrough through the second layer 22 or rewet from the first
layer compared to a non-apertured second layer.
[0079] Referring to FIG. 7, a schematic illustration of an example
cross-sectional of another apertured web 10 is illustrated. The
apertured web 10 may comprise a first apertured layer 24 and a
second apertured layer 26. Apertures of the first apertured layer
24 may be fully overlapped by non-apertured portions or "land
areas" of the second apertured layer 26 in the Z-direction
(indicated by arrow Z). The first apertured layer 24 may be
combined with, bonded to, or joined to the second patterned
aperture layer 26 to form a laminated apertured web.
[0080] Referring to FIG. 8, a schematic illustration of an example
cross-sectional view of another apertured web 10 is illustrated.
The apertured web 10 may comprise a first apertured layer 28 and a
second apertured layer 30. Apertures of the first apertured layer
28 may be partially overlapped by non-apertured portions or "land
areas" of the second apertured layer 30 in the Z-direction
(indicated by arrow Z). The first apertured layer 28 may be
combined with, bonded to, or joined to the second apertured layer
30 to form a laminated apertured web. The overlap of the areas of
the apertures in the first apertured layer 28 and the areas of the
apertures in the second apertured layer may be in the range of
about 5% to about 95%, about 10% to about 90%, about 20% to about
80%, about 25% to about 75%, about 25%, about 50%, or about 75%,
specifically reciting all 0.5% increments within the specified
ranges and all ranges formed therein or thereby.
[0081] The example apertured web 10 of FIG. 8 may also comprise a
pigmented substance (full continuous layer) or a patterned
pigmented substance 29 at least partially intermediate the first
and second apertured layers 28 and 30. The pigmented substance or
patterned pigmented substance 29 may comprise graphics, inks,
pigmented adhesives or other pigmented substances and may be
viewable through the overlapping areas of the apertures from either
side of the apertured web 10. The pigmented substance or patterned
pigmented substance 29 may be positioned under the second apertured
layer 30 and may still be viewable through the overlapping areas of
the apertures when viewing from the first apertured layer 28. The
pigmented substance 29 may be viewable through the apertured layer
28. For those instances where the pigmented substance 29 is
disposed on a side of the second apertured layer 30 not between the
first and second apertured patterned layers can be visible through
both the first and second apertured layers 28 and 30.
[0082] The first apertured layer 28, the second apertured layer 30,
and the pigmented substance or the patterned pigmented substance 29
may be the same color or may each be a different color.
Alternatively, the apertured layers 28 and 30 may have a different
color as the pigmented substance or the patterned pigmented
substance 29. Such forms allow for a three-dimensional appearance
to be provided in the apertured web 10 without actually making the
apertured web 10 three-dimensional, such as through embossing, for
example.
[0083] Forms of the present invention are contemplated where the
pigmented substance 29 is associated with an apertured layer, e.g.
first apertured layer 28, and a non-apertured layer, e.g. third
layer 21 (shown in FIG. 6). In such forms, a portion of the
pigmented substance 29 may be viewable through the apertures and
another portion of the pigmented substance 29 may be viewable
through the lands of the apertured layer and/or non-apertured
layer.
Materials
[0084] Any of the layers of the apertured webs described herein may
comprise any materials known in the art including, but not limited
to, nonwovens, wovens, cellulosic materials, films, elastic
materials, non-elastic materials, highloft materials, and/or foams.
The apertured webs may also comprise one or more layers of one or
more nonwoven materials, one or more films, combinations of
different nonwoven materials, combinations of different films,
combinations of one or more films and one or more nonwoven
materials, or combinations of one or more different materials, for
example. Apertured webs having one or more layers of the same or
similar materials are also within the scope of the present
disclosure. The basis weight, color, opacity, hydrophilcity,
Interaperture Distance, Absolute Feret Angle, Effective Aperture
Area, Effective Open Area, or other parameters or characteristics
of the various materials in the various layers may be the same or
different.
[0085] For those instances where the apertured web comprises a
plurality of substrates, each substrate may be integrally formed
with one another. For example, all substrates of a layer may be
produced via a spunbond process. A first substrate may be produced
by a first spin beam and a second substrate may be produced via a
second spin beam. Additional substrates may be produced via
additional spin beams on the same spunbond manufacturing line.
[0086] Some precursor web materials may comprise PE/PP bi-component
fiber spunbond webs. Other suitable precursor webs may comprise
spunbond webs comprising side-by-side crimped fibers (e.g. PE/PP or
PP/PP) that are bonded via calendar (thermal point) bonding or
through-air bonding. For those configurations with multiple layers
a first layer and second layer of the apertured web of the present
invention may comprise a crimped spunbond layer. For these
configurations, the crimped spunbond layers may be combined from
roll stock and joined as provided herein. However, where the
apertured web comprises a first substrate and a second substrate,
each may be crimped spunbond substrates formed on a spunbond
manufacturing line where the first substrate is formed from a first
spin beam while the second substrate is formed from a second spin
beam.
[0087] Other suitable precursor webs may comprise carded staple
fibers comprising polypropylene, polyethylene terephthalate,
polyethylene/polypropylene bi-component, polyethylene/polyethylene
terephthalate bi-component, or the like, which are calendar bonded,
through-air bonded, resin bonded or hydroentangled. The precursor
webs may comprise microfibers and/or nanofibers, optionally with
other fibers. In some circumstances, multiple layer webs may be
desired over a single layer webs (even at the same basis weight)
due to increased uniformity/opacity and the ability to combine webs
having different properties. For example, an extensible spunbond
nonwoven carrier layer may be combined with a soft, crimped fiber
nonwoven (spunbond or carded) to create an apertured web that is
both soft and strong. The layers may have the same or different
surface energy, for example, the top layer may be hydrophobic and
the lower layer may be hydrophilic. The layers may have different
permeability/capillarity, e.g. the upper layer may have higher
permeability and the lower layer have higher capillarity in order
to set up a capillary gradient and aid in moving fluid away from
the surface (or topsheet) of an absorbent article and into an
absorbent core of the absorbent article.
[0088] Further regarding coloration, the webs of the present
invention may comprise pigments, inks or dyes to achieve any color
difference as provided herein. The fibers of the first layer and
the fibers of the second layer may differ from each other in
pigmentation. As used herein, to "differ in pigmentation" or
"difference in pigmentation" means (a) the constituent material of
a first layer comprises a pigment which is different from the
pigment of a second layer; or (b) the constituent material of a
first layer comprises a different combination of pigments; or (c)
the constituent material of a first layer comprise different
amounts of the same pigment(s) versus a second layer; or (d)
combinations of any of options a) to c). The pigment or colorant
may be added uniformly throughout the constituent material within
each layer or may be added to one or both components in same or
different type/amount within multicomponent fibers.
[0089] A pigment is a material, which can be organic or inorganic
and may include activatable, structural and or special effects
pigments. A pigment changes the color of reflected or transmitted
light as the result of wavelength-selective absorption. This
physical process differs from fluorescence, phosphorescence, and
other forms of luminescence, in which a material emits light. A
pigment is a generally insoluble powder, which differs from a dye,
which either is itself a liquid or is soluble in a solvent
(resulting in a solution). Dyes are often used to provide a print
on the surface of a nonwoven web, such as graphics, pattern or
images. Hence, these dyes do not form a part of the fibers of the
nonwoven web but are rather applied on the web surface. In the
present invention the pigments may be comprised within the fibers
of the multilayered nonwoven web, which eliminates the risk of
rub-off or wash-off of the color(s) imparted to the multilayered
nonwoven web by the pigment.
[0090] For the present invention, the pigment will typically be
mixed with the thermoplastic material, of which the fibers are
made. Often, the pigment is added to the thermoplastic material in
the form of a master batch or concentrate at the time of formation
of the fibers. Colored master batches useful for the present
invention include polypropylene based custom color master batches
e.g. supplied by Ampacet; Lufilen and Luprofil supplied by BASF;
Remafin for polyolefin fibers, Renol-AT for polyester fibers,
Renol-AN for polyamide fibers and CESA for renewable polymers
supplied by Clamant. Hence, the pigment will be suspended in the
molten thermoplastic material prior to the thermoplastic material
being forced through the spinnerets to form and lay down the fibers
which form the nonwoven web.
[0091] To increase the whiteness and/or opacity of the fibers in
either or both layers, titanium dioxide (TiO2) may be used.
Different crystal forms are available, however most preferred are
rutile or anatase TiO2. Other white pigments include zinc oxide,
zinc sulfide, lead carbonate or calcium carbonate. To create a
black color, carbon black or any other suitable colorant may be
used. Various colored inorganic pigments may be used depending upon
the desired color and may include metal oxides, hydroxides and
sulfides or any other suitable material. Non-limiting examples of
inorganic pigments include cadmium orange, iron oxide, ultramarine,
chrome oxide green. One or more pigments may be combined to create
the desired color. Non-limiting examples of organic colorants
include anthraquinone pigments, azo pigments, benzimidazolone
pigments, BONA Lakes, Dioxazine, Naphthol, Perylene, Perinone,
Phthalocyanine, Pyranthrone, Quinacridones. Effects pigments
including metal, pearlescent and fluorescent may also be used.
Various colorants are described in Plastics Additives Handbook, 5th
Edition.
[0092] Webs of the present invention may additionally comprise
hydrophobic and/or hydrophilic treatments. Such treatments may be
in the form of melt additives and/or spray/coat on chemistries.
Some suitable examples of hydrophilic treatments include: Techmer
PPM15560; Techmer TPM12713; Polyvel VW351 PP Wetting Agent;
Goulston Hydrosorb 1001; as well as those hydrophilic additive
disclosed in US Patent Application Publication No. 2012/0077886.
One suitable examples of hydrophobic treatments include Techmer
PPM17000 High Load Hydrophobic. Other examples of hydrophobic
additives are disclosed in U.S. patent application Ser. No.
14/849,630.
Joining of Layers
[0093] If more than one layer is provided in a particular apertured
web, the layers may be bonded together using any bonding methods
known to those of skill in the art, such as adhesive bonding,
patterned adhesive coating, ultrasonic bonding, thermal bonding,
mechanical bonding, or any combination of these bonding methods.
Alternatively, the various layers may be bonded together only at
the perimeter of the apertures, through the overbonding step. The
bonding may be done in a pattern of bonds or in arrays of bonds.
The pattern may be a regular, uniform pattern or an irregular,
non-uniform pattern. The bonding patterns may comprise a
substantially continuous bond pattern or may be formed of discrete
bonding points. The discrete bonding points may form a pattern. The
pattern of bonding points may be homogeneous or non-homogeneous. A
bond pattern in one region of a apertured web may differ from a
bond pattern in another region of the apertured web. For example,
the bond pattern may be different in the machine direction or the
cross-machine direction of the apertured web laminate. An absorbent
article including the apertured web may have a different bond
pattern in the front region vs. the back region, the center region
vs. side regions, or the crotch region vs. waist regions of the
absorbent article, for example. Bonding in apertured webs is
typically accomplished by joining the land areas of various layers
of the apertured webs. If adhesive is used in the bonding process,
the adhesive may be tinted, pigmented, and/or patterned to create a
complementary or contrasting pattern compared to the aperture
pattern or patterns.
[0094] Any suitable method may be utilized to form bonds between
layers/substrates described herein. Some suitable examples are
ultrasonic, heated rolls, and the like. In a specific example,
substrates, layers and/or elements of a disposable absorbent
articles may be bonded together via fusion bonding, ultrasonic
bonding, or the like. The bonding may comprise a pattern or a
plurality of patterns which form graphics and/or other depictions,
hereafter "bond indicia". In another example, substrates, layers
and/or elements of disposable absorbent articles may be adhesively
bonded together.
[0095] The mechanical bonding methods, e.g. fusion bond,
ultrasonic, etc. can cause localized areas of the web to thin and
become film like--in the case of nonwovens. These thinner areas can
have different opacity characteristics with respect to the
constituent material around the bond. As such, visual/color effects
can be achieved. For example, the thinner areas may appear as a
different color than the constituent material around the bond.
[0096] Some examples of bond indicia are shown in FIGS. 62-66. In
order to ensure the integrity of the product and of a topsheet, the
total area of the bonding (calculated as a percent area of the
outer perimeter of bonding region) may range from 5% to 25%, 10% to
20%, or 12% to 18%. The size of each individual bond nub may range
from 0.5 sqmm to 5 sqmm, 1 sqmm to 3 sqmm. The spacing between bond
nubs can range from 1 mm to 5 cm, 1.6 mm to 3 cm.
[0097] In some forms, the bonds, as stated previously, may be
configured in patterns so as to create bond indicia. But apart from
forming bond indicia, the bonds can help secure the layers of
material together. Additionally, in some forms, the bonds may be
utilized to secure a topsheet to subjacent layers of a disposable
absorbent article, e.g. a secondary topsheet, absorbent core,
etc.
[0098] As shown in FIGS. 62-66, bond patterns 3000A, 3000B, 3000C,
and 3000D of the present invention may comprise a plurality of bond
sites 3002. The bond sites may be any suitable shape.
[0099] As shown, the bond sites are approximately circular;
however, elliptical, diamond, heart, star, clover (3 leaf, 4 leaf),
bowtie, combinations thereof, and the like are contemplated. In
some forms, the constituent bond sites 3002 of a bond pattern may
comprise combinations of shapes.
[0100] As shown in FIG. 66, the bond pattern 3000A may comprise a
plurality of arrays of bond sites, e.g. 3010, 3020, 3030, and 3040.
The first array 3010 may be a continuous series of bond sites 3002
which enclose the second array 3020, the third array 3030, and the
fourth array 3040. As shown, the second array 3020 may be
discontinuous and disposed between the first array 3010 and the
third array 3030. The third array 3030, much like the first array
3010 may be continuous and may enclosed the fourth array 3040. The
fourth array 3040 may be discontinuous and be disposed in a target
area on the absorbent article. The target area signifies the
location of the article which is likely to receive the fluid insult
from the wearer assuming the absorbent product is donned
properly.
[0101] With the discontinuous fourth array 3040, fluid insults can
be provided with adequate access to the nonwoven laminate.
Additionally, with the continuous third array 3030, fluid insults
are encouraged to stay within the target area as opposed to
meandering to outer edges of the article.
[0102] As shown in FIG. 67, the bond pattern 3000B may comprise a
plurality of arrays of bond sites. For example, a first array 3010B
may be continuous and comprise bond sites which are arranged in the
shape of hearts, clouds, etc. A second array 3020B is disposed
within the first array 3010B and disposed about a third array
3030B. The third array 3030B is continuous and surrounds the fourth
array 3040B. Much like the arrays of the bond pattern 3000A, the
arrays of the bond pattern 3000B can provide fluid handling
benefits.
[0103] As shown in FIG. 68, a bond pattern 3000C may comprise a
plurality of arrays of bond sites. However, in contrast with the
previous bond patterns, a first array 3010C may be discontinuous
about the entire periphery of a pad. As shown, the first array
3010C comprises a plurality of continuous segments of bond sites
each of which is disconnected from one another. A second array
3020C may be disposed inboard of the first plurality 3010C and may
also comprise a plurality of continuous segments which are
discontinuous. A third array 3030C may comprise continuous bond
sites and enclose a fourth array 3040C. The fourth array 3040C
comprises a plurality of discontinuous bond sites. Much like the
bond patterns discussed previously, the bond pattern 3000C may
provide fluid handling benefits.
[0104] As shown in FIG. 69, a bond pattern 3000D may comprise a
plurality of arrays of bond sites. For example, a first array 3010D
may comprise a plurality of bond sites which are arranged in a
continuous fashion and may enclosed a second array 3020D, a third
array 3030D and a fourth array 3040D of bond sites. The second
array 3020D may comprise a plurality of bond sites which form
continuous elements as well as a plurality of bond sites which form
discontinuous elements. These continuous elements may be disposed
at a first end and second end of the absorbent article. The third
array 3030D of plurality of bond sites may be continuous and may
enclosed the fourth array 3040D. The fourth array 3040D may
comprise a plurality of bond sites which form a plurality of
elements. Each of the elements may be continuous but discontinuous
with respect to the other elements. For example, each element may
comprise a plurality of bond sites, e.g. 4. The bond sites would be
considered continuous for each respective element, but the bond
sites from element to element would be discontinuous.
Color
[0105] Any of the layers of the apertured webs may have a color
that is the same or different than another layer of the apertured
web, regardless of whether a layer is apertured or non-apertured.
For instance, in a two layer apertured web, a first layer may be
blue and a second layer may be white, or a first layer may be dark
blue and the second layer may be light blue. There may be a Delta E
difference between at least some of the layers. The layers may also
have the same opacity or a different, as described in further
detail below.
[0106] Either in addition to or in lieu of the various layers being
colored, referring to FIG. 9, one or more of the layers of the
apertured webs 10 of the present disclosure may include printing
32, e.g., with ink or a pigmented or colored pattern. The ink may
be deposited via any printing process known in the art including,
but not limited to, flexographic printing and digital inkjet
printing. The printing may comprise a pattern or a plurality of
patterns which form graphics and/or other depictions, hereafter,
"printed indicia." The printing may be on an external surface of a
first layer 34 of the apertured web 10, between the first and
second layers 34, 36 (as illustrated) of the apertured web 10, or
may be on a surface beneath the second layer 36 of the apertured
web 10. The printing may also be situated in any suitable location
if the apertured web has more than two layers (e.g., on the surface
of any of the layers). The printing may also be deposited in zones
of the apertured web and/or in patterns throughout the apertured
web. The printing may be different or the same in different zones
of the apertured web. If the printing will be covered by one of the
layers (e.g., layer 34), the covering layer (e.g., layer 34) may
have a relatively low opacity to enhance the visual appearance of
the printing. The density of the printing (e.g., clarity and
contrast) may be enhanced by including small-denier fibers in the
printed layer including, but not limited to, melt-blown fibers,
microfibers, and nanofibers. The printing 32 may be on the first
layer 34, the second layer 36, and/or may be on a separate layer
positioned at least partially intermediate the first and second
layers 34 and 36. In an instance, the printing may indicate the
proper orientation of an absorbent article on a wearer (e.g.,
front/rear). It will be understood that printing may be used with
any of the various forms and configurations of the apertured webs
disclosed herein. In some forms, more than one type or color, for
example, of printing may be used in a single apertured web.
Additional layers may also be provided in a pattered apertured web
having one or more printed patterns. For those forms of the present
invention comprising a single layer apertured web, the apertured
web may comprise printing and/or be pigments as described
herein.
[0107] Either in addition to or in lieu of the various layers being
colored and/or having printing, referring to FIG. 10, the apertured
webs may comprise a colored adhesive 38 or other colored substance
(hereinafter "colored adhesive"). The colored adhesive 38 may
include a pigment, a tint, or a dye, for example. The colored
adhesive, in a form, may be positioned between a first layer 40 and
second layer 42 of an apertured web 10. In some forms, more than
one colored adhesive may be used in a single apertured web. The
colored adhesive may also be situated in any suitable location if
the apertured web has more than two layers (e.g., on the surface of
or intermediate any of the layers). The colored adhesive may also
be deposited in zones of the apertured web and/or in patterns
throughout the apertured web. The colored adhesive may be different
or the same in different zones of the apertured web. The colored
adhesive may be positioned intermediate the two layers 40, 42 or
positioned on any other surfaces of the layers 40, 42. Additional
layers may also be provided in a apertured web having one or more
colored adhesives. As stated previously, adhesive and particularly
colored adhesive may be applied such that the adhesive forms a
pattern or a plurality of patterns which form graphics and/or other
depictions, referred to as "adhesive indicia." Adhesive indicia are
discussed in additional detail hereafter.
[0108] In an instance, a colored adhesive may be positioned between
two low basis weight materials (e.g., 15 gsm or less, 10 gsm or
less) forming an apertured web, so that the colored adhesive may be
visible from either side of the apertured web. In a laminate
topsheet context, this can provide a high basis weight topsheet to
achieve improved softness, while still retaining the benefit of
seeing the colored adhesive from either side of the apertured
web.
[0109] In some forms of the present invention, adhesive indicia may
be created from non-colored adhesive. In some forms of the present
invention, the provision of clear adhesive can change the
appearance of the apertured web. For example, in such forms, the
provision of clear adhesive can make the web appear more opaque
and/or more dense in the area of adhesive application. As such, the
provision of adhesive--whether colored or non-colored (clear)--can
form adhesive indicia. As an example, a disposable absorbent
article of the present invention may comprise adhesive indicia
which comprises a plurality of discrete adhesive bond sites which
may comprise a combination of non-colored (clear) adhesive and/or
colored adhesive.
Structures
[0110] Apertured webs described herein may additionally comprise an
array of structures. For example, a first portion of the apertured
web may comprise an array of apertures as described herein while a
second portion comprises an array of structures. The structures may
be those shown in FIGS. 38A-38B. For example, as shown in FIG. 38A,
an apertured web 1700 of the present invention may comprise a
looped nonwoven tuft 1770 or any array thereof. As shown, the
apertured web 1700 comprises a first nonwoven layer 1710 and a
second nonwoven layer 1750. The first nonwoven layer 1710 comprises
a generally planar first surface 1715 and a generally planar second
surface 1720 opposed to the first surface 1715, and the second
nonwoven layer 1750 has a generally planar first surface 1755 and a
generally planar second surface 1760. The first nonwoven layer 1710
comprises a first plurality of substantially randomly oriented
fibers, and the second nonwoven layer 1750 comprises a second
plurality of substantially randomly oriented fibers. At least a
portion of the second plurality of fibers in the second nonwoven
layer 1750 is in liquid communication with the first nonwoven layer
710. The respective surfaces of the first nonwoven layer 1710 and
second nonwoven layer 1750, can be arranged such that the first
surfaces 1715 and 1755, respectively, are body-facing surfaces, and
the second surfaces 1720 and 1760, respectively, can be arranged as
garment-facing surfaces.
[0111] As shown in FIG. 38A, the second surface 1720 of the first
nonwoven layer 1710 may comprise a first discontinuity 1735. The
first discontinuity 1735 may be formed when localized areas of
constituent fibers of the first nonwoven layer 1710 are urged in
the Z-direction such that these constituent fibers are disposed
superjacent to the first surface 1715 of the first nonwoven layer
1710. The urging in the Z-direction of the constituent fibers of
the first nonwoven layer 1710 may be such that a plurality of
fibers break thereby forming the first discontinuity 1735.
[0112] As shown, the second surface 1760 of the second nonwoven
layer 1750 may comprise a second discontinuity 1775. With regard to
the second discontinuity 1775, localized areas of constituent
fibers of the second nonwoven layer 750 are urged in the
Z-direction such that these constituent fibers are disposed
superjacent to a plane of the first surface 1755 of the second
nonwoven layer 1750. This Z-direction urging also forces these
constituent fibers to extend through the first of discontinuity
1735 in the second surface 1720 of the first nonwoven layer 1710.
The extension of the constituent fibers of the second nonwoven
layer 1750 forms a tufts 1770.
[0113] With regard to FIG. 38B, the nonwoven web 1700 may be
configured as shown. Namely, as shown, the first surface 1715 of
the first nonwoven layer 1710 may comprise the first discontinuity
1735. The first discontinuity 1735 in the embodiment shown in FIG.
38B, is formed when localized areas of constituent fibers of the
first nonwoven layer 1710 are urged in the negative Z-direction
such that these constituent fibers are disposed subjacent to the
first surface 1715 of the first nonwoven layer 1710 thereby forming
the tuft 1770. In some embodiments, the tuft 1770 may extend beyond
the second surface 1760 of the second nonwoven layer 1750 such that
at least a portion of the tuft 1770 is subjacent to the second
surface 1760.
[0114] As shown, in some embodiments, the tuft 1770 may extend
through the second discontinuity 1775. The second discontinuity
1775 may be created when localized areas of constituent fibers of
the second nonwoven layer 1750 are urged in the negative
Z-direction such that these constituent fibers are disposed
subjacent to the first surface 1755 of the second nonwoven layer
1750. The urging in the negative Z-direction of the constituent
fibers of the second nonwoven layer 1750 may be such that a
plurality of fibers break thereby forming the second discontinuity
1775.
[0115] Tufts 1770 can comprise a plurality of looped fibers that
are substantially aligned such that each of the tufts 1770 have a
distinct linear orientation and a longitudinal axis L. By "looped"
fibers it is meant to refer to fibers of the tufts 1770 that are
integral with and begin and end in the second layer 1750 but extend
generally outwardly in the Z-direction from the first surface 1755
of the second layer 1750 and extend beyond the first surface 1715
of the first layer 1710. Similar orientations are contemplated for
the tufts 1770 formed by the first layer 1710.
[0116] The tufts 1770 described herein may have longitudinal axes
generally aligned in the MD. However, tufts 1770 and, therefore,
longitudinal axes L, can, in principle, be aligned in any
orientation with respect to the MD or CD. Therefore, in general, it
can be said that for each tuft 1770, the looped aligned fibers are
aligned generally orthogonal to the longitudinal axis L such that
they have a significant vector component parallel to transverse
axis and can have a major vector component parallel to the
transverse axis.
[0117] As described below, another characteristic of tufts 1770 can
be their generally open structure characterized by open void area
defined interiorly of tufts 1770. The void area may have a shape
that is wider or larger at a distal portion of the tuft 1770 and
narrower at the tuft base of the tuft 270. This is opposite to the
shape of the tooth which is used to form the tuft 270 which is
discussed hereafter. The term "void area" is not meant to refer to
an area completely free of any fibers. Rather, the term is meant as
a general description of the general appearance of tufts 1770.
[0118] These structures described with regard to FIGS. 38A-38B are
similarly applicable to those apertured webs which comprise a
plurality of substrates in addition to those apertured webs which
comprise a plurality of layers.
[0119] The structures disclosed herein may be provided in arrays or
a plurality thereof. Such arrays of structures or plurality of
arrays of structures may comprise a pattern or a plurality of
patterns which form graphics and/or other depictions, hereafter,
"structural indicia." Additional forms are contemplated where the
structures described herein may be utilized in any combination.
[0120] The structures described herein can aid in fluid management
as well as provide a comfortable feel to the user. For example,
those structures, e.g. tufts 1770 oriented in the Z-direction can
provide a user with a soft feel. As another example, those
structures, e.g. tufts 1770 oriented in the negative Z-direction
can provide fluid management benefits.
[0121] Forms of the present invention are contemplated, where the
constituent material of either the first layer or second layer does
not break upon the Z-direction urging mentioned heretofore. In such
forms, inner tufts 1770 and outer tufts may be created. Some
examples of suitable structures and their method of manufacture are
described in U.S. Pat. Nos. 7,172,801; 7,838,099; 7,754,050;
7,682,686; 7,410,683; 7,507,459; 7,553,532; 7,718,243; 7,648,752;
7,732,657; 7,789,994; 8,728,049; and 8,153,226.
[0122] Other suitable structures can include ridges/grooves. Such
structures and processes for producing ridges and/or grooves are
disclosed in U.S. Pat. Nos. 6,458,447; 7,270,861; 8,502,013;
7,954,213; 7,625,363; 8,450,557; and 7,741,235. Additional suitable
processes and structures are described in US Patent Application
Publication Nos. US2003/018741; US2009/0240222; US2012/0045620;
US20120141742; US20120196091; US20120321839; US2013/0022784;
US2013/0017370; US2013/013732; US2013/0165883; US2013/0158497;
US2013/0280481; US2013/0184665; US2013/0178815; and
US2013/0230236700. Still additional suitable processes and
structures are described with regard to PCT Patent Application
Publication Nos. WO2008/156075; WO2010/055699; WO2011/125893;
WO2012/137553; WO2013/018846; WO2013/047890; and WO2013/157365.
[0123] Other suitable structures include nubs. Some suitable
processes for creating nubs on a web and the resulting structures
are described in U.S. Pat. Nos. 7,713,683; 6,852,475; 7,303,861;
8,057,729; 8,287,800; and U.S. Patent Application Publication No.
2004/0121120.
[0124] Additional structures include embossing. Embossing of
absorbent articles generally results in thinned out areas in the
absorbent article. Embossing, similar to fusion bonding, involves
the manipulation of material in a first layer and a second layer in
the positive and/or negative Z-direction. Generally, embossing does
not result in the fusion of layers. Unlike fusion bonds, embossing
typically results in macro depressions in an absorbent article.
Embossing is further discussed in U.S. Pat. Nos. 8,496,775 and
8,491,742.
Opacity
[0125] The opacity of at least one of the layers of an apertured
web may differ from the opacity of the other layers of the
apertured web. In some instances, the layer of the apertured web
closest to an external observer may have a lower opacity than an
underlying layer in order to maximize observable contrast
differences between the layers and/or to observe printing or
colored adhesives.
[0126] Alternatively, the layer of the apertured web closest to an
external observer may have a higher opacity than an underlying
layer in order to more effectively mask bodily exudates (e.g.,
urine, menses, or BM) or to provide for greater color contrast with
the layers below. When an apertured web is used as a
fluid-permeable topsheet, the layer closest to an external observer
would be the wearer-facing surface. In a form, where the apertured
web is located on the external surface of an absorbent article
(e.g., an outer cover, fastening system element, stretch ear, belt,
or side panel), the layer closest to an external observer would be
the garment-facing surface. For example, the opacity of a
non-apertured layer may be lower than that of an apertured layer,
or vice versa, depending on the specific orientation of an
apertured web in an absorbent article.
[0127] An apertured web may have a high opacity. This enables an
aperture pattern to be more easily distinguished, provides contrast
to any colors and materials underneath, and in the case of a diaper
topsheet or a sanitary napkin topsheet, masks the presence of
bodily fluids contained within the absorbent core, providing a
cleaner appearance to the wearer. To achieve this benefit,
opacities of about 30, about 40, about 50, or about 60 may be
desired. In some forms of the present invention, opacities may
range from about 40-100 or from about 50-90, specifically reciting
all values within these ranges and any ranges created thereby.
[0128] Increases in opacity can be achieved via any known suitable
product/process. Some suitable examples include adding fillers
(e.g. TiO2), fiber shape (e.g. Trilobal vs. round), smaller fiber
diameters (including microfibers and/or nano fibers), etc. A
specific example of nonwoven web having high opacity is an SMS
(spunbond, meltblown, spunbond) or an SMNS (spunbond, meltblown,
nano fiber, spunbond) construction. Another specific example is a
nonwoven comprising nano fibers, such as those produced by melt
film fibrillation as described in U.S. Pat. No. 8,487,156 and U.S.
Patent Application Publication No. 2004/0266300. In one specific
example, the web of the invention may comprise a layer having
meltblown and nanofibers--SMNS construction.
Components of Absorbent Articles
[0129] The apertured webs of the present disclosure may be used as
components of absorbent articles. More than one apertured web may
be used in a single absorbent article. In such a context, the
apertured webs may form at least a portion of: a topsheet; a
topsheet and an acquisition layer; a topsheet and a distribution
layer; an acquisition layer and a distribution layer; a topsheet,
an acquisition layer, and a distribution layer; an outer cover; a
backsheet; an outer cover and a backsheet, wherein a film
(non-apertured layer) of the apertured web forms the backsheet and
a nonwoven material forms the outer cover; a leg cuff; an ear or
side panel; a fastener; a waist band; or any other suitable portion
of an absorbent article. The apertured webs may take on different
configurations and patterns of land and aperture areas depending on
their particular use in an absorbent article. The number of layers
in a apertured web may also be determined by the apertured webs'
particular use.
[0130] As referenced above, any of the apertured webs of the
present disclosure may be disposed on an external surface of the
absorbent article (i.e., the outer cover or garment
facing-surface). In such an instance, the aperture arrays,
patterns, or properties of the same may be the same or different in
different regions of the external surface. In one outer cover form,
effective aperture areas and effective open areas may be higher in
a waist region than in a crotch region of the outer cover for
better breathability. In another outer cover form, the waist
regions may include aperture arrays, while the crotch region
comprises more uniform aperture patterns. In each of these forms,
the effective aperture area and effective open area, or apertures
arrays may provide higher air porosity in the waist region than in
the crotch region, allowing more sweat evaporation and better
breathability in the tightly occluded waist area
Feminine Hygiene Products
[0131] The apertured webs may also be used as components of
absorbent articles, such as feminine hygiene products, including
sanitary napkins, liners, and tampons. More than one apertured web
may be used in a single feminine hygiene product. In a sanitary
napkin context, the apertured webs may form at least a portion of:
a topsheet; a topsheet and an acquisition layer; a topsheet and a
distribution layer; a topsheet and a secondary topsheet; a
backsheet; an outer cover; an outer cover and a backsheet; wings;
wings and a topsheet or a backsheet; a covering for a tampon; or
any other suitable portion of a feminine hygiene product. The
apertured webs may take on different configurations and patterns of
land and aperture areas depending on their particular use in a
feminine hygiene product. The number of layers in an apertured web
may also be determined by the apertured webs' particular use. The
use of the apertured web in a feminine hygiene article is further
disclosed with regard to FIG. 33.
Other Consumer Products
[0132] The apertured webs may also be used as components of
absorbent articles, such as cleaning substrates, dusting
substrates, and/or wipes. More than one apertured web may be used
in a single cleaning or dusting substrate and/or a single wipe. The
apertured webs may take on different configurations and patterns of
land and aperture areas depending on their particular use in a
cleaning substrate, dusting substrate, and/or a wipe. The number of
layers in a apertured web may also be determined by the apertured
webs' particular use.
Physical Characteristics
[0133] The apertured webs of the present disclosure may take on
different physical characteristics depending on their intended or
desired use in absorbent articles, feminine hygiene products,
cleaning substrates, dusting substrates, wipes, or other consumer
products. For instance, the properties of density, basis weight,
aperture pattern, land area pattern, caliper, opacity,
three-dimensionality, and/or elasticity, for example, may be varied
depending on the desired use of the apertured web. More than one
apertured web may be combined with other, similar or different,
apertured webs in some instances for certain design criteria.
Method of Making
[0134] The apertured webs of the present disclosure may be made
generally by using the process generally described in U.S. Pat. No.
5,628,097 entitled "Method for Selectively Aperturing a Nonwoven
Web" which issued May 13, 1997 and U.S. Patent Publication
2003/0021951 entitled "High Elongation Apertured Nonwoven Web and
Method of Making" which published Jan. 20, 2003. Additional
references include U.S. Pat. Nos. 5,658,639; 5,916,661; and
7,917,985. This process is described in further detail below.
Additional processes such as hydroforming carded webs, laser
cutting, punching, hot pin, etc. are contemplated. These processes
are generally known in the art.
[0135] Referring to FIG. 11 there is schematically illustrated at
100 one process for forming the apertured webs of the present
disclosure. First, a precursor material 102 is supplied as the
starting material. The precursor material 102 can be supplied as
discrete webs, e.g. sheets, patches, etc. of material for batch
processing. For commercial processing, however, the precursor
material 102 may be supplied as roll stock, and, as such it can be
considered as having a finite width and an infinite length. In this
context, the length is measured in the machine direction (MD).
Likewise, the width is measured in the cross machine direction
(CD).
[0136] The precursor material 102 may be one or more nonwoven
materials (same or different), one or more films (same or
different), a combination of one or more nonwoven materials and one
or more films, or any other suitable materials or combinations
thereof. The precursor material 102 may be purchased from a
supplier and shipped to where the apertured webs are being formed
or the precursor material 102 formed at the same location as where
the apertured web are being produced. The precursor material 102
may be extensible, elastic, or nonelastic. Further, the precursor
material 102 may be a single layer material or a multilayer
material. In an instance, the precursor material 102 may be joined
to a polymeric film to form a laminate.
[0137] The precursor material 102 may comprise or be made of
mono-component, bi-component, multi-constituent blends, or
multi-component fibers comprising one or more thermoplastic
polymers. In an example, the bi-component fibers of the present
disclosure may be formed of a polypropylene core and a polyethylene
sheath. Further details regarding bi-component or multi-component
fibers and methods of making the same may be found in U.S. Patent
Application Publ. No. 2009/0104831, published on Apr. 23, 2009,
U.S. Pat. No. 8,226,625, issued on Jul. 24, 2012, U.S. Pat. No.
8,231,595, issued on Jul. 31, 2012, U.S. Pat. No. 8,388,594, issued
on Mar. 5, 2013, and U.S. Pat. No. 8,226,626, issued on Jul. 24,
2012. The various fibers may be sheath/core, side-by-side, islands
in the sea, or other known configurations of fibers. The fibers may
be round, hollow, or shaped, such as trilobal, ribbon, capillary
channel fibers (e.g., 4DG). The fibers may comprise microfibers or
nanofibers.
[0138] The precursor material 102 may be unwound from a supply roll
104 and travel in a direction indicated by the arrow associated
therewith as the supply roll 104 rotates in the direction indicated
by the arrow associated therewith. The precursor material 102
passes through a nip 106 of a weakening roller (or overbonding)
arrangement 108 formed by rollers 110 and 112, thereby forming a
weakened precursor material. The weakened precursor material 102
has a pattern of overbonds, or densified and weakened areas, after
passing through the nip. At least some of, or all of, these
overbonds are used to form apertures in the precursor material 102.
Therefore, the overbonds correlate generally to the patterns of
apertures created in the precursor material 102.
[0139] Referring to FIG. 12, the precursor material weakening
roller arrangement 108 may comprises a patterned calendar roller
110 and a smooth anvil roller 112. One or both of the patterned
calendar roller 110 and the smooth anvil roller 112 may be heated
and the pressure between the two rollers may be adjusted by known
techniques to provide the desired temperature, if any, and pressure
to concurrently weaken and melt-stabilize (i.e., overbond) the
precursor material 102 at a plurality of locations 202. As will be
discussed in further detail below, after the precursor material 102
passes through the weakening roller arrangement 108, the precursor
material 102 may be stretched in the CD, or generally in the CD, by
a cross directional tensioning force to at least partially, or
fully, rupture the plurality of weakened, melt stabilized locations
202, thereby creating a plurality of at least partially formed
apertures in the precursor material 102 coincident with the
plurality of weakened, melt stabilized locations 202.
[0140] The patterned calendar roller 110 is configured to have a
cylindrical surface 114, and a plurality of protuberances or
pattern elements 116 which extend outwardly from the cylindrical
surface 114. The pattern elements 116 are illustrated as a
simplified example of a patterned calendar roller 110, but more
detailed patterned calendar rollers that can be used to produce
apertured webs of the present disclosure will be illustrated in
subsequent figures. The protuberances 116 may be disposed in a
predetermined pattern with each of the protuberances 116 being
configured and disposed to precipitate a weakened, melt-stabilized
location in the precursor material 102 to affect a predetermined
pattern of weakened, melt-stabilized locations 202 in the precursor
material 102. The protuberances 116 may have a one-to-one
correspondence to the pattern of melt stabilized locations in the
precursor material 102. As shown in FIG. 12, the patterned calendar
roller 110 may have a repeating pattern of the protuberances 116
which extend about the entire circumference of surface 114.
Alternatively, the protuberances 116 may extend around a portion,
or portions of the circumference of the surface 114. Also, a single
patterned calendar roller may have a plurality of patterns in
various zones (i.e., first zone, first pattern, second zone, second
pattern).
[0141] A photograph of an exemplary roller that may be used as
patterned calendar roller 110 in the process 100 of FIG. 11 to
produce the apertured webs of the present disclosure are
illustrated in FIG. 13. The pattern of protuberances 116 on the
rollers in FIG. 13 would be formed in the precursor web 102, much
like the melt-stabilized locations 202 of FIG. 12. Exemplary
apertured webs produced from the various rolls after
cross-directional tensioning of the precursor material 102 are
illustrated in FIGS. 14, 15, and 16, with the apertures being
indicated as element 204 and the land areas (i.e., non-apertured
areas) being indicated as element 205. As seen in FIGS. 14, 15, and
16, apertures 204 and/or aperture arrays have been formed in the
webs 102. The land areas 205 in FIGS. 14, 15, and 16 correspond to
areas in the precursor material 102 that have not been melt
stabilized or overbonded. Stated another way, the land areas have
not been contacted by a protuberance on the roller 110.
[0142] The protuberances 116 may extend radially outwardly from
surface 114 and have distal end surfaces 117. The anvil roller 112
may be a smooth surfaced, circular cylinder of steel, rubber or
other material. The anvil roller 112 and the patterned calendar
roller 110 may be switched in position (i.e., anvil on top) and
achieve the same result.
[0143] From the weakening roller arrangement 108, the material 102
passes through a nip 130 formed by an incremental stretching system
132 employing opposed pressure applicators having three-dimensional
surfaces which at least to a degree may be complementary to one
another.
[0144] Referring now to FIG. 17, there is shown a fragmentary
enlarged view of the incremental stretching system 132 comprising
two incremental stretching rollers 134 and 136. The incremental
stretching roller 134 may comprise a plurality of teeth 160 and
corresponding grooves 161 which may about the entire circumference
of roller 134. The incremental stretching roller 136 may comprise a
plurality of teeth 162 and a plurality of corresponding grooves
163. The teeth 160 on the roller 134 may intermesh with or engage
the grooves 163 on the roller 136 while the teeth 162 on the roller
136 may intermesh with or engage the grooves 161 on the roller 134.
As the precursor material 102 having weakened, melt-stabilized
locations 202 passes through the incremental stretching system 132
the precursor material 102 is subjected to tensioning in the CD
causing the material 102 to be extended (or activated) in the CD,
or generally in the CD. Additionally the material 102 may be
tensioned in the MD, or generally in the MD. The CD tensioning
force placed on the material 102 is adjusted such that it causes
the weakened, melt-stabilized locations 202 to at least partially,
or fully, rupture thereby creating a plurality of partially formed,
or formed apertures 204 coincident with the weakened
melt-stabilized locations 202 in the material 102. However, the
bonds of the material 102 (in the non-overbonded areas) are strong
enough such that they do not rupture during tensioning, thereby
maintaining the material 102 in a coherent condition even as the
weakened, melt-stabilized locations rupture. However, it may be
desirable to have some of the bonds rupture during tensioning.
[0145] Referring to FIG. 18, a more detailed view of the teeth 160
and 162 and the grooves 161 and 163 on the rollers 134 and 136 is
illustrated. The term "pitch" refers to the distance between the
apexes of adjacent teeth. The pitch may be between about 0.02
inches to about 0.30 inches (about 0.51 mm to about 7.62 mm) or may
be between about 0.05 inches and about 0.15 inches (about 1.27 mm
to about 3.81 mm), specifically reciting all 0.001 inch increments
within the above-specified ranges and all ranges formed therein or
thereby. The height (or depth) of the teeth is measured from the
base of the tooth to the apex of the tooth, and may or may not be
equal for all teeth. The height of the teeth may be between about
0.010 inches (about 0.254 mm) and about 0.90 inches (about 22.9 mm)
or may be between about 0.025 inches (about 0.635 mm) and about
0.50 inches (about 12.7 mm), specifically reciting all 0.01 inch
increments within the above-specified ranges and all ranges formed
therein or thereby. The teeth 160 in one roll may be offset by
about one-half of the pitch from the teeth 162 in the other roll,
such that the teeth of one roll (e.g., teeth 160) mesh in the
valley (e.g., groove 163) between teeth in the mating roll. The
offset permits intermeshing of the two rolls when the rolls are
"engaged" or in an intermeshing, operative position relative to one
another. The teeth of the respective rolls may only be partially
intermeshing in some instances. The degree to which the teeth on
the opposing rolls intermesh is referred to herein as the "depth of
engagement" or "DOE" of the teeth. The DOE may be constant or not
constant. As shown in FIG. 18, the DOE, indicated as "E", is the
distance between a position designated by plane P1 where the apexes
of the teeth on the respective rolls are in the same plane (0%
engagement) to a position designated by plane P2 where the apexes
of the teeth of one roll extend inward beyond the plane P1 toward
the groove on the opposing roll. The optimum or effective DOE for
particular laminate webs may be dependent upon the height and the
pitch of the teeth and/or the structure of the material. Some
example DOEs may in the range of about 0.01 inches to about 0.5
inches, about 0.03 inches to about 0.2 inches, about 0.04 inches to
about 0.08 inches, about 0.05 inches, or about 0.06 inches,
specifically reciting all 0.001 inch increments within the
above-specified ranges and all ranges formed therein or
thereby.
[0146] As the material 102 having the weakened, melt-stabilized
locations 202 passes through the incremental web stretching
apparatus 132, the material 102 is subjected to tensioning in the
cross machine direction, or substantially in the cross machine
direction, thereby causing the nonwoven web 102 to be extended in
the cross machine direction. The tensioning force placed on the
material 102 may be adjusted by varying the pitch, DOE, or teeth
size, such that the incremental stretching is sufficient to cause
the weakened, melt-stabilized locations 202 to at least partially,
or fully rupture, thereby creating, or at least partially creating,
a plurality of apertures 204 coincident with the weakened,
melt-stabilized locations 202 in the material 102.
[0147] After the material 102 passes through the incremental web
stretching apparatus 132, the web 102 may be advanced to and at
least partially around a cross machine directional tensioning
apparatus 132' (see e.g., FIGS. 11 and 19). The cross machine
directional tensioning apparatus 132' may be offset from the main
processing line by running the web partially around two idlers 133
and 135 or stationary bars, for example. In other instances, the
cross machine tensioning apparatus 132' may be positioned in line
with the main processing line. The cross machine directional
tensioning apparatus 132' may comprise a roll that comprises at
least one outer longitudinal portion that expands along a
longitudinal axis, A, of the roll, relative to a middle portion of
the roll, to stretch and/or expand the material 102 in the cross
machine direction. Instead of or in addition to expanding along the
longitudinal axis, A, of the roll, the outer longitudinal portion
may be angled relative to the longitudinal axis, A, of the roll in
a direction away from the material 102 being advanced over the roll
to stretch the material 102 in the cross machine direction or
generally in the cross machine direction. In an instance, the roll
may comprise two outer longitudinal portions that each may expand
in opposite directions generally along the longitudinal axis, A, of
the roll. The two outer portions may both be angled downwards in a
direction away from the material 102 being advanced over the roll.
This movement or positioning of the outer longitudinal portions of
the roll allows for generally cross machine directional tensioning
of the material 102, which causes the plurality of weakened
locations 202 to rupture and/or be further defined or formed into
apertures 204.
[0148] The outer longitudinal portions of the roll may comprise
vacuum, a low tack adhesive, a high coefficient of friction
material or surface, such as rubber, and/or other mechanisms and/or
materials to hold the material 102 to the outer lateral portions of
the roll during movement of the outer longitudinal portion or
portions relative to the middle portion of the roll. The vacuum,
low tack adhesive, high coefficient of friction material or
surface, and/or other mechanisms and/or materials may prevent, or
at least inhibit, the held portions of the material 102 from
slipping relative to the longitudinal axis, A, of the roll during
stretching of the outer lateral portions of the material in the
cross machine direction or generally in the cross machine
direction.
[0149] FIG. 19 is a top perspective view of the example cross
machine directional tensioning apparatus 132'. The cross machine
directional tensioning apparatus 132' may comprise a roll
comprising a middle portion 2000 and two outer longitudinal
portions 2020 situated on either end of the middle portion 2000.
The roll may rotate about its longitudinal axis, A, on a drive
shaft 2040. The roll may rotate relative to the drive shaft 2040 or
in unison with the drive shaft 2040, as will be recognized by those
of skill in the art. The material 102 may be advanced over the
entire cross machine directional width of the middle portion 2000
and at least portions of the cross machine directional widths of
the outer longitudinal portions 2020. The material 102 may be
advanced over at least about 5% up to about 80% of the
circumference of the roll so that the cross machine directional
stretching may be performed.
[0150] FIG. 20 is a schematic representation of a front view of an
example cross machine directional tensioning apparatus with outer
longitudinal portions 2020 in an unexpanded or non-angled position
relative to the middle portion 2000. FIG. 21 is a schematic
representation of a front view of the cross machine directional
tensioning apparatus of FIG. 20 with the outer longitudinal
portions 2020 in a longitudinally expanded position relative to the
middle portion 2000.
[0151] FIG. 22 is a schematic representation of a front view of the
cross machine directional tensioning apparatus of FIG. 20 with the
outer longitudinal portions 2020 in an angled and expanded position
relative to the middle portion 2000. In regard to FIG. 22, the
outer longitudinal portions 2020 may merely move or slide in a
direction generally perpendicular to the machine direction of the
material passing over the roll to apply the cross machine
directional tensioning force to the material 102.
[0152] FIG. 23 is a schematic representation of a front view of a
cross machine directional tensioning apparatus with the outer
longitudinal portions 2020 fixed in an angled position relative to
the middle portion 2000 to apply the cross machine directional
tensioning force to the material 102. In such a form, the middle
portion 2000 and each of the outer longitudinal portions 2020 may
comprise a separate roll.
[0153] Regardless of whether one or both of the outer longitudinal
portions 2020 is moved, slid, rotated, fixed, and/or expanded
relative to the middle portion 2000, this relative motion or
positioning between the outer longitudinal portions 2020 and the
middle portion 2000 stretches the materials 102 in a cross machine
direction to further rupture or further define the weakened
locations 2020 in the material 102 and create, or further form, a
plurality the apertures 2040 the material 102. The cross machine
directional tensioning force applied by the cross machine
directional tensioning apparatus 132' may be, for example, 10-25
grams or 15 grams. In an instance, the cross machine directional
tensioning apparatus may be similar to, or the same as, the
incremental stretching apparatus 132 to apply the cross machine
directional tensioning force. In still other instances, any
suitable cross machine directional tensioning apparatus may be used
to apply the cross machine directional tensioning force to the
material 102.
[0154] If desired, the incremental stretching step or the cross
machine directional stretching step described herein may be
performed at elevated temperatures. For example, the material 102
and/or the rolls may be heated. Utilizing heat in the stretching
step may serve to soften the material, and may aid in extending the
fibers without breaking.
[0155] Referring again to FIG. 11, the material 102 may be taken up
on wind-up roll 180 and stored. Alternatively, the material 102 may
be fed directly to a production line where it is used to form a
portion of an absorbent article or other consumer product.
[0156] It is important to note that the overbonding step
illustrated in FIGS. 11 and 12 could be performed by the material
supplier and then the material may be shipped to a consumer product
manufacturer to perform step 132. In fact, the overbonding step may
be used in the nonwoven production process to form overbonds, which
may be in addition to, or in lieu of, primary bonds formed in the
nonwoven production process. Alternatively, the material supplier
may fully perform the steps illustrated in FIG. 11 and then the
material may be shipped to the consumer product manufacturer. The
consumer product manufacturer may also perform all of the steps in
FIG. 11 after obtaining a nonwoven material from a nonwoven
material manufacturer.
[0157] One of ordinary skill in the art will recognize that it may
be advantageous to submit the material 102 to multiple incremental
stretching processes depending on various desired characteristics
of the finished product. Both the first and any additional
incremental stretching may either be done on-line or off-line.
Furthermore, one of ordinary skill will recognize that the
incremental stretching may be done either over the entire area of
the material or only in certain regions of the material depending
on the final desired characteristics.
[0158] Returning now to FIGS. 14, 15, and 16, there is shown
photographs of example apertured webs after having been subjected
to the tensioning force applied by the incremental stretching
system 132 and the cross machine directional tensioning apparatus
132'. As can be seen in the photographs of FIGS. 14, 15, and 16,
the apertured webs now include a plurality of apertures 204 which
are coincident with the weakened, melt-stabilized locations made by
the rolls 17-19, respectively. A portion of the circumferential
edges of an aperture 204 may include remnants of the
melt-stabilized locations. It is believed that the remnants help to
resist further tearing of the material particularly when the
material is used as a portion of an absorbent article or another
consumer product.
Percent of CD Stretch
[0159] The extent to which the material 102 is stretched in the CD
may have a correlation to the size, shape, and area of the
apertures. In general, the apertures may have a larger area and be
more open the more the material 102 is stretched in the CD
direction by the cross machine directional tensioning apparatus
132'. As such, a manufacturer can further vary an aperture pattern
based on the amount of CD tensioning applied to a material even
when the melt-stabilized pattern in the material is the same. As an
example, FIG. 24 illustrates an overbond pattern in a material 102
prior to the incrementally stretching step 132 and the cross
machine directional tension step 132. The plurality of melt
stabilized locations are indicated as 202. The material is then run
through the incrementally stretching step 132 and the cross machine
directional tensioning apparatus 132'. The cross machine
directional tensioning apparatus 132' may be set to extend the
material 102 to over 100% of its CD width "W" after exiting the
incremental stretching apparatus 132, such as 125%, 135%, 145%,
155% of W. In other instances, the material 102 may be stretched in
the cross machine direction in the range of about 110% to about
180% of W, about 120% to about 170% of W, specifically reciting all
0.5% increments within the specified ranges and all ranged formed
therein or thereby. FIG. 25 illustrates an example of the material
102 with the overbond pattern of FIG. 24 and stretched to 125% of
W. FIG. 26 illustrates an example of the material 102 with the
overbond pattern of FIG. 24 and stretched to 135% of W. FIG. 27
illustrates an example of the material 102 with the overbond
pattern of FIG. 24 and stretched to 145% of W. FIG. 28 illustrates
an example of the material 102 with the overbond pattern of FIG. 24
and stretched to 155% of W. As illustrated, the amount of CD
stretch can be a significant factor on the apertured web
produced.
[0160] Other suitable processes for forming apertures in a web are
described in U.S. Pat. Nos. 8,679,391 and 8,158,043, and U.S.
Patent Application Publication Nos. 2001/0024940 and 2012/0282436.
Other suitable processes are described in U.S. Pat. Nos. 3,566,726;
4,634,440; and 4,780,352.
Absorbent Article
[0161] As described herein, the apertured webs of the present
disclosure may be used as one or more components of an absorbent
article. An example absorbent article is set forth below. FIG. 29
is a plan view of an example absorbent article that is a diaper 520
in its flat-out, uncontracted state (i.e., with elastic induced
contraction pulled out) with portions of the structure being
cut-away to more clearly show the construction of the diaper 520
and with the portion of the diaper 520 which faces the wearer, the
inner surface 540, facing the viewer. The diaper 520 may comprise a
chassis 522 comprising a liquid pervious topsheet 524, a liquid
impervious backsheet 526 joined to the topsheet, and an absorbent
core 528 positioned at least partially between the topsheet 524 and
the backsheet 526. The diaper 520 may comprise elasticized side
panels 530, elasticized leg cuffs 532, elasticized waistbands 534,
and a fastening system 536 that may comprise a pair of securement
members 537 and a landing member (not illustrated) on a
garment-facing surface or outer surface 542. The diaper 520 may
also comprise an outer cover 533 that may comprise one or more of
the patterned adhesive webs of the present disclosure. The outer
cover 533 may comprise nonwoven materials and/or films.
[0162] The diaper 520 is shown to have an inner surface 40 (facing
the viewer in FIG. 29), an outer surface 542 opposed to the inner
surface 540, a rear waist region 544, a front waist region 546
opposed to the rear waist region 544, a crotch region 548
positioned between the rear waist region 544 and the front waist
region 546, and a periphery which is defined by the outer perimeter
or edges of the diaper 520 in which the longitudinal edges are
designated 550 and the end edges are designated 552. The inner
surface 540 of the diaper 520 comprises that portion of the diaper
520 which is positioned adjacent to the wearer's body during use
(i.e., the inner surface 540 generally is formed by at least a
portion of the topsheet 524 and other components joined to the
topsheet 524). The outer surface 542 comprises that portion of the
diaper 520 which is positioned away from the wearer's body (i.e.,
the outer surface 542 is generally formed by at least a portion of
the backsheet 526 and other components joined to the backsheet
526). The rear waist region 544 and the front waist region 546
extend from the end edges 552 of the periphery to the crotch region
548.
[0163] The diaper 520 also has two centerlines, a longitudinal
centerline 590 and a transverse centerline 592. The term
"longitudinal", as used herein, refers to a line, axis, or
direction in the plane of the diaper 520 that is generally aligned
with (e.g., approximately parallel with) a vertical plane which
bisects a standing wearer into left and right halves when the
diaper 520 is worn. The terms "transverse" and "lateral", as used
herein, are interchangeable and refer to a line, axis or direction
which lies within the plane of the diaper that is generally
perpendicular to the longitudinal direction (which divides the
wearer into front and back body halves).
[0164] The chassis 522 of the diaper 520 is shown in FIG. 29 as
comprising the main body of the diaper 520. The containment
assembly 522 may comprise at least the topsheet 524, the backsheet
526, and the absorbent core 528. When the absorbent article 520
comprises a separate holder and a liner, the chassis 522 may
comprise the holder and the liner (i.e., the chassis 522 comprises
one or more layers of material to define the holder while the liner
comprises an absorbent composite such as a topsheet, a backsheet,
and an absorbent core.) For unitary absorbent articles (or one
piece), the chassis 522 comprises the main structure of the diaper
with other features added to form the composite diaper structure.
Thus, the chassis 522 for the diaper 520 generally comprises the
topsheet 524, the backsheet 526, and the absorbent core 528.
[0165] FIG. 29 shows a form of the chassis 522 in which the
topsheet 524 and the backsheet 526 have length and width dimensions
generally larger than those of the absorbent core 528. The topsheet
524 and the backsheet 526 extend beyond the edges of the absorbent
core 528 to thereby form the periphery of the diaper 520. While the
topsheet 524, the backsheet 526, and the absorbent core 528 may be
assembled in a variety of well-known configurations know to those
of skill in the art.
[0166] The absorbent core 528 may be any absorbent member which is
generally compressible, conformable, non-irritating to the wearer's
skin, and capable of absorbing and retaining liquids such as urine
and other certain body exudates. As shown in FIG. 29, the absorbent
core 528 has a garment-facing side, a body-facing side, a pair of
side edges, and a pair of waist edges. The absorbent core 528 may
be manufactured in a wide variety of sizes and shapes (e.g.,
rectangular, hourglass, "T"-shaped, asymmetric, etc.) and from a
wide variety of liquid-absorbent materials commonly used in
disposable diapers and other absorbent articles such as comminuted
wood pulp which is generally referred to as airfelt. The absorbent
core may comprise superabsorbent polymers (SAP) and less than 15%,
less than 10%, less than 5%, less than 3%, or less than 1% of
airfelt, or be completely free of airfelt. Examples of other
suitable absorbent materials comprise creped cellulose wadding,
meltblown polymers including coform, chemically stiffened, modified
or cross-linked cellulosic fibers, tissue including tissue wraps
and tissue laminates, absorbent foams, absorbent sponges,
superabsorbent polymers, absorbent gelling materials, or any
equivalent material or combinations of materials.
[0167] The configuration and construction of the absorbent core 528
may vary (e.g., the absorbent core may have varying caliper zones,
a hydrophilic gradient, a superabsorbent gradient, or lower average
density and lower average basis weight acquisition zones; or may
comprise one or more layers or structures). Further, the size and
absorbent capacity of the absorbent core 528 may also be varied to
accommodate wearers ranging from infants through adults. However,
the total absorbent capacity of the absorbent core 528 should be
compatible with the design loading and the intended use of the
diaper 520.
[0168] Referring to FIGS. 30-32, the absorbent core 528 of the
absorbent articles may comprise one or more channels 626, 626',
627, 627' (627 and 627' are shown in dash in FIG. 30), such as two,
three, four, five, or six channels. The absorbent core 528 may
comprise a front side 280, a rear side 282, and two longitudinal
sides 284, 286 joining the front side 280 and the rear side 282.
The absorbent core 528 may comprise one or more absorbent
materials. The absorbent material 628 of the absorbent core 528 may
be distributed in higher amounts towards the front side 280 than
towards the rear side 282 as more absorbency may be required at the
front of the absorbent core 528 in particular absorbent articles.
The front side 280 may be positioned generally in the front waist
region of an absorbent article and the rear side 282 may be
positioned generally in the rear waist region of an absorbent
article.
[0169] A core wrap (i.e., the layers enclosing the absorbent
material of the absorbent core 528) may be formed by two nonwoven
materials, substrates, laminates, films, or other materials 616,
616'.
[0170] The core wrap may be at least partially sealed along the
front side 280, the rear side 282, and/or the two longitudinal
sides 284, 286 of the absorbent core 528 so that substantially no
absorbent material is able to exit the core wrap. In a form, the
core wrap may only comprise a single material, substrate, laminate,
or other material wrapped at least partially around itself. The
first material, substrate, or nonwoven 616 may at least partially
surround a portion of the second material, substrate, or nonwoven
116' to form the core wrap, as illustrated as an example in FIG.
31. The first material 616 may surround a portion of the second
material 616' proximate to the first and second side edges 284 and
286 and/or the front side 280 and the rear side 282.
[0171] The absorbent core 528 of the present disclosure may
comprise one or more adhesives, for example, to help immobilize the
SAP or other absorbent materials within the core wrap and/or to
ensure integrity of the core wrap, in particular when the core wrap
is made of two or more substrates. The core wrap may extend to a
larger area than required for containing the absorbent material(s)
within.
[0172] Absorbent cores comprising relatively high amounts of SAP
with various core designs are disclosed in U.S. Pat. No. 5,599,335
to Goldman et al., EP 1,447,066 to Busam et al., WO 95/11652 to
Tanzer et al., U.S. Pat. Publ. No. 2008/0312622A1 to Hundorf et
al., and WO 2012/052172 to Van Malderen.
[0173] The absorbent material may comprise one or more continuous
layers present within the core wrap with channels having no, or
little (e.g., 0.1%-10%) absorbent material positioned therein. In
other forms, the absorbent material may be formed as individual
pockets or stripes within the core wrap. In the first case, the
absorbent material may be, for example, obtained by the application
of the continuous layer(s) of absorbent material, with the
exception of the absorbent material free, or substantially free,
channels. The continuous layer(s) of absorbent material, in
particular of SAP, may also be obtained by combining two absorbent
layers having discontinuous absorbent material application
patterns, wherein the resulting layer is substantially continuously
distributed across the absorbent particulate polymer material area,
as disclosed in U.S. Pat. Appl. Pub. No. 2008/0312622A1 to Hundorf
et al., for example. The absorbent core 528 may comprise a first
absorbent layer and at least a second absorbent layer. The first
absorbent layer may comprise the first material 616 and a first
layer 661 of absorbent material, which may be 100% or less of SAP,
such as 85% to 100% SAP, 90% to 100% SAP, or even 95% to 100% SAP,
specifically including all 0.5% increments within the specified
ranges and all ranges formed therein or thereby. The second
absorbent layer may comprise the second material 616' and a second
layer 662 of absorbent material, which may also be 100% or less of
SAP (including the ranges specified above). The absorbent core 528
may also comprise a fibrous thermoplastic adhesive material 651 at
least partially bonding each layer of the absorbent material 661,
662 to its respective material 616, 616'. This is illustrated in
FIGS. 31 and 32, as an example, where the first and second SAP
layers have been applied as transversal stripes or "land areas"
having the same width as the desired absorbent material deposition
area on their respective substrate before being combined. The
stripes may comprise different amount of absorbent material (SAP)
to provide a profiled basis weight along the longitudinal axis 580'
of the core 528.
[0174] The fibrous thermoplastic adhesive material 651 may be at
least partially in contact with the absorbent material 661, 662 in
the land areas and at least partially in contact with the materials
616 and 616' in the channels 626, 626'. This imparts an essentially
three-dimensional structure to the fibrous layer of thermoplastic
adhesive material 651, which in itself is essentially a
two-dimensional structure of relatively small thickness, as
compared to the dimension in length and width directions. Thereby,
the fibrous thermoplastic adhesive material 651 may provide
cavities to cover the absorbent material in the land areas, and
thereby immobilizes this absorbent material, which may be 100% or
less of SAP (including the ranges specified above).
[0175] The channels 626, 626' may be continuous or discontinuous
and may have a length of L' and a width, W.sub.c, for example, or
any other suitable length or width. The channels 626, 626', 627,
and 627' may have a lateral vector component and a longitudinal
vector component or may extend entirely longitudinally or entirely
laterally. The channels may each have one or more arcuate portions.
One or more channels may extend across the lateral axis or the
longitudinal axis 580' of the absorbent core 528, or both.
[0176] Referring to FIG. 31, it can be seen that the channels 626
and 626' do not comprise absorbent material. In other instances,
the channels 626 and 626' may comprise a relatively small amount
(compared to the amount of the absorbent material within the
remainder of the absorbent core 528) of absorbent material. The
relatively small amount of absorbent material within the channels
may be in the range of 0.1% to 20%, specifically reciting all 0.1%
increments within the specified ranges and all ranges formed
therein.
[0177] Referring again to FIG. 30, the absorbent core 528 may
comprise one or more pockets 650 (shown in dash). The one or more
pockets 650 may be provided in addition to the one or more channels
or instead of the one or more channels. The pockets 650 may be
areas in the absorbent core 528 that are free of, or substantially
free of absorbent material, such as SAP (including the ranges
specified above). The pockets 650 may overlap the longitudinal axis
580' and may be positioned proximate to the front side 280, the
rear side 282, or may be positioned at a location intermediate the
front side 280 and the rear side 282, such as longitudinally
centrally, or generally longitudinally centrally between the front
side 280 and the rear side 282.
[0178] Other forms and more details regarding channels and pockets
that are free of, or substantially free of absorbent materials,
such as SAP, within absorbent cores are discussed in greater detail
in U.S. Patent Application Publication Nos. 2014/0163500,
2014/0163506, and 2014/0163511, all published on Jun. 12, 2014.
[0179] The diaper 520 may have an asymmetric, modified T-shaped
absorbent core 528 having ears in the front waist region 546 but a
generally rectangular shape in the rear waist region 544. Example
absorbent structures for use as the absorbent core 528 of the
present disclosure that have achieved wide acceptance described in
U.S. Pat. No. 4,610,678, entitled "High-Density Absorbent
Structures" issued to Weisman et al., on Sep. 9, 1986; U.S. Pat.
No. 4,673,402, entitled "Absorbent Articles With Dual-Layered
Cores", issued to Weisman et al., on Jun. 16, 1987; U.S. Pat. No.
4,888,231, entitled "Absorbent Core Having A Dusting Layer", issued
to Angstadt on Dec. 19, 1989; and U.S. Pat. No. 4,834,735, entitled
"High Density Absorbent Members Having Lower Density and Lower
Basis Weight Acquisition Zones", issued to Alemany et al., on May
30, 1989. The absorbent core may further comprise the dual core
system containing an acquisition/distribution core of chemically
stiffened fibers positioned over an absorbent storage core as
detailed in U.S. Pat. No. 5,234,423, entitled "Absorbent Article
With Elastic Waist Feature and Enhanced Absorbency" issued to
Alemany et al., on Aug. 10, 1993; and in U.S. Pat. No. 5,147,345
entitled "High Efficiency Absorbent Articles For Incontinence
Management", issued to Young et al. on Sep. 15, 1992.
[0180] The backsheet 526 is positioned adjacent the garment-facing
surface of the absorbent core 528 and may be joined thereto by
attachment methods (not shown) such as those well known in the art.
For example, the backsheet 526 may be secured to the absorbent core
528 by a uniform continuous layer of adhesive, a patterned layer of
adhesive, or an array of separate lines, spirals, or spots of
adhesive. Alternatively, the attachment methods may comprise using
heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical
bonds, or any other suitable attachment methods or combinations of
these attachment methods as are known in the art. Forms of the
present disclosure are also contemplated wherein the absorbent core
is not joined to the backsheet 526, the topsheet 524, or both in
order to provide greater extensibility in the front waist region
546 and the rear waist region 544.
[0181] The backsheet 526 may be impervious, or substantially
impervious, to liquids (e.g., urine) and may be manufactured from a
thin plastic film, although other flexible liquid impervious
materials may also be used. As used herein, the term "flexible"
refers to materials which are compliant and will readily conform to
the general shape and contours of the human body. The backsheet 526
may prevent, or at least inhibit, the exudates absorbed and
contained in the absorbent core 528 from wetting articles which
contact the diaper 520 such as bed sheets and undergarments,
however, the backsheet 526 may permit vapors to escape from the
absorbent core 528 (i.e., is breathable). Thus, the backsheet 526
may comprise a polymeric film such as thermoplastic films of
polyethylene or polypropylene. A suitable material for the
backsheet 526 is a thermoplastic film having a thickness of from
about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils), for
example.
[0182] The topsheet 524 is positioned adjacent the body-facing
surface of the absorbent core 528 and may be joined thereto and to
the backsheet 526 by attachment methods (not shown) such as those
well known in the art. Suitable attachment methods are described
with respect to joining the backsheet 526 to the absorbent core
528. The topsheet 524 and the backsheet 526 may be joined directly
to each other in the diaper periphery and may be indirectly joined
together by directly joining them to the absorbent core 528 by the
attachment methods (not shown).
[0183] The topsheet 524 may be compliant, soft feeling, and
non-irritating to the wearer's skin. Further, the topsheet 524 may
be liquid pervious permitting liquids (e.g., urine) to readily
penetrate through its thickness. A suitable topsheet 524 may
comprise one or more of the apertured webs of the present
disclosure forming one or more layers. As described herein, the
apertured webs of the present disclosure may form any other
suitable components of an absorbent article or the example diaper
520, such as an over cover, an ear panel, and/or an acquisition
material, for example.
Sanitary Napkin
[0184] Referring to FIG. 33, the absorbent article may be a
sanitary napkin 310. A topsheet, a secondary topsheet, wings, or
another portion of the sanitary napkin may comprise one or more of
the apertured webs of the present disclosure. The sanitary napkin
310 may comprise a liquid permeable topsheet 314, a liquid
impermeable, or substantially liquid impermeable, backsheet 316,
and an absorbent core 318 positioned intermediate the topsheet 314
and the backsheet 316. The absorbent core 318 may have any or all
of the features described herein with respect to the absorbent
cores 528 and, in some forms, may have a secondary topsheet instead
of the acquisition layer(s) disclosed above. The sanitary napkin
310 may comprise wings 320 extending outwardly with respect to a
longitudinal axis 380 of the sanitary napkin 310. The sanitary
napkin 310 may also comprise a lateral axis 390. The wings 320 may
be joined to the topsheet 314, the backsheet 316, and/or the
absorbent core 318. The sanitary napkin 310 may also comprise a
front edge 322, a rear edge 324 longitudinally opposing the front
edge 322, a first side edge 326, and a second side edge 328
laterally opposing the first side edge 326. The longitudinal axis
380 may extend from a midpoint of the front edge 322 to a midpoint
of the rear edge 324. The lateral axis 390 may extend from a
midpoint of the first side edge 328 to a midpoint of the second
side edge 328. The sanitary napkin 310 may also be provided with
additional features commonly found in sanitary napkins as is known
in the art.
[0185] For those instances where the apertured webs of the present
invention are utilized as a topsheet, 314, arrays of apertures may
not cover all of the topsheet 314. For example, an array of
apertures may be disposed adjacent to the longitudinal axis 380
while further outboard of the longitudinal axis 380, the topsheet
314 may comprise no array of apertures. The array of apertures may
straddle the longitudinal axis 380 and extend laterally outboard
therefrom such that the array of apertures is about 10 mm wide. In
some forms, the array of apertures is about 15 mm wide, about 20 mm
wide, about 30 mm wide, about 35 mm wide, about 40 mm wide, about
45 mm wide, about 50 mm wide, or about 55 mm wide including all
values and ranges included therein. Yet in other forms, the array
of apertures may extend the full width of the topsheet 314 and
extend from the first side edge 326 to the second side edge
328.
[0186] Forms of the present invention are contemplated where
apertured webs of the present invention comprise structures as
described herein in the negative Z-direction. In such forms, the
urging of the material of the apertured web in the negative
Z-direction may fracture material of an absorbent core or a portion
thereof. As shown in FIG. 89, a sanitary pad, or portion thereof,
may comprise the apertured web 8914, an absorbent material 8918,
and a support layer 8916. As shown the structures described herein
may cause fracturing of the absorbent material 8918, particularly
where the absorbent material comprises a high internal phase
emulsion foam. However, other forms of the invention are
contemplated where the absorbent material 8918 comprises SAP. Still
in other forms, the apertured web 8914 may comprise the topsheet,
the absorbent material 8918 may comprise a first liquid retention
layer, and the support layer 8916 may comprise a secondary topsheet
or acquisition layer. In such forms, additional absorbent cores in
addition to a backsheet may be provided.
[0187] The depressions in the apertured web 8914 and absorbent
material 8918 may extend through the thickness of the absorbent
material 8918 such that a plurality of discrete pieces of absorbent
material are produced. In other forms, the depressions in the
apertured web 8914 and the absorbent material 8918 may only
partially extend through the thickness of the absorbent material
8916 such that absorbent material remains a continuous element.
[0188] High internal phase emulsion foams are known in the art.
Methods of making high internal phase emulsion foams are described
in U.S. Pat. No. 5,149,720 (DesMarais et al), issued Sep. 22, 1992;
U.S. Pat. No. 5,827,909 (DesMarais) issued Oct. 27, 1998; and U.S.
Pat. No. 6,369,121 (Catalfamo et al.) issued Apr. 9, 2002.
Patterned Adhesive
[0189] As stated previously, the adhesive utilized to bond/join
layers and/or elements of disposable absorbent articles using the
apertured web of the present invention may comprise adhesive
indicia. Accordingly, the apertured webs and/or absorbent articles
of the present disclosure, or portions thereof, may comprise one or
more patterned adhesives applied thereto or printed thereon. The
patterned adhesives may be present within the apertured webs or
under the apertured webs such that at least a portion of the
patterned adhesives can be viewable through the apertured webs,
either though apertures or land areas. Patterned adhesives are
adhesives that are applied to one or more layers of the apertured
webs, or between layers of the same, in particular patterns to
provide the absorbent articles, or portions thereof, with certain
patterns, visible patterns, and/or certain textures. Examples of
printed adhesive patterns are illustrated in FIGS. 34, 35 and
82-88.
[0190] In FIGS. 34 and 35, element 406, as an example, is a
non-apertured layer of a apertured web onto which the patterned
adhesive is applied, element 410 is a surface of the layer 406 to
which the patterned adhesive is applied, element 430 is a fluid
that is applied to the layer 406, such as an adhesive, and element
432 is a discrete pattern area. The two figures illustrate some
examples of patterned adhesives that may be used in the apertured
webs of the present disclosure. Other adhesive patterns having any
suitable configuration are also within the scope of the present
disclosure. The patterned adhesives may be printed on or otherwise
applied to any suitable layer of the apertured webs or applied
above or beneath them. Methods for applying patterned adhesives to
layers or substrates by adhesive printing are disclosed, for
example, in U.S. Pat. No. 8,186,296, to Brown et al., issued on May
29, 2012, and in U.S. Pat. Appl. Publ. No., 2014/0148774, published
on May 29, 2014, to Brown et al. Other methods of applying
patterned adhesives to substrates known to those of skill in the
art are also within the scope of the present disclosure.
[0191] A patterned adhesive may have the same color or a different
color as at least one layer of an apertured web. In some instances,
the patterned adhesive may have the same or a different color as
both or all layers of an apertured web. In some instances, aperture
patterns in at least one layer of a apertured web may coordinate
with a patterned of a patterned adhesive to visually create a
three-dimensional appearance. The apertured patterns may be the
same or different than patterns of the patterned adhesive.
[0192] In an instance, an apertured web may comprise a first layer
comprising a plurality of apertures and a plurality of land areas
and a second layer comprising a plurality of apertures and a
plurality of land areas. A patterned pigmented substance, such as
ink or a patterned adhesive, may be positioned at least partially
intermediate the first layer and the second layer. The plurality of
apertures of the first layer may be at least partially misaligned
with the plurality of apertures of the second layer (see e.g., FIG.
8). The patterned pigmented or colored substance (29 of FIG. 8) may
be at least partially viewable through the misaligned portions of
the apertures in the first and second layers.
[0193] Regarding FIGS. 82-84, a plurality of overbonds are shown on
a web arranged in a plurality of arrays which will eventually when
processed as described herein--produce apertured indicia. In FIG.
83 adhesive indicia on a web is depicted. As noted previously, the
adhesive may comprise a color or may be clear in some forms.
Regarding FIG. 84, a combination of the overbonds of FIG. 82 and
the adhesive indicia of FIG. 83 are shown. Note that given the
arrangement of the overbonds of FIG. 82, the resulting apertured
indicia would appear similar (coordinated) with the adhesive
indicia shown in FIG. 83. In such forms, it may be beneficial to
register the apertured indicia with the adhesive indicia to produce
the desired visual effect. Adhesive indicia and apertured indicia
which may not require registration are depicted in FIGS. 85-87. A
similar effect is depicted in FIG. 88.
[0194] Regarding FIG. 88, a combination of apertured indicia and
adhesive indicia is shown on a web. The apertured indicia and the
adhesive indicia are not registered. As such, portions of the
adhesive indicia are visible through only a portion of the
apertures. The effect can highlight portions of the adhesive
indicia which are visible through the apertures. The remainder of
the adhesive indicia may still be visible through the web which
comprises the apertured indicia.
Patterns
[0195] The apertures in at least one layer of an apertured web may
be grouped in spaced arrays of apertures (see e.g., FIGS. 1-4 and
40-53). An aperture array includes two or more apertures having
much closer spacing between the apertures than the distance between
the aperture arrays. The distance between the array and other
apertures is at least about 1.5, at least about 2 times, or at
least about 3 times the Interaperture distance between apertures in
the array. The aperture arrays may form a regular or recognizable
shape, such as a heart shape, polygon, ellipse, arrow, chevron,
and/or other shapes known in the pattern art. The apertures arrays
may differ in one portion of the apertured web compared to another
portion of the apertured web. In an absorbent article context, the
aperture arrays may differ in one region of the absorbent article
compared to another region of the absorbent article. Additionally,
the aperture arrays may be coordinated in regions of the absorbent
article where the aperture arrays are present. The apertures of the
aperture arrays may perimeters which are concave, convex, or may
include concavities and convexities. The aperture arrays may be
organized into "macro-arrays" having a higher order structure. For
example, an apertured web may comprise aperture arrays that may be
separated by a continuous, inter-connected land area pattern. In
such an instance, the land area pattern may function as a fluid
distribution pathway and the aperture arrays may function as fluid
"drains" thereby promoting fluid access to the underlying absorbent
material or absorbent core. The shape of the aperture arrays may
enhance the ability of the arrays to manage fluid, such as bodily
exudates (i.e., urine, runny BM, menses). For example, aperture
arrays including a concavity facing a fluid insult location in an
absorbent article may function as fluid collection "traps" as the
fluid may travel along the "land area" in the concavity to a point
where the concavity ends. At this location, the fluid may enter the
apertures in the direction of the fluid path or those on either
side of the concavity if the fluid turns in either lateral
direction. Example aperture array shapes having a concavity include
heart shapes, star shapes, some polygons, crescents, and chevrons,
to name a few examples.
[0196] In some forms, apertures, or arrays thereof, in an apertured
web, may form one or more continuous or semi-continuous patterns,
resulting in discrete "macro" land areas. In such an instance, the
discrete macro land areas may function as fluid deposition regions.
Fluid moving from the discrete macro land areas in any direction
may be absorbed into the apertures of the continuous or
semi-continuous pattern.
[0197] In other forms, the apertures, or aperture arrays thereof,
in an apertured web may form linear patterns alternating with
continuous or semi-continuous land areas. The apertured webs may
include unidirectional or multi-directional (and intersecting)
aperture or aperture array patterns. Linear aperture or array
patterns may be oriented parallel to the longitudinal or lateral
axis, or at an angle between 0 and 90 degrees, specifically
reciting all 0.5 degree increments within the specified range and
all ranges formed therein, from either the longitudinal or lateral
axis. Linear apertures or aperture array patterns may function to
restrict fluid movement along the apertured web to a greater degree
in one direction compared to another direction.
[0198] Additional examples of apertures or arrays thereof in a
patterned web are shown in FIGS. 40-53. A patterned web 1000 may
comprise an array of apertures comprising a plurality of patterns
1110A and 1110B with continuous or semi-continuous land areas. As
shown, a first pattern 1110A may comprise a first plurality of
apertures which are oriented in a direction which is generally
parallel to a machine direction 1675 as well as a second plurality
of apertures which are oriented at multiple angles with respect to
the machine direction. Similarly, a second pattern 1110B may
comprise a third plurality of apertures which are oriented at
multiple angles with respect to the machine direction 1675 as well
as a fourth plurality of apertures which are generally parallel to
the machine direction 1675. As shown, the apertures of the first
pattern 1110A and/or the second pattern 1110B may be of different
lengths, different angles with respect to the machine direction
1675, and/or different Effective Aperture AREAs. Effective Aperture
Areas are discussed hereafter.
[0199] Additionally, at least one or a plurality of apertures in
the first pattern 1110A may be substantially enclosed by the second
pattern 1110B, e.g. third plurality of apertures and fourth
plurality of apertures. For example, the second pattern may form a
quilt like pattern, e.g. diamond shaped boundaries or any other
suitable shape, with the first pattern disposed within the second
pattern thereby forming a unit. The combination of the first
pattern and the second pattern may repeat so that there are a
plurality of units. Additionally, the first pattern within the
second pattern may be different from one unit to the next.
Additional patterns may be utilized. The apertures angled with
respect to the machine direction 1675 are believed to aid in fluid
acquisition/distribution. For example, fluid moving along the
patterned web 1164 in the machine direction 1675 may be diverted,
in part, because of the angled apertures.
[0200] Referring to FIGS. 39-53, as noted previously, the first
pattern 1110A and/or the second pattern 1110B may comprise a
plurality of apertures of which at least a portion are angled with
respect to the machine direction 1675 at a first angle 1680 and
another portion are angled with respect to the machine direction at
a second angle 1682. The first angle 1680 and the second angle 1682
may be different from one another. In some forms, the second angle
1682 may be the mirror image of the first angle 1680. For example,
the first angle may be about 30 degrees from an axis parallel to
the machine direction 1675 while a second angle is -30 degrees from
the axis parallel to the machine direction 1675. Similarly, the
first pattern 1110A and/or the second pattern 1110B may comprise a
plurality of apertures which are oriented generally parallel to the
machine direction 1675. As mentioned previously, apertures which
are oriented generally parallel to the machine direction 1675
generally have a lower aspect ratio (discussed hereafter) and
larger Effective Aperture AREA (described hereafter) as opposed to
those apertures which are angled with respect to the machine
direction 1675. It is believed that those apertures with increased
Effective Aperture AREA allow for quicker fluid acquisitions time.
While any suitable angle may be utilized, as discussed hereafter,
once the first angle 1680 and the second angle 1682 are increased
beyond 45 degrees from the machine direction 1675 (-45 in the case
of the second angle 1682), the forces of the cross-direction 1677
stretching act more along a long axis of the aperture than
perpendicular thereto. So, apertures which are angled more than 45
degrees with respect to the machine direction 1675 (-45 degrees in
the case of the second angle 1682) typically comprise less
Effective Aperture AREA than those which are angled to a lesser
extent with respect to the machine direction 1675.
[0201] As stated previously, the angled apertures are believed to
provide additional fluid handling benefits for the patterned web
1164. In some forms, greater than about 10 percent of the apertures
are angled with respect to the machine direction 1675. Additional
forms are contemplated where greater than about 20 percent, greater
than about 30 percent, greater than about 40 percent, greater than
about 50 percent, greater than about 60 percent, greater than about
70 percent, greater than about 80 percent and/or less than 100
percent, less than about 95 percent, less than about 90 percent,
less than about 85 percent of the apertures are angled with respect
to the machine direction 1675 including any number or any ranges
encompassed by the foregoing values.
[0202] Referring to FIGS. 40-53, the population density of
apertures may be greater nearer a centerline 1690 of the patterned
web 1000. For example, interaperture distance between adjacent
apertures near the centerline 1690 may be a first distance while
interaperture distance between adjacent apertures further away from
the centerline 1690 may be a second distance. The first distance
may be less than the second distance. As an example, interaperture
distance between adjacent apertures can be about 1 mm. As such, the
first distance may be about 1 mm while the second distance may be
about 5 mm or greater. Additional forms are contemplated where the
interaperture distance between adjacent apertures increases with
increasing distance from the centerline. Interaperture distances
are discussed further hereafter.
[0203] Additionally, in some instances, apertures nearer the
centerline 1690 may be angled at the first angle 1680 while
apertures further from the centerline 1690 are positioned at the
second angle 1682. The first angle 1680 may be greater than the
second angle 1682 with respect to the centerline 1690. For,
example, the apertures further from the centerline 1690 may be
oriented such that they are generally parallel to the centerline
1690 while the apertures positioned closer to the centerline 1690
are angled with respect to the centerline 1690. In some forms, the
angle at which apertures are positioned relative to the centerline
1690 may decrease as the distance from the centerline 1690
increases. For example, a first aperture adjacent the centerline
1690 may be oriented at a first angle of 30 degrees with respect to
the centerline 1690, while a second aperture 1 mm from the
centerline 1690 may be oriented at 20 degrees from the centerline.
The apertures positioned furthest away from the centerline 1690 may
be generally parallel to the centerline 1690. Additional
configurations are contemplated where apertures near the centerline
1690 are angled to a lesser extent than those further from the
centerline 1690. In some embodiments, the apertures near the
centerline 1690 may be generally parallel to the centerline 1690
while the apertures further from the centerline 1690 are angled
with respect to the centerline 1690. Feret angles of apertures are
discussed further hereafter.
[0204] As stated previously the lengths of the apertures may vary
as well. In conjunction with being angled as disclosed above or
independently therefrom, in some embodiments, the apertures
adjacent the centerline 1690 may be longer than those which are
further away from the centerline 1690. Similarly, the size of the
apertures may vary. Variances in aperture size (Effective Aperture
AREA) may be employed in conjunction with the variation of aperture
angle and/or the variation in aperture length, or variances in
aperture size may be employed independently of the variation of
aperture angle and/or variation in aperture length. For those
embodiments where aperture size may vary, larger apertures may be
positioned adjacent the centerline 1690 while apertures having a
smaller Effective Aperture AREA are positioned further away from
the centerline 1690. For example, apertures adjacent the centerline
1690 may have an Effective Aperture AREA of 15 square millimeters
while apertures further away from the centerline may have less
Effective Aperture AREA, e.g. 1.0 square mm. Any of the
values/ranges of Effective Aperture AREA provided herein may be
utilized for configuring the Effective Aperture AREA variance
described above.
[0205] As mentioned previously, the angle of orientation of the
aperture can impact the fluid handling capabilities of the
apertured web 1164. Moreover, length of the aperture, width of the
aperture, Effective Aperture AREA, spacing between apertures, as
well as aperture density can similarly impact fluid handling.
However, many of length of apertures, width of apertures, angle of
orientation, spacing and density can have competing/negative
impacts on the other variables. As stated previously, apertures
which are at a greater angle to the machine direction 1675 tend to
open less and therefore have less Effective Aperture AREA than
apertures which are either parallel to the machine direction 1675
or which have a smaller angle with respect to the machine direction
1675. Similarly, angled apertures which are too closely spaced
together tend to open less and therefore have less Effective
Aperture AREA. As such, Interaperture distance between adjacent
angled apertures may be increased over that which is between
apertures which are generally oriented parallel to the machine
direction 1675.
Coordinated Patterns
[0206] The array of apertures in an apertured web of the present
invention may comprise a pattern or a plurality of patterns which
form graphics and/or other depictions, hereafter, "apertured
indicia." The apertured indicia may coordinate with graphics,
indicia, printing, inks, color, and/or patterned adhesives, for
example, located beneath the apertured web or within the apertured
web. In an instance, the apertured web may be used a topsheet, an
outer cover, an ear, or other portion of an absorbent article. Each
of the heretofore mentioned indicia may be visible from a
wearer-facing surface, e.g. topsheet, of a disposable absorbent
article. In some forms, the heretofore mentioned indicia may be
visible from a garment-facing surface, e.g. backsheet, of a
disposable absorbent article. Still in other forms, the heretofore
mentioned indicia may be visible from both the wearer-facing and
garment-facing surfaces of a disposable absorbent article.
[0207] The aperture pattern in an apertured web may coordinate with
features under it, such as bond sites, material edges, channels,
and/or discolored or colored materials. In some specific
executions, the apertured web may be used to accentuate or
block/hide these features. The aperture patterns of a apertured web
may also be used to indicate the correct front vs. rear, left vs.
right orientation of an absorbent article or other consumer
product.
[0208] Forms are contemplated where the apertured indicia is
coordinated with printed indicia elsewhere on the product and/or
packaging. For example, comprise disposable absorbent article of
the present invention may comprise apertured indicia which provides
the appearance of a snowflake. The feminine article may
additionally comprise printed indicia elsewhere on the feminine
article itself and/or its packaging, wherein the printed indicia
provides the appearance of a snowflake. In such embodiments, the
feminine article may comprise a release liner which includes a
printed snowflake pattern and/or be placed in a package comprising
a printed snowflake pattern.
[0209] Forms are contemplated where the apertured indicia is
coordinated with adhesive indicia, bond indicia, and/or structural
indicia. Embodiments are contemplated where at least two of the
following are coordinated on an absorbent article: apertured
indicia, adhesive indicia, printed indicia, bond indicia,
structural indicia. Similar embodiments are contemplated with
regard to the packaging for the disposable absorbent articles
described herein (including release liners and/or secondary
packaging). Additionally, the aforementioned indicia may be
coordinated across the absorbent article, its packaging, and/or its
secondary packaging (including release liners) or any combination
thereof.
[0210] In some specific forms of the present invention, while a
portion of the topsheet may include apertured indicia, other
portions of the topsheet--the non-apertured portion(s)--may include
printed indicia which is coordinated with the apertured indicia. In
other embodiments, a sub-layer, e.g. acquisition layer, secondary
topsheet, and/or absorbent core may comprise printed indicia which
is coordinated with the apertured indicia of the topsheet. Still in
other embodiments, the backsheet may comprise printed indicia which
is coordinated with the apertured indicia of the topsheet. Forms
are contemplated where a portion of the topsheet includes apertured
indicia, the backsheet includes printed indicia coordinated with
the apertured indicia, packaging of the feminine article includes
printed indicia coordinated with the apertured indicia, a
non-apertured portion of the topsheet includes printed indicia
which is coordinated with the apertured indicia and/or a sub-layer,
e.g. acquisition layer, secondary topsheet, and/or absorbent core
comprise printed indicia which is coordinated with the apertured
indicia. Similar embodiments are contemplated with adhesive
indicia, structural indicia, bond indicia, and/or any combinations
thereof.
[0211] In other specific forms, the topsheet may comprise apertured
indicia and first printed indicia. The first printed indicia may
coordinate with printed indicia on secondary packaging while
apertured indicia may coordinate with printed indicia on primary
packaging for the absorbent article.
[0212] Indicia is visually coordinated when one or more elements of
the indicia have two or more visual characteristics that are either
matched or are caused to match. As used herein, the term "match" or
"matched" is used to describe the way or degree to which apertured
indicia, printed indicia, bond indicia, adhesive indicia, and/or
structural indicia, or characteristics thereof visually fit
together or are caused to fit together. For example, apertured
indicia and printed indicia are considered matched if some aspects
of the apertured indicia are identical to similar aspects of the
printed indicia. In one form of match, for example, apertured
indicia and printed indicia that resemble each other are said to
match. The same can be true for any combination of the heretofore
mentioned indicia. As used herein, the term "coordinate" or
"coordination" is used to describe how indicia of the overall
absorbent article and/or its packaging visually belong together.
Components or elements are considered to be coordinated if they
match, or are caused to match. As used herein, the term "caused to
match" is used to describe how any combination of aforementioned
indicia are made to appear matched to one another by using
coordinating indicia (any combination of the above) which has a
coordinating feature which ties the aforementioned indicia
together. For example, if apertured indicia and printed indicia
each have a visual characteristic different from one another and
coordinating indicia has visual characteristics which match each of
the apertured indicia and printed indicia, the coordinating feature
causes the apertured indicia and printed indicia to be matched to
one another.
[0213] Additionally, patterns comprising multiple features may be
coordinated. As an example, a first array of apertures may be
grouped with adjacent bond sites to form a pattern unit. This
pattern unit may be repeating. For example, a first pattern unit
may be disposed adjacent a first end of an absorbent article while
a second pattern unit is disposed adjacent a second end of an
absorbent article. As another example, the first pattern unit may
be disposed adjacent a first end of an absorbent article while the
second pattern unit is disposed adjacent a transverse axis of the
absorbent article. Still another example may comprise additional
pattern units which may be disposed in any suitable location on an
absorbent article. Pattern units may comprise any combination of
features. For example a pattern unit may comprise apertures, bonds,
print, structures, or combinations thereof.
[0214] Some examples of coordinated indicia include theme related
indicia. In some embodiments, indicia described herein may be
coordinated where at least two of the indicia, e.g. apertured and
printed include at least one of items generally thought of as
lucky, e.g. hearts, stars, horseshoes, clovers, moons (printed
indicia may include blue moons), pots of gold, rainbows, balloons,
and the like or combinations thereof. Other examples of coordinated
indicia include numbers, letters, combinations of numbers and
letters; winter themes including snowflakes and/or the like; spring
themes including flowers, bees, birds, trees, sun, geometric
shapes, squares, rectangles, triangles, oval, circles; curves
including uni-radial arcs, multi-radial arcs, spirals, truncated
sinusoidal waves.
[0215] Apertured webs of the present invention may be utilized in
multiple areas of the disposable absorbent articles described
herein. For example, in some embodiments, an apertured web of the
present invention may be utilized as a leg cuff of an absorbent
article, a backsheet and/or outer cover, and/or a topsheet. For
such embodiments, the array of apertures utilized for the topsheet
may be coordinated with the array of apertures utilized for the leg
cuffs and/or backsheet. In some embodiments, the array of apertures
in the leg cuff may coordinate with the array of apertures for the
backsheet but not for the topsheet. In other embodiments, the array
of apertures of the backsheet may coordinate with the array of
apertures for the topsheet.
[0216] If an apertured web is used as part, or all of, an outer
cover (garment-facing layer) of an absorbent article, the aperture
pattern or patterns may provide enhanced breathability in certain
regions (e.g., waist, hips) or reduced breathability in areas over
an absorbent core, for example. The aperture pattern or patterns in
an apertured web used as an outer cover may also provide enhanced
textures and/or signals in certain regions of the outer cover. Such
texture and/or signals may provide intuitive instructions on how to
property apply the absorbent article, where to grip the absorbent
article, and/or where/how to fasten the absorbent article, among
other functions, such as to enhance graphics or aesthetics.
[0217] If an apertured web is used as a portion of a fastener
(e.g., taped fastener) of an absorbent article, an apertured
pattern of an apertured web of the fastener may indicate how to
grip and fasten the fastener and indicate when it is and is not
fastened correctly. An apertured pattern of the apertured web used
as a fastener, or portion thereof, may coordinate with an aperture
pattern of an apertured web used as a topsheet and/or an outer
cover of the same absorbent article to signal a holistic
function.
[0218] The optimum balance of bodily exudate acquisition speed and
rewet in an absorbent article comprising an apertured web as a
topsheet and/or topsheet and acquisition system may be derived from
a combination of aperture diameter, shape or area, depth or
thickness of the apertured web, and the spacing between the various
apertures or aperture arrays within the apertured web.
[0219] An absorbent article comprising an apertured web as a
topsheet and/or a topsheet and an acquisition system may comprise a
longitudinal axis, much like the longitudinal axis of 590 of FIG.
29. Arrays of apertures in the apertured web may repeat themselves
along a line that is angled about 20 degrees to about 160 degrees,
specifically reciting all 1 degree increments within the specified
range and all ranges formed therein, relative to the longitudinal
axis. Additionally, there may be a plurality of aperture sizes,
shapes, or areas along the line or the spacing between the
apertures may not the same between all of the apertures along the
line for purposes of channeling liquid bodily exudates into
preferred areas of the absorbent article or the absorbent core
thereof to help avoid leakage.
[0220] An aperture pattern in an apertured web may form a
recognizable visual element, such as a heart or a water droplet,
for example. An aperture pattern that forms one or more water
droplet shapes in an apertured web used as a topsheet or an outer
cover of an absorbent article may be used to aid communication of
absorbency and/or wetness. Such a feature may be combined with a
wetness indicator of an absorbent article.
[0221] Various commonly understood shapes may be created in an
apertured web. These shapes may be shapes that have commonly
understood proper orientations, such as hearts, for example. An
example is the use of one or more hearts on an outer cover or
topsheet of a front waist region and/or a back waist region of a
diaper. The caregiver would understand to place the diaper on the
wearer with the point of the heart facing toward the wearer's feet
because of the common knowledge of the orientation of hearts.
[0222] In an instance, an apertured web may comprise a first
non-apertured layer comprising a pattern having a color and a
second apertured layer comprising a pattern of apertures. The
pattern on the first non-apertured layer may be printed on the
layer, for example, and may form graphics or other indicia. At
least 50% to 100% of the pattern on the first non-apertured layer
may be aligned with the pattern of apertures in the second
apertured layer to draw attention to the apertures. The alignment,
or partial alignment, of the pattern of apertures on the first
layer with the pattern having a color of the second layer may make
aid in aligning the product on a wearer if the apertured web is
provided on an absorbent article.
[0223] The apertured indicia, printed indicia, adhesive indicia,
bond indicia when used on a topsheet and/or backsheet of a
disposable absorbent article, may be utilized to ensure proper
alignment of the absorbent article. For example, any one of
apertured indicia, printed indicia, adhesive indicia, bond indicia,
and/or combinations thereof, may be utilized to highlight proper
alignment. In one specific example, printed indicia may be utilized
to communicate to a wearer the proper orientation of a feminine
hygiene pad. Proper orientation of the feminine hygiene pad can
reduce the likelihood of leakage.
[0224] Additionally, the apertured indicia, printed indicia,
adhesive indicia, bond indicia when used on a topsheet and/or
backsheet of a disposable absorbent article may be utilized to
highlight features of the absorbent article which would otherwise
not be noticeable by simple visual inspection of the article. For
example, absorbent cores of disposable absorbent articles are
generally disposed between the topsheet and the backsheet. In many
instances, upon visual inspection, a wearer may not be able to
discern the boundaries of the absorbent core which are typically
inboard of the periphery of the absorbent article. In such
instances, at least one of apertured indicia, printed indicia,
adhesive indicia, bond indicia or any combination thereof, may be
utilized to communicate the boundaries of the absorbent core. This
may provide some reassurance to the wearer regarding the "zone" of
absorbency. Still in other configurations, at least one of
apertured indicia, printed indicia, adhesive indicia, bond indicia
or any combination thereof, may be utilized to communicate a
particular area of the absorbent core. For example, an absorbent
article may comprise an absorbent core having variable absorbing
capacity. In such instances, at least one of the apertured indicia,
printed indicia, adhesive indicia, bond indicia or any combination
thereof, may be utilized to highlight an area of the core having
higher absorbing capacity than other areas. Conversely, apertured
indicia, printed indicia, adhesive indicia, bond indicia or any
combination thereof, may be utilized to highlight those portions of
the absorbent core which have lower capacity than another portion
of the absorbent core. Still other executions are contemplated
where a first array of apertured indicia, printed indicia, adhesive
indicia, bond indicia or any combination thereof is utilized to
communicate to the wearer a portion of the absorbent core having
higher absorbing capacity than other portions while a second array
of apertured indicia, printed indicia, adhesive indicia, bond
indicia or any combination thereof are used to communicate to the
wearer regarding other portions of the absorbent core having lower
absorbing capacity. In such executions, the first array and the
second array may or may not be coordinated.
Zones
[0225] In any context of an apertured web, but especially in an
absorbent article context, the apertured webs may be employed in a
zonal fashion. For instance, a first zone of a topsheet of an
absorbent article may have a first apertured web having a first
pattern, while a second zone of a topsheet of an absorbent may have
a second apertured web having a second, different pattern. The
patterns in the different zones may be configured to receive
certain bodily exudates or inhibit or encourage their flow in any
desired direction. For example, the first pattern may be better
configured to receive and/or direct the flow of urine, while the
second pattern may be better configured to receive and/or direct
the flow of runny BM. In other instances where the apertured webs
are used as a topsheet of an absorbent article, a first apertured
web having a first pattern may be configured to receive heavy
gushes of bodily exudates while a second apertured web having a
second different pattern may be configured to restrict lateral
bodily exudate flow in any desired direction. The first pattern may
be situated in, for instance, the middle of the absorbent article
or in the crotch region, while the second pattern may be situated
in the front and rear waist regions or outer perimeter topsheet
regions of the absorbent article.
[0226] The zones in an apertured web may be positioned in the
machine direction, the cross direction, or may be concentric. If a
product, such as an absorbent article, has two different zones in
the machine direction, the zones may have the same or a similar
cross-direction width (e.g., +/-2 mm) for ease in processing. One
or more of the zones may have curved or straight boundaries or
partial boundaries.
[0227] Any suitable zones, including more than two, of different or
the same apertured webs are envisioned within the scope of the
present disclosure. The various zones may be in the topsheet as
mentioned above, but may also be present on an outer cover or a
cuff for example. In some instances, the same or a different
pattern of zones of apertured webs may be used on the wearer-facing
surface (e.g., topsheet) and the garment-facing surface (e.g.,
outer cover).
[0228] In an instance, a topsheet or other portion of an absorbent
article may have two or more zones in an apertured web. A first
zone of the apertured web may have a different aperture pattern
than a second zone. The first zone and the second zone may have
different functionalities owing to the different aperture patterns.
A functionality of the first zone may be to provide liquid bodily
exudate distribution (fluid moving on the apertured web), while the
functionality of the second zone may be to provide liquid bodily
exudate acquisition (fluid penetrating the apertured web). Benefits
of such a zoned apertured web can be better use of an absorbent
core and more efficient liquid bodily exudate distribution within
the absorbent core. This is especially important if an air-felt
free core is used in that typical air-felt free cores may
distribute liquid bodily exudates to a lesser extent.
[0229] In an instance, an absorbent article may comprise an
apertured web that forms a first portion and a second, different
portion thereof. Aperture patterns in each portion of the apertured
web may be the same, substantially similar, or different. In
another instance, an absorbent article may comprise an apertured
web that comprises a first portion of an absorbent article, and
wherein a second portion of the absorbent article has graphics,
printing, patterned adhesives, or other indicia that forms a
pattern that is similar to, substantially similar to, coordinates
with, or is different than an aperture pattern in the apertured
web.
[0230] In an instance, an apertured web may have a plurality of
zones. A first zone may have at least some apertures having a first
angle (central longitudinal axis of aperture vs. MD), first size,
and/or first shape, while a second zone (or third or fourth zone
etc.) may have apertures having a second, different angle (central
longitudinal axis of aperture vs. MD), second, different size,
and/or second, different shape.
[0231] As stated previously, the apertured webs of the present
invention may be utilized in a number of different components of
absorbent articles. Referring to FIG. 54, in one specific example,
disposable absorbent articles utilizing the apertured web of the
present invention may comprise a plurality of zones. As shown, a
topsheet 2014 of a disposable absorbent article 2010, may comprise
a first zone 2007, a second zone 2011 and a third zone 2013.
Absorbent articles may comprise more zones or less zones as
described hereafter.
[0232] The first zone 2007 may comprise an array of apertures as
described herein. As shown the first zone 2007 may have a width
parallel to a lateral axis 2090 which does not extend the full
width of the topsheet 2014. Instead, the second zone 2011 and the
third zone 2013 may be placed on either side of the first zone
2007. In some embodiments, the second zone 2011 and the third zone
2013 may comprise a first array of structures and a second array of
structures, respectively. For these embodiments, the array of
apertures in the first zone 2007 may form apertured indicia which
may be coordinated with the array of structures in the second zone
2011 and/or the array of structures in the third zone 2013. In a
specific execution, the first zone 2007 comprises an array of
apertures, the second and third zones 2011 and 2013, respectively,
comprise an array of structures, wherein the array of structures in
both the second zone 2011 and the third zone 2013 comprise tufts
1770 oriented in the Z-direction or negative Z-direction.
[0233] Still in other forms, the first zone 2007 may comprise an
array of structures while the second zone 2011 and the third zone
2013 comprise a first array of apertures and a second array of
apertures, respectively. In such embodiments, the array of
structures may be coordinated with the array of apertures in the
second zone 2011 and the third zone 2013.
[0234] In some forms, the first zone 2007 may comprise the array of
apertures as well as an array of bonds. The bonds, as mentioned
previously, may be configured to provide bond indicia. In some
embodiments, bond indicia may be coordinated with the apertured
indicia in the first zone 2007. In other embodiments, bond indicia
may be present, in addition to the first zone 2007, in the second
zone 2011 and/or third zone 2013. In such embodiments, the bond
indicia may be coordinated with the apertured indicia in the first
zone 2007 or may be un-coordinated with respect to the apertured
indicia. Adhesive indicia, printed indicia may similarly be
provided in the first zone 2007, the second zone 2011, and/or the
third zone 2013. In such embodiments, the adhesive indicia, printed
indicia may be coordinated with the apertured indicia or may be
un-coordinated with the apertured indicia. In a specific execution,
the first zone 2007 comprises an array of apertures forming
apertured indicia and an array of bonds forming bond indicia. The
second zone 2011 and the third zone 2013 may each comprise an array
of structures, wherein the array of structures comprise tufts 1770
oriented in the Z-direction. In such executions, the apertured
indicia may be coordinated with bond indicia. In other executions,
bond indicia may not be coordinated with apertured indicia.
[0235] In some forms, the first zone 2007, the second zone 2011
and/or the third zone 2013 may comprise a plurality of indicia
selected from printed indicia, apertured indicia, adhesive indicia,
structural indicia, and bond indicia. In such embodiments, any
combination of the plurality of indicia may be coordinated with
indicia within its respective zone and/or with regard to one of the
other or both zones.
[0236] Webs without apertures and webs without patterned apertures
may similarly comprise variable zones. For example, the first zone
2007 may comprise printed indicia while the second zone 2011 and
the third zone 2013 comprise structural indicia. The printed
indicia and the structural indicia may be coordinated. In other
examples, the first zone 2007 may comprise adhesive indicia while
the second and the third zones 2011 and 2013, respectively,
comprise structural indicia. The adhesive indicia may be
coordinated with the structural indicia. In yet another example,
the first zone 2007 may comprise bond indicia while the second zone
2011 and third zone 2013 comprise structural indicia. The bond
indicia may be coordinated with the structural indicia. Still in
other forms, the first zone 2007 may comprise apertured indicia and
printed indicia while the second zone 2011 and the third zone 2013
comprise structural indicia. The structural indicia may be
coordinate with the apertured indicia which in turn may be
coordinated with the printed indicia.
[0237] Other suitable configurations of zones are described with
regard to FIGS. 54-58. FIGS. 54-58 may represent a portion of a
wearer-facing surface of an absorbent article, such as a diaper, an
adult incontinence product, and/or a sanitary napkin.
[0238] FIG. 55 illustrates an example of a substrate having three
zones. The front portion, F, may be positioned in a front portion
of an absorbent article or a back portion of an absorbent article.
The back portion, B, may be positioned in a front portion of an
absorbent article or a back portion of an absorbent article. A
first zone 4004 and a second zone 4006 may be positioned
intermediate two portions of the third zone 4008. The zones 4004,
4006, and 4008 may be provided as separate pieces of material that
are partially overlapped and joined or bonded together or may be
provided as one piece of material. In an instance, the first zone
4004 and the second zone 4006 may be provided as one piece of
material or as two pieces of material that partially overlapped and
joined or bonded together.
[0239] The first zone 4004 may comprise a plurality of
three-dimensional protrusions as described above with reference to
FIGS. 2A-9B. The three-dimensional protrusions may extend upwardly
out of the page or downwardly into the page. The second zone 4006
may comprise a plurality of three-dimensional protrusions as
described above with reference to FIGS. 38A-38B. The
three-dimensional protrusions may extend upwardly out of the page
or downwardly into the page. The second zone 4006 may have a
different or the same pattern, shape, size, and/or orientation of
the three-dimensional protrusions compared to the pattern, shape,
size, and/or orientation of the first zone 4004. The third zone
4008 may comprise a pattern of apertures, wherein at least two
apertures of the pattern of apertures have different sizes, shapes,
and/or orientations. The pattern of apertures may be any of the
various patterns described herein or other suitable patterns. A
substantially-laterally extending separation element, 4010, may
extend between the intersection of the first zone 4004 and the
second zone 4006.
[0240] In another instance, still referring to FIG. 55, the first
zone 4004 may comprise a pattern of apertures, wherein at least two
apertures of the pattern of apertures have different sizes, shapes,
and/or orientations. The pattern of apertures may be any of the
various patterns described herein or other suitable patterns. The
second zone 4006 may comprise a pattern of apertures, wherein at
least two apertures of the pattern of apertures have different
sizes, shapes, and/or orientations. The pattern of apertures may be
any of the various patterns described herein or other suitable
patterns. The second zone 4006 may have a different or the same
pattern of apertures as the first zone 4004. The third zone 4008
may comprise a plurality of three-dimensional protrusions as
described above with reference to FIGS. 2A-9B. The
three-dimensional protrusions may extend upwardly out of the page
or downwardly into the page. A substantially-laterally extending
separation element, 4010, may extend between the intersection of
the first zone 4004 and the second zone 4006.
[0241] FIG. 56 illustrates an example of a substrate having a first
zone 4012 and a second zone 4014. The front portion, F, may be
positioned in a front portion of an absorbent article or a back
portion of an absorbent article. The back portion, B, may be
positioned in a front portion of an absorbent article or a back
portion of an absorbent article. The zones 4012 and 4014 may be
provided as two separate pieces of material that are partially
overlapped and joined or bonded together or may be provided as one
piece of material. The first zone 4012 may comprise a pattern of
apertures, wherein at least two apertures of the pattern of
apertures have different sizes, shapes, and/or orientations. The
pattern of apertures may be any of the various patterns described
herein or other suitable patterns. The second zone 4014 may
comprise a plurality of three-dimensional protrusions as described
above with reference to FIGS. 2A-9B. The three-dimensional
protrusions may extend upwardly out of the page or downwardly into
the page. A substantially-laterally extending separation element,
4010, may extend between the intersection of the first zone 4012
and the second zone 4014.
[0242] In another instance, still referring to FIG. 56, the second
zone 4014 may comprise a pattern of apertures, wherein at least two
apertures of the pattern of apertures have different sizes, shapes,
and/or orientations. The pattern of apertures may be any of the
various patterns described herein or other suitable patterns. The
first zone 4012 may comprise a plurality of three-dimensional
protrusions as described above with reference to FIGS. 38A-38B. The
three-dimensional protrusions may extend upwardly out of the page
or downwardly into the page. A substantially-laterally extending
separation element, 4010, may extend between the intersection of
the first zone 4012 and the second zone 4014.
[0243] FIG. 57 illustrates an example of a substrate having a first
zone 4016 and a second zone 4018. The front portion, F, may be
positioned in a front portion of an absorbent article or a back
portion of an absorbent article. The back portion, B, may be
positioned in a front portion of an absorbent article or a back
portion of an absorbent article. The zones 4016 and 4018 may be
provided as two separate pieces of material that are partially
overlapped and joined or bonded together or may be provided as one
piece of material. The second zone 4018 may at least partially, or
fully, surround the first zone 4016.
[0244] Still referring to FIG. 57, the first zone 4016 may comprise
a plurality of three-dimensional protrusions as described above
with reference to FIGS. 2A-9B. The three-dimensional protrusions
may extend upwardly out of the page or downwardly into the page.
The second zone 4018 may comprise a plurality of three-dimensional
protrusions as described above with reference to FIGS. 38A-38B. The
three-dimensional protrusions may extend upwardly out of the page
or downwardly into the page. The second zone 4018 may have a
different or the same pattern, shape, size, and/or orientation of
the three-dimensional protrusions compared to the pattern, shape,
size, and/or orientation of the first zone 4016.
[0245] In another instance, still referring to FIG. 57, the first
zone 4016 may comprise a pattern of apertures, wherein at least two
apertures of the pattern of apertures have different sizes, shapes,
and/or orientations. The pattern of apertures may be any of the
various patterns described herein or other suitable patterns. The
second zone 4018 may comprise a plurality of three-dimensional
protrusions as described above with reference to FIGS. 38A-38B. The
three-dimensional protrusions may extend upwardly out of the page
or downwardly into the page.
[0246] In yet another instance, still referring to FIG. 57, the
second zone 4018 may comprise a pattern of apertures, wherein at
least two apertures of the pattern of apertures have different
sizes, shapes, and/or orientations. The pattern of apertures may be
any of the various patterns described herein or other suitable
patterns. The first zone 4016 may comprise a plurality of
three-dimensional protrusions as described above with reference to
FIGS. 38A-38B. The three-dimensional protrusions may extend
upwardly out of the page or downwardly into the page.
[0247] In another instance, still referring to FIG. 57, the first
zone 4016 may comprise a pattern of apertures, wherein at least two
apertures of the pattern of apertures have different sizes, shapes,
and/or orientations. The pattern of apertures may be any of the
various patterns described herein or other suitable patterns. The
second zone 4018 may comprise a pattern of apertures, wherein at
least two apertures of the pattern of apertures have different
sizes, shapes, and/or orientations. The pattern of apertures may be
any of the various patterns described herein or other suitable
patterns. The patterns of apertures of the first zone 4016 and the
second zone 4018 may be different or the same.
[0248] FIG. 58 illustrates an example of a substrate having a first
zone 4020 and a second zone 4022. The front portion, F, may be
positioned in a front portion of an absorbent article or a back
portion of an absorbent article. The back portion, B, may be
positioned in a front portion of an absorbent article or a back
portion of an absorbent article. The zones 4020 and 4022 may be
provided as two separate pieces of material that are partially
overlapped and joined or bonded together or may be provided as one
piece of material. The second zone 4022 may at least partially, or
fully, surround the first zone 4020.
[0249] Still referring to FIG. 58, the first zone 4020 may comprise
a pattern of apertures, wherein at least two apertures of the
pattern of apertures have different sizes, shapes, and/or
orientations. The pattern of apertures may be any of the various
patterns described herein or other suitable patterns. The second
zone 4022 may comprise a pattern of apertures, wherein at least two
apertures of the pattern of apertures have different sizes, shapes,
and/or orientations. The pattern of apertures may be any of the
various patterns described herein or other suitable patterns. The
patterns of apertures of the first zone 4020 and the second zone
4022 may be different or the same.
[0250] Still referring to FIG. 58, the first zone 4020 may comprise
a pattern of apertures, wherein at least two apertures of the
pattern of apertures have different sizes, shapes, and/or
orientations. The pattern of apertures may be any of the various
patterns described herein or other suitable patterns. The second
zone 4022 may comprise a plurality of three-dimensional protrusions
as described above with reference to FIGS. 38A-38B. The
three-dimensional protrusions may extend upwardly out of the page
or downwardly into the page
[0251] Still referring to FIG. 58, the second zone 4022 may
comprise a pattern of apertures, wherein at least two apertures of
the pattern of apertures have different sizes, shapes, and/or
orientations. The pattern of apertures may be any of the various
patterns described herein or other suitable patterns. The first
zone 4020 may comprise a plurality of three-dimensional protrusions
as described above with reference to FIGS. 38A-38B. The
three-dimensional protrusions may extend upwardly out of the page
or downwardly into the page
[0252] Still referring to FIG. 58, the first zone 4020 may comprise
a plurality of three-dimensional protrusions as described above
with reference to FIGS. 38A-38B. The three-dimensional protrusions
may extend in a positive Z-direction or in a negative Z-direction.
The second zone 4022 may comprise a plurality of three-dimensional
protrusions as described above with reference to FIGS. 38A-38B. The
three-dimensional protrusions may extend upwardly out of the page
or downwardly into the page. The second zone 4022 may have a
different or the same pattern, shape, size, and/or orientation of
the three-dimensional protrusions compared to the pattern, shape,
size, and/or orientation of the first zone 4020.
[0253] Some specific examples of absorbent articles comprising
zones as described herein are provided with respect to FIGS. 59-65.
The disposable absorbent article is in the form of a sanitary
napkin 2100 comprising wings. As shown, the second zone 2011 and
the third zone 2013 may each comprise an array of structures 2150,
e.g. tufts 1770 (shown in FIGS. 38A-38B). Additionally, the second
zone 2011 and third zones 2013 may comprise an array of bonds 2160
or a plurality thereof. Similarly, the first zone 2007 may comprise
an array of bonds 2161 in addition to an array of apertures 2175.
As shown, the array of bonds 2160 in the second zone 2011 and the
third zone 2013 may form bond indicia which is coordinated with the
bond indicia formed by the array of bonds 2161 in the first zone
2007.
[0254] In other executions, the array of bonds 2161 may be
comprised in the first zone 2007, second zone 2011, and third zone
2013. In such executions, the array of bonds 2161 may collectively
form bond indicia. In addition, an as stated previously, the array
of apertures 2175 may form apertured indicia. In some executions,
the apertured indicia may be coordinated with the bond indicia. In
other executions, the apertured indicia may not be coordinated with
the bond indicia.
[0255] In some executions, the number of the bonds 2161 in the
first zone 2007 adjacent the lateral axis 2090 may be higher than
the number of bonds adjacent ends of the sanitary napkin 2100. For
example, the sanitary napkin 2100 may comprise an intermediate area
2193, a first end area 2195 and a second end area 2197. Each of the
first end area 2195, the second end area 2197, and the intermediate
area 2193 are each about 1/3 of the length of the sanitary napkin
2100. The length of the intermediate area 2193 is bisected by the
lateral axis 2090, may comprise a higher number of bonds 2161 in
the first zone 2007 than in a first end area 2195 and a second end
area 2197.
[0256] In other executions, the first end area 2195 may comprise a
first array of bonds and the second end area 2197 may comprise a
second array of bonds. Each of the first array of bonds and the
second array of bonds may form bond indicia which may be different
than bond indicia formed by a third array of bonds in the
intermediate area 2193. The bond indicia in the intermediate zone
2193 may be coordinated with the bond indicia in the first end zone
2195 and/or the bond indicia in the second end zone 2197.
[0257] Still in other executions, the bonds 2161 in the first zone
2007 may comprise bond sites which resemble dots and/or shaped bond
sites 2163, 2165 which resemble hearts. The bond sites of the bonds
2161 and/or 2160 may be shaped in any suitable manner. Any suitable
shapes for shaped bond sites 2163, 2165 can be used. Some suitable
examples of shapes for the shaped bond sites 2163 and 2165 include
hearts, short lines (dashes), ovals, stars, bows, flowers, squares,
triangles, the like, and combinations thereof. As shown, the shaped
bond sites 2163, 2165 may be coordinated with apertured indicia
formed by apertures 2175. In other executions, a plurality of
shaped bond sites 2163, 2165 may form bond indicia. In such
executions, the shaped bond sites 2163, 2165 may be coordinated
with the bond indicia. Additionally, in such executions, the bond
indicia may be coordinated with the apertured indicia. Still in
other executions, the shaped bond sites 2163, 2165 may combine with
the bond sites to form bond indicia, e.g. a bowtie.
[0258] Still referring to FIGS. 59-65, the bond sites disposed in
the first end area 2195 in the second zone 2011 and third zone 2013
may be greater than the number of bond sites disposed in the
intermediate area 2193. Additionally, the bond sites in the first
end area 2195 and the second end area 2197 can curve inward toward
their respective ends of the sanitary pad 2100. The second end area
2197 may be configured similarly to the first end area 2195. In
such configurations, a width and/or boundary of the first zone 2007
can be masked by the bond sites in the first end area 2195 and the
second end are 2197. Specifically referring to FIG. 61, the width
of the first zone 2007 appears wider in the intermediate area 2193
than in the first end area 2195 and second end area 2197. That
said, the first zone 2007 which can be defined by the apertures (or
features as described herein) which are most outboard from a
longitudinal axis of the sanitary napkin 2100.
[0259] Additionally, this effect can be enhanced by the presence of
bond sites in the intermediate area 2193. For example, referring to
FIG. 61, bond sites may be disposed in the second zone 2011 and
third zone 2013 adjacent a transverse axis of the sanitary pad
2100. However, the bond sites may curve inboard into the first zone
2007 closer to the first end area 2195 and the second end area
2197. This curving of the bond sites in the intermediate area 2193
can also help mask the width of the first zone 2007.
[0260] Where the width of the first zone 2007 is defined by the
outboard most apertures, the width of the first zone 2007 can be
constant from the first end area 2195 to the second end area 2197.
The constant width can help preclude unequal strain applied to the
web during the stretching process described herein. However, the
uniform width of the first zone 2007 creates some difficulty in
highlighting the apertures in the intermediate area 2193. So, the
above configuration of bond sites can be beneficial in highlighting
the apertures in the intermediate area 2193. Such above
configurations are believed to be beneficial even where the first
zone 2007 does not have a uniform width.
[0261] Referring specifically to FIG. 61--without being limited to
sanitary pads--absorbent articles of the present invention may
comprise a plurality of portions defined by the zones described
with regard to FIG. 54 and the end areas defined in FIG. 61. For
example, in some forms of the present invention, boundaries of the
first zone 2007 may be coincident with the most outboard apertures
of the first zone 2007 or may be approximately one third of a
transverse width of the absorbent article in a flattened position.
Similarly, the second zone 2011 and third zone 2013 may each
comprise one third of the lateral width of the absorbent article.
The first end area 2195, second end area 2197, and intermediate
area 2193 may each comprise approximately one third of a length of
the absorbent article in a flattened state.
[0262] In such forms, an absorbent article may comprise several
portions: a portion in the first end area 2195 in the second zone
2011; a portion in the first end area 2195 in the first zone 2007;
a portion in the first end area 2195 in the third zone 2013; a
portion in the intermediate area 2193 in the second zone 2011; a
portion in the intermediate area 2193 in the first zone 2007; a
portion in the intermediate area in the third zone 2013; a portion
in second end area 2197 in the second zone 2011;
[0263] a portion in the second end area 2197 in the first zone
2007; and a portion in the second end area 2197 in the third zone
2013. Each of these portions may comprise any of the features
described herein or any combination thereof. For example, a portion
in the first end area 2195 in the second zone 2011 may comprise a
plurality of apertures while another portion in the first end area
2195 in the first zone 2007 comprises a plurality of tufts. In some
forms of the present invention the portion in the first end area
2195 and the second zone 2011 may further comprise tufts, ridges,
grooves, etc.
[0264] Without wishing to be bound by theory it is believed that
the masking effect of the bond sites may be attributable to a
higher .DELTA.E* value compared to land areas between adjacent bond
sites as opposed to the .DELTA.E* value of the apertures compared
to the land areas between adjacent apertures. That said, it is
further believed that bond site spacing may also play a significant
role. For example, discontinuous bond sites may not produce the
same masking effect as continuous bond sites. In some forms,
embossing may provide a similar effect.
Visual Texture
[0265] Apertures, aperture arrays, three-dimensional elements,
tufts, ridges, grooves, nubs, printing, patterned adhesives, or any
combinations of these "texture elements" may impart a variable
visually observed texture in an apertured web. Variations in
observable textures have been extensively studied in the
psychological and neurological sciences. Some small texture
elements are much more readily ("instantly") detected by the human
visual perception system than others. Most texture patterns having
similar "second order" (iso-dipole) statistics cannot be
discriminated in a brief "flash" observation. However, exceptions
to this (i.e., iso-dipole texture elements that are easily
discriminated) have been defined and are known in the literature as
"textons". Apertured webs including texture elements forming texton
shapes provide a way to create easily recognizable "zones" on a
laminate or in an absorbent article, signaling regions having
different functions, and/or providing strong cues as to correct
product orientation on a wearer (e.g., front/back). Forms of the
apertured webs of the present disclosure may include texture
elements forming texton shapes, including quasi-collinearity,
corner features, and closure of local features. A reference is
Julesz, B., et al, Visual Discrimination of Textures with Identical
Third-Order Statistics, Biological Cybernetics vol. 31, 1978, pp.
137-140).
Effective Open Area
[0266] An apertured web may have an Effective Open Area between
about 5% to about 50%, about 5% to about 40%, about 8% to about
35%, about 10% to about 30%, about 10% to about 25%, about 3% to
about 15%, or about 8% to about 15%, specifically including all
0.1% increments within the specified ranges and all ranges formed
therein or thereby. All Effective Open Area percents are determined
using the Aperture Test described herein. Apertured webs having a
higher Effective Open Area may have utility as a topsheet or
acquisition layer or system in an absorbent article (more
functional to absorbent bodily exudates), while apertured webs
having a lower Effective Open Area may have utility as an outer
cover of an absorbent article (more decorative or for breathability
purposes). In some forms of the present invention, for hydrophilic
webs--where a body contacting surface is hydrophilic--the
percentage open area can generally be less. For hydrophobic
webs--where a body contacting surface is hydrophobic--the
percentage open area may be increased to ensure good acquisition
rates. As an example, for a hydrophobic topsheet, the percentage
open area can be from about 5% to about 50%. As another example,
for a hydrophilic topsheet, the percentage can be from about 1% to
about 50%.
Effective Aperture Area
[0267] An apertured web may have apertures having an Effective
Aperture AREA in the range of about 0.1 mm.sup.2 to about 15
mm.sup.2, 0.3 mm.sup.2 to about 14 mm.sup.2, 0.4 mm.sup.2 to about
12 mm.sup.2, 0.3 mm.sup.2 to about 10 mm.sup.2, 0.5 mm.sup.2 to
about 8 mm.sup.2, 1.0 mm.sup.2 to about 8 mm.sup.2, or about 1.0
mm.sup.2 to about 5 mm.sup.2, specifically including all 0.05 mm
increments within the specified ranges and all ranges formed
therein or thereby. All Effective Aperture Areas are determined
using the Aperture Test described herein. A plurality of the
apertures in an apertured web may be different in Effective
Aperture Areas. The Relative Standard Deviation ("RSD") of the
Effective Aperture Areas may be at least about 20 percent, at least
about 30 percent, at least about 50 percent or at least about 55
percent, or at least about 60 percent.
Interaperture Distance and Average Interaperture Distance
[0268] The apertured webs or layers thereof may have apertures that
have an Average Interaperture Distance of less than about 3.5 mm,
less than about 3 mm, less than about 2.5 mm, less than about 2 mm,
less than about 1.5 mm, less than about 1 mm, in the range of about
1 mm to about 6 mm, in the range of about 1 mm to about 5 mm, in
the range from about 1 mm to about 4 mm, in the range from about 1
mm to about 3.5 mm, in the range of about 1 mm to about 3 mm, in
the range of about 1 mm to about 2.5 mm, in the range of about 2 mm
to about 4 mm, in the range of about 3.5 mm to about 10 mm, or in
the range of about 0.08 mm to about 11 mm, specifically reciting
all 0.1 mm increments within the above-specified ranges and all
ranges formed therein or thereby, according to the Interaperture
Distance Test herein.
[0269] An apertured web may have Interaperture Distances,
calculated according to the Interaperture Distance Test herein. The
Interaperture Distances may have a distribution having a mean and a
median. The mean may be greater than, different than, or less than
the median. The difference between the mean and the median may be
in the range of about 1% to about 25%, about 4% to about 25%, about
5% to about 20%, about 8% to about 20%, about 4% to about 15%, or
about 1% to about 8%, for example, specifically reciting all 0.1%
increments within the above specified ranges and all ranges formed
therein or thereby. A first zone of an apertured web may have
Interaperture Distances. The Interaperture Distances of a first
zone may have a first distribution having a first mean and a first
median. The first mean may be greater than, different than, or less
than the first median by the ranges set forth above in this
paragraph. A second zone of the apertured web may have
Interaperture Distances. The Interaperture Distances of the second
zone may have a second distribution having a second mean and a
second median. The second mean may be greater than, less than, or
different than the second median by the ranges set forth above in
this paragraph. A third zone of the apertured web may have
Interaperture Distances. The Interaperture Distances of the third
zone may have a third distribution having a third mean and a third
median. The third mean may be greater than, different than, or less
than the third median by the ranges set forth above in this
paragraph. The first, second, and third means may be the same or
different. The first, second, and third medians may be the same or
different. The first, second, and third zones may be in a topsheet,
a topsheet layer, an acquisition layer, an outercover, an
outercover layer, or any other component of an absorbent article or
other consumer products.
[0270] In other instances, a first portion of an absorbent article
or other consumer product may have a first apertured web that has
Interaperture Distances, according to the Interaperture Distance
Test herein. The Interaperture Distances of the first portion have
a first distribution. A second portion of an absorbent article or
other consumer product may have a second apertured web that has
Interaperture Distances, according to the Interaperture Distance
Test herein. The Interaperture Distances of the second portion have
a second distribution. A third portion of an absorbent article or
other consumer product may have a third apertured web that has
Interaperture Distances, according to the Interaperture Distance
Test herein. The Interaperture Distances of the third portion have
a third distribution. The first, second, and third distributions
may be the same or different. The first distribution may have a
first mean and a first median. The first mean may be greater than,
less than, or different than the first median in the range of about
1% to about 25%, about 4% to about 25%, about 5% to about 20%,
about 8% to about 20%, about 4% to about 15%, or about 1% to about
8%, for example, specifically reciting all 0.1% increments within
the above-specified ranges and all ranges formed therein or
thereby. The second distribution may have a second mean and a
second median. The second mean may be greater than, different than,
or less than the second median by the ranges set forth above in
this paragraph. The third distribution may have a second mean and a
second median. The second mean may be greater than, different than,
or less than the second median by the ranges set forth above in
this paragraph. The first, second, and third means may be the same
or different. The first, second, and third medians may be the same
or different. The Relative Standard Deviation (RSD) of the
Interaperture Distances may be at least 25%, at least about 35%, at
least about 40%, at least about about 50%, or at least about 55%.
The Maximum Interaperture Distance in a given web or pattern may be
at least about 5 mm, at least about 8 mm, at least about 10 mm, or
at least about 11 mm.
Average Absolute Feret Angle and Absolute Feret Angle
[0271] An apertured web may have one or more apertures having an
Absolute Ferret Angle, according to the Absolute Feret Angle Test,
of at least about 2 degrees, 5 degrees, 15 degrees, at least about
18 degrees, at least about 20 degrees, at least about 22 degrees,
at least about 25 degrees, at least about 30 degrees, at least
about 35 degrees, at least about 40 degrees, at least about 45
degrees, at least about 50 degrees, at least about 55 degrees, at
least about 60 degrees, or in the range of about 2 degrees to about
80 degrees, in the range of about 5 degrees to about 75 degrees, in
the range of about 10 degrees to about 70 degrees, or in the range
of about 15 degrees to about 65 degrees, specifically reciting all
0.1 degrees increments within the above-specified ranges and all
ranges formed therein or thereby.
[0272] An apertured web may have a plurality of apertures having an
Average Absolute Ferret Angle, according to the Average Absolute
Feret Angle Test, of at least about 2 degrees, 5 degrees, 15
degrees, at least about 18 degrees, at least about 20 degrees, at
least about 22 degrees, at least about 25 degrees, at least about
30 degrees, at least about 35 degrees, at least about 40 degrees,
at least about 45 degrees, at least about 50 degrees, at least
about 55 degrees, at least about 60 degrees, or in the range of
about 2 degrees to about 80 degrees, in the range of about 5
degrees to about 75 degrees, in the range of about 10 degrees to
about 70 degrees, or in the range of about 15 degrees to about 65
degrees, specifically reciting all 0.1 degrees increments within
the above-specified ranges and all ranges formed therein or
thereby. These apertures may all be within a single repeat unit of
the apertured web.
[0273] At least two, at least 3, at least 4, at least 5, at least
6, at least 7, at least 8, at least 9, or at least 10 of the
apertures in an apertured web, or a repeat unit of an apertured
web, may each have a different Absolute Feret Angle, according to
the Absolute Feret Angle Test herein. In other instances, some of
the apertures may have Absolute Feret Angles that are the same,
while other of the apertures may have Absolute Feret Angles that
are different. In addition to having different Absolute Feret
Angles, the at least two, at least 3, at least 4, at least 5, at
least 6, at least 7, at least 8, at least 9, or at least 10
apertures may have different sizes and/or shapes. At least some of
the At least two, at least 3, at least 4, at least 5, at least 6,
at least 7, at least 8, at least 9, or at least 10 apertures may
also have the same size and/or shape, while having different
Absolute Feret Angles.
[0274] Apertures oriented at ferret angles greater than zero
relative to the machine direction may have a higher aspect ratio
than apertures that are aligned in the machine direction or vice
versa. Apertured webs having elongated apertures oriented at
different ferret angles may provide liquid bodily exudate handling
benefits when the apertured web is used as a topsheet in an
absorbent article. For example, fluid run-off may be reduced in the
front or back of the absorbent article when the apertures are not
all aligned in the machine direction, but instead are oriented at
an angle relative to the machine direction (e.g., about 30 degrees,
about 45 degrees, or even about 90 degrees) as the apertures can
more readily acquire the liquid bodily exudates. Therefore, it may
be desirable to have the central longitudinal axes of the elongated
apertures oriented at multiple different ferret angles in order to
most effectively acquire liquid bodily exudates running along the
surface of the apertured web and prevent, or at least inhibit,
run-off and soiling of garments.
[0275] In some forms of the present invention, an apertured web may
comprise a plurality of apertures wherein a first portion of the
apertures have an Absolute Feret angle of less than about 20
degrees and wherein a second portion of the apertures have an
Absolute Feret angle of greater than about 20 degrees. In some
forms, the first portion may comprise about 50% of the plurality of
apertures. In some forms, the first portion may comprise about 40%
of the plurality of apertures. In some forms, a first plurality of
apertures may comprise more apertures than a second plurality of
apertures by a ratio of about 3 to 1 or about 5 to 1. In some
forms, the first plurality of apertures may be disposed about the
second plurality of apertures.
[0276] In some example apertured webs of the present disclosure, a
pattern of overbonds, each of which is oriented solely in the
machine direction, or substantially in the machine direction (i.e.,
+/-5 degrees or less from the machine direction), may be used to
create an apertured web with apertures having central longitudinal
axes that are not all oriented in the machine direction or, stated
another way, that have ferret angles of more than 5 degrees with
respect to the machine direction. An example overbond pattern
having overbonds "0" oriented solely in the machine direction is
contemplated. This overbond pattern may be used to produce the
example apertured web 10 of FIG. 3. The apertured web 10 of FIG. 3
may have some apertures 12 having a central longitudinal axis, L,
having an angle with respect to the machine direction. The aperture
ferret angle may range from about 5 degrees to about 70 degrees,
specifically reciting all 0.5 degree increments within the
specified range and all ranges formed therein. Some of the
apertures 12 in the apertured web 10 may also have a central
longitudinal axis, L1, that extends parallel to, or substantially
parallel to (e.g., +/-less than 5 degrees), the machine direction.
The cross directional stretching step or steps described herein may
be used to create the apertures and to orient the central
longitudinal axes, L, of at least some of the apertures in a
direction not parallel to, or substantially parallel to, the
machine direction. At least some of the apertures in an apertured
web having their central longitudinal axes not parallel to, or
substantially parallel to, the machine direction may have a first
plurality of apertures having central longitudinal axes extending
in a first direction with respect to the machine direction and a
second plurality of apertures having central longitudinal axes
extending at a second, different direction relative to the machine
direction. The first and second directions may be 30 degrees and
-30 degrees, respectively, 10 degrees and 20 degrees respectively,
or -20 degrees and 30 degrees respectively, to provide a few
examples. Those of skill in the art will recognize that angles
relative to the machine direction are also within the scope of the
present disclosure. The Relative Standard Deviation (RSD) of the
Absolute Feret Angles may be at least about 30%, or at least about
40%, or at least about 50%. The Absolute Feret Angle of apertures
within a repeat unit may differ by at least about 5 degrees, at
least about 10 degrees, at least about 20 degrees, or at least
about 03 degrees. The apertures in an apertured web having a
central longitudinal axis angled with respect to the machine
direction and produced by machine direction overbonds may be more
open (i.e., have a lower aspect ratio) than they would have been if
the overbonds had been oriented at an angle (5 degrees or more)
with respect to the machine direction. Overbonds oriented at an
angle with respect to the machine direction typically produce
apertures having higher aspect ratios post cross directional
stretching that are less open.
Example Overbond Patterns for Apertured Webs
[0277] Some example schematic representations of overbond patterns
that could be used on an overbonding roller, like roller 110 of
FIG. 13 are illustrated in FIGS. 70 and 71. Those of skill in the
art will recognize that other suitable overbond patterns are also
within the scope of the present disclosure, along with variations
of the illustrated patterns.
Aperture Aspect Ratio and Area
[0278] The apertures of the apertured webs of the present
disclosure may have an aspect ratio of greater than one, for
example, greater than two, greater than 3, greater than 5, or
greater than 10, but typically less than 15. The aperture patterns
in the apertured web may comprise apertures having more than one
aspect ratio, such as two or more distinct populations or having a
substantially continuous distribution of aspect ratios having a
slope greater than zero. Additionally, the aperture patterns of the
apertured webs may comprise apertures with more than two effective
aperture area, either as two or more distinct populations or as a
distribution of aperture areas having a slope greater than zero.
The Relative Standard Deviation (RSD) of the aperture aspect ratios
may be at least about 15%, at least about 25%, at least about 30%,
or at least about 40%, or at least about 45%.
Fused Portions
[0279] Referring to FIG. 36, areas surrounding at least a portion
of an aperture 12 in an apertured web of the present disclosure may
comprise one or more fused portions 5000. The fused portions 5000
may at least partially surround the apertures 12, or fully surround
the apertures 12. The fused portions 5000 may surround at least 25%
of a perimeter of the apertures 12 up to about 100% of the
perimeter of the apertures 12. In some instances, the fused
portions 5000 may be formed on the lateral sides of the apertures
12 and not on the leading and trailing edges of the apertures 12
(see MD and CD arrows for reference in FIG. 36). The fused portions
5000 are believed to be formed during the overbonding step and are
believed to add strength to the apertured webs.
Packages
[0280] Absorbent articles comprising the apertured webs of the
present disclosure may be placed into packages. The packages may
comprise polymeric films and/or other materials. Graphics or
indicia relating to properties of the absorbent articles may be
formed on, positioned on, and/or placed on outer portions of the
packages. Each package may comprise one or more absorbent articles.
The absorbent articles may be packed under compression so as to
reduce the size or height of the packages while still providing an
adequate amount of absorbent articles per package.
[0281] Accordingly, packages of the absorbent articles according to
the present disclosure may have an in-bag stack height of less than
about 80 mm, less than about 78 mm, or less than about 76 mm,
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 72 mm to
about 80 mm or from about 74 mm to about 78 mm, specifically
reciting all 0.5 mm increments within the specified ranges and all
ranges formed therein or thereby, according to the In-Back Stack
Height Test described herein. Further details regarding in-back
stack height are disclosed in U.S. Pat. No. 8,585,666, to Weisman
et al., issued on Nov. 19, 2013.
Arrays of Products
[0282] In some forms, arrays of products are contemplated which
comprise a plurality of features. For example, a first plurality of
absorbent articles may comprise a first array of features forming
indicia, e.g. apertured indicia, adhesive indicia, bond indicia,
print indicia, structural indicia. A second plurality of articles
may comprise a second array of features forming indicia, e.g.
apertured indicia, adhesive indicia, bond indicia, print indicia,
structural indicia. In some forms, the indicia provided for the
first plurality of articles may be different than the indicia
provided for the second plurality of articles. In some forms, a
third plurality of articles may comprise a third array of features
forming indicia, e.g. apertured indicia, adhesive indicia, bond
indicia, print indicia, structural indicia. In some forms, the
indicia provided for the third plurality of article can be
different than the indicia provided for the first and the second
plurality of articles. However, in some forms, the indicia between
a first plurality and second plurality may be coordinated while the
indicia provided for the third plurality of articles is not
coordinated with the first plurality and/or second plurality. For
example, where the first plurality and second plurality of articles
are related functionally. For example, where the first and second
plurality of articles are the same size, or are the same level of
absorbency but different sizes, etc. Still in other forms of the
present invention, a first plurality of products may comprise a
plurality of features which form indicia, e.g. apertured indicia,
adhesive indicia, bond indicia, print indicia, structural indicia.
In such forms, a second plurality of products may comprise a
plurality of features which do not create indicia.
Opacity Method
[0283] Opacity by contrast ratio measurements are made using a
0.degree./45.degree. spectrophotometer suitable for making standard
CIE L*a*b* color measurements (e.g. Hunterlab Labscan XE
spectrophotometer, Hunter Associates Laboratory Inc., Reston Va. or
equivalent). The diameter of the instrument's measurement port
should be chosen such that only the region of interest is included
within the measurement port. Analyses are performed in a room
controlled at about 23.degree. C..+-.2 C..degree. and 50%.+-.2%
relative humidity. Samples are conditioned at the same condition
for 2 hours before testing.
[0284] Calibrate the instrument per the vender instructions using
the standard black and white tiles provided by the vendor. Set the
spectrophotometer to use the CIE XYZ color space, with a D65
standard illumination and 10.degree. observer. Using cryogenic
spray and scissors carefully excise the specimen from the article
for testing. Place the specimen flat against the instrument with
the outward facing surface toward the spectrophotometer's
measurement port and the region of interest within the port. Ensure
that no tears, holes or apertures are within the measurement port.
Place the white standard tile onto the opposing surface of the
specimen such that it completely covers the measurement port. Take
a reading for XYZ and record to 0.01 units. Without moving the
specimen, remove the white plate and replace it with the black
standard plate. Take a second reading for XYZ and record to 0.01
units. Repeat this procedure at a corresponding site for a total of
ten (10) replicate specimens.
[0285] Opacity is calculated by dividing the Y value measured using
the black tile as backing, divided by the Y value measured using
the white tile as backing, then multiplying the ratio by 100.
Record the opacity value to the nearest 0.01%. Calculate opacity
for the 10 replicates and report the average opacity to the nearest
0.01%.
Aperture/Feret Angle Tests
[0286] Aperture dimensions, Effective Open Area and Inter-Aperture
Distance measurements are obtained from specimen images acquired
using a flatbed scanner. The scanner is capable of scanning in
reflectance mode at a resolution of 6400 dpi and 8 bit grayscale (a
suitable scanner is an Epson Perfection V750 Pro from Epson America
Inc., Long Beach Calif. or equivalent). The scanner is interfaced
with a computer running an image analysis program (a suitable
program is ImageJ v. 1.47 or equivalent, National Institute of
Health, USA). The specimen images are distance calibrated against
an acquired image of a ruler certified by NIST. A steel frame is
used to mount the specimen, which is then backed with a black glass
tile (P/N 11-0050-30, available from HunterLab, Reston, Va.) prior
to acquiring the specimen image. The resulting image is then
threshold, separating open aperture regions from specimen material
regions, and analyzed using the image analysis program. All testing
is performed in a conditioned room maintained at about
23.+-.2.degree. C. and about 50.+-.2% relative humidity.
Sample Preparation:
[0287] To obtain a specimen, tape the absorbent article to a rigid
flat surface in a planar configuration. Any leg elastics may be cut
to facilitate laying the article flat. A rectilinear steel frame
(100 mm square, 1.5 mm thick with an opening 60 mm square) is used
to mount the specimen. Take the steel frame and place double-sided
adhesive tape on the bottom surface surrounding the interior
opening. Remove the release paper of the tape, and adhere the steel
frame to the apertured layer of the article. Align the frame so
that it is parallel and perpendicular to the machine direction (MD)
and cross direction (CD) of the apertured layer. Using a razor
blade excise the apertured layer from the underlying layers of the
article around the outer perimeter of the frame. Carefully remove
the specimen such that its longitudinal and lateral extension is
maintained to avoid distortion of the apertures. A cryogenic spray
(such as Cyto-Freeze, Control Company, Houston Tex.) can be used to
remove the specimen from the underlying layers if necessary. Five
replicates obtained from five substantially similar articles are
prepared for analysis. If the aperture layer of interest is too
small to accommodate the steel frame, reduce the frame dimensions
accordingly to accomplish the goals of removal of the specimen
without distortion of the apertures while leaving an opening of
sufficient size to allow for scanning a significant portion of the
apertured layer. An apertured substrate raw material is prepared
for testing by extending or activating it under the same process
conditions, and to the same extent, as it would be for use on the
absorbent article, and then in its extended state adhering it to
the steel frame as described above for testing. Condition the
samples at about 23.degree. C..+-.2 C..degree. and about 50%.+-.2%
relative humidity for 2 hours prior to testing.
Image Acquisition:
[0288] Place the ruler on the scanner bed, oriented parallel to the
sides of the scanner glass, and close the lid. Acquire a
calibration image of the ruler in reflectance mode at a resolution
of 6400 dpi (approximately 252 pixels per mm) and 8 bit grayscale,
with the field of view corresponding to the dimensions of the
interior of the steel frame. Save the calibration image as an
uncompressed TIFF format file. Lift the lid and remove the ruler.
After obtaining the calibration image, all specimens are scanned
under the same conditions and measured based on the same
calibration file. Next, place the framed specimen onto the center
of the scanner bed, lying flat, with the outward facing surface of
the specimen facing the scanner's glass surface. Orient the
specimen so that sides of the frame are aligned parallel with and
perpendicular to the sides of the scanner's glass surface, so that
the resulting specimen image will have the MD vertically running
from top to bottom. Place the black glass tile on top of the frame
covering the specimen, close the lid and acquire a scanned image.
Scan the remaining four replicates in like fashion. If necessary,
crop all images to a rectangular field of view circumscribing the
apertured region, and resave the files.
Effective Open Area Calculation:
[0289] Open the calibration image file in the image analysis
program and perform a linear distance calibration using the imaged
ruler. This distance calibration scale will be applied to all
subsequent specimen images prior to analysis. Open a specimen image
in the image analysis program and set the distance scale. View the
8 bit histogram (0 to 255, with one bin per GL) and identify the
gray level (GL) value for the minimum population located between
the dark pixel peak of the aperture holes and the lighter pixel
peak of the specimen material. Threshold the image at the minimum
gray level value to generate a binary image. In the binary image
the apertures appear as black, with a GL value of 255, and specimen
as white, with a GL value of 0.
[0290] Using the image analysis program, analyze each of the
discrete aperture regions. Measure and record all of the individual
aperture areas to the nearest 0.01 mm.sup.2, including partial
apertures along the edges of the image. Discard any apertures with
an area less than 0.3 mm.sup.2. Apertures having a lower area than
0.3 mm.sup.2 may prove difficult to measure particularly when stray
fibers cross the boundary of the aperture. And such apertures with
that small of an area are considered to contribute insignificantly
to the Effective Open Area. Sum the remaining aperture areas
(including whole and partial apertures), divide by the total area
included in the image and multiply by 100. Record this value as the
% Effective Open Area to the nearest 0.01%.
[0291] In like fashion, analyze the remaining four specimen images.
Calculate and report the average % effective area values to the
nearest 0.01% for the five replicates.
Effective Aperture Area and Absolute Feret Angle:
[0292] Open the calibration image (containing the ruler) file in
the image analysis program. Resize the resolution of the original
image from 6400 dpi to 640 dpi (approximately 25.2 pixels per mm)
using a bicubic interpolation. Perform a linear distance
calibration using the imaged ruler. This distance calibration scale
will be applied to all subsequent specimen images prior to
analysis. Open a specimen image in the image analysis program.
Resize the resolution of the original image from 6400 dpi to 640
dpi (approximately 25.2 pixels per mm) using a bicubic
interpolation. Set the distance scale. View the 8 bit histogram (0
to 255, with one bin per GL) and identify the gray level (GL) value
for the minimum population located between the dark pixel peak of
the aperture holes and the lighter pixel peak of the specimen
material. Threshold the image at the minimum gray level value to
generate a binary image. In the binary image the apertures appear
as black, with a GL value of 255, and specimen as white, with a GL
value of 0. Next, two morphological operations are performed on the
binary image. First, a closing (a dilation operation followed by an
erosion operation, iterations=1, pixel count=1), which removes
stray fibers within an aperture hole. Second, an opening (an
erosion operation followed by a dilation operation, iterations=1,
pixel count=1), which removes isolated black pixels. Pad the edges
of the image during the erosion step to ensure that black boundary
pixels are maintained during the operation. Lastly, fill any
remaining voids enclosed within the black aperture regions.
[0293] Using the image analysis program, analyze each of the
discrete aperture regions. During the analysis exclude measurements
of partial apertures along the edges of the image, so that only
whole apertures are measured. Measure and record all of the
individual aperture areas, perimeters, feret diameters (length of
the apertures) along with its corresponding angle of orientation in
degrees from 0 to 180, and minimum feret diameters (width of the
apertures). Record the measurements for each of the individual
aperture areas to the nearest 0.01 mm.sup.2, the perimeters and
feret diameters (length and width), to the nearest 0.01 mm, and
angles to the nearest 0.01 degree. Discard any apertures with an
area less than 0.3 mm.sup.2. Record the number of remaining
apertures, divide by the area of the image and record as the
Aperture Density value. The angle of orientation for an aperture
aligned with the MD (vertical in the image) will have an angle of
90 degrees. Apertures with a positive slope, increasing from left
to right, will have an angle between zero and 90 degrees. Apertures
with a negative slope, decreasing from left to right, will have an
angle between 90 and 180 degrees. Using the individual aperture
angles calculate an Absolute Aperture Angle by subtracting 90
degrees from the original angle of orientation and taking its
absolute value. In addition to these measurements, calculate an
Aspect Ratio value for each individual aperture by dividing the
aperture length by its width. Repeat this analysis for each of the
remaining four replicate images. Calculate and report the
statistical mean and standard deviation for each of the effective
aperture dimension measurements using all of the aperture values
recorded from the replicates. Calculate and report the % relative
standard deviation (RSD) for each of the aperture dimension
measurements by dividing the standard deviation by the mean and
multiplying by 100.
Inter-Aperture Distance Measurements:
[0294] The average, standard deviation, median, and maximum
distance between the apertures can be measured by further analyzing
the binary image that was analyzed for the aperture dimension
measurements. First, obtain a duplicate copy of the resized binary
image following the morphological operations, and using the image
analysis program, perform a Voronoi operation. This generates an
image of cells bounded by lines of pixels having equal distance to
the borders of the two nearest pattern apertures, where the pixel
values are outputs from a Euclidian distance map (EDM) of the
binary image. An EDM is generated when each inter-aperture pixel in
the binary image is replaced with a value equal to that pixel's
distance from the nearest pattern aperture. Next, remove the
background zeros to enable statistical analysis of the distance
values. This is accomplished by using the image calculator to
divide the Voronoi cell image by itself to generate a 32-bit
floating point image where all of the cell lines have a value of
one, and the remaining parts of the image are identified as Not a
Number (NaN). Lastly, using the image calculator, multiply this
image by the original Voronoi cell image to generate a 32-bit
floating point image where the distance values along the cell lines
remain, and all of the zero values have been replaced with NaN.
Next, convert the pixel distance values into actual inter-aperture
distances by multiplying the values in the image by the pixel
resolution of the image (approximately 0.04 mm per pixel), and then
multiply the image again by 2 since the values represent the
midpoint distance between apertures. Measure and record the mean,
standard deviation, median and maximum inter-aperture distances for
the image to the nearest 0.01 mm. Repeat this procedure for all
replicate images. Calculate the % relative standard deviation (RSD)
for the inter-aperture distance by dividing the standard deviation
by the mean and multiplying by 100.
Land Area Light Transmission Method
[0295] The land area light transmission method measures the average
amount of light transmitted through specific regions of a specimen.
A calibrated light transmission image is obtained using a flatbed
scanner. A binary mask is generated to separate discrete aperture
regions from the surrounding land area. The binary mask is then
registered to the light transmission image, and used to exclude the
apertures from the land area in the light transmission image. This
enables the average light transmission value for the land area to
be calculated.
Sample Preparation:
[0296] To obtain a specimen, tape the absorbent article to a rigid
flat surface in a planar configuration. Any leg elastics may be cut
to facilitate laying the article flat. A rectilinear steel frame
(100 mm square, 1.5 mm thick with an opening 60 mm square) is used
to mount the specimen. Take the steel frame and place double-sided
adhesive tape on the bottom surface surrounding the interior
opening. Remove the release paper of the tape, and adhere the steel
frame to the apertured layer of the article. Align the frame so
that it is parallel and perpendicular to the machine direction (MD)
and cross direction (CD) of the apertured layer. Using a razor
blade excise the apertured layer from the underlying layers of the
article around the outer perimeter of the frame. Carefully remove
the specimen such that its longitudinal and lateral extension is
maintained to avoid distortion of the apertures. A cryogenic spray
(such as Cyto-Freeze, Control Company, Houston Tex.) can be used to
remove the specimen from the underlying layers if necessary. Five
replicates obtained from five substantially similar articles are
prepared for analysis. If the aperture layer of interest is too
small to accommodate the steel frame, reduce the frame dimensions
accordingly to accomplish the goals of removal of the specimen
without distortion of the apertures while leaving an opening of
sufficient size to allow for scanning a significant portion of the
apertured layer. Condition the samples at about 23.degree. C..+-.2
C..degree. and about 50%.+-.2% relative humidity for 2 hours prior
to testing.
Light Transmission Image
[0297] The light transmission measurement is based on the CIE
L*a*b* color system (CIELAB). A flatbed scanner capable of scanning
a minimum of 24 bit color at 800 dpi and has manual control of
color management (a suitable scanner is an Epson Perfection V750
Pro from Epson America Inc., Long Beach Calif. or equivalent) is
used to acquire images. The scanner is interfaced with a computer
running color management software (suitable color management
software is MonacoEZColor available from X-Rite Grand Rapids, Mich.
or equivalent). The scanner is calibrated against a color
transparency target and corresponding reference file compliant with
ANSI method IT8.7/1-1993 using the color management software to
construct a calibrated color profile. The resulting calibrated
scanner profile is used to color correct an image from a test
specimen within an image analysis program that supports sampling in
CIE L*a*b* (a suitable program is Photoshop S4 available from Adobe
Systems Inc., San Jose, Calif. or equivalent). All testing is
performed in a conditioned room maintained at about 23.+-.2.degree.
C. and about 50.+-.2% relative humidity.
[0298] Turn on the scanner for 30 minutes prior to calibration.
Deselect any automatic color correction or color management options
that may be included in the scanner software. If the automatic
color management cannot be disabled, the scanner is not appropriate
for this application. Place the IT8 target face down onto the
scanner glass, close the scanner lid, acquire an image at 200 dpi
and 24 bit color and remove the IT8 target. Open the image file on
the computer with the color management software. Follow the
recommended steps within the color management software to create
and export a calibrated color profile. These steps may include,
ensuring that the scanned image is oriented and cropped correctly.
The calibrated color profile must be compatible with the image
analysis program. The color management software uses the acquired
image to compare with the included reference file to create and
export the calibrated color profile. After the profile is created
the scan resolution (dpi) for test specimens can be changed, but
all other settings must be kept constant while imaging
specimens.
[0299] Open the scanner lid and place the specimen flat against the
scanner glass with the outward facing surface facing the glass.
Acquire and import a scan of the specimen region within the
interior of the frame into the image analysis software at 24 bit
color and at 800 dpi in transparency mode. If necessary, crop image
to a rectangular field of view circumscribing the apertured region.
Transparency mode illuminates the specimen from one side with the
sensor capturing the image from the opposite side. Assign the
calibrated color profile to the image and change the color space
mode to L*a*b* Color corresponding to the CIE L*a*b* standard. This
produces a color corrected image for analysis. Save this color
corrected image in an uncompressed format, such as a TIFF file.
Land Area Mask
[0300] The boundaries of the apertured areas and land area are
identified by thresholding the L* channel image to generate a
binary image, separating apertured areas from the surrounding land
area. This binary image will then be used as a mask on the
corresponding light transmission image to measure the average Light
Transmission Value of only the land area.
[0301] To do this, first open the color corrected light
transmission image in the image analysis software. To generate the
land area mask, first separate the L*, a* and b* channels, and
select only the L* channel for analysis. The L* channel represents
the "Lightness" of the image and has values that range from 0-100.
Threshold the L* channel image at a value of 90 to generate a
binary image. By thresholding at the level described above, a
binary mask image is produced with the discrete aperture areas
assigned one value, and the surrounding land area assigned a
different value. For example, the discrete aperture areas could
appear black, and the surrounding land area could appear white.
Save this binary mask image in an uncompressed format, such as a
TIFF file.
Analysis of Light Transmission Image
[0302] Open both the color corrected light transmission image and
the corresponding binary mask image in the image analysis software.
To analyze the specimen light transmission image, first separate
the L*, a* and b* channels, and select only the L* channel for
analysis. Register the light transmission image and the binary mask
image to each other. Use the binary mask to exclude the apertures
from the light transmission image, and calculate an average L*
value (Light Transmission Value) for the remaining surrounding land
area. Record this value as the Land Area Light Transmission Value
to the nearest 0.1 units. In like fashion, repeat this procedure on
all of the replicate specimens. Calculate and report the average of
the five individual Land Area Light Transmission Values to the
nearest 0.1 units.
Basis Weight Method
[0303] Basis weight of the apertured webs may be determined by
several available techniques, but a simple representative technique
involves taking an absorbent article or other consumer product,
removing any elastic which may be present and stretching the
absorbent article or other consumer product to its full length. A
punch die having an area of 45.6 cm.sup.2 is then used to cut a
piece of the apertured web (e.g., topsheet, outer cover) from the
approximate center of the absorbent article or other consumer
product in a location which avoids to the greatest extent possible
any adhesive which may be used to fasten the apertured web to any
other layers which may be present and removing the apertured web
from other layers (using cryogenic spray, such as Cyto-Freeze,
Control Company, Houston, Tex., if needed). The sample is then
weighed and dividing by the area of the punch die yields the basis
weight of the apertured web. Results are reported as a mean of 5
samples to the nearest 0.1 cm.sup.2.
In-Bag Stack Height Test
[0304] The in-bag stack height of a package of absorbent articles
is determined as follows:
Equipment
[0305] 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.
Definitions
[0306] As illustrated in FIG. 37, a package 1000 defines an
interior space 1002 and comprises a plurality of absorbent articles
1004. The absorbent articles are in a stack 1006. The package has a
package width 1008. The package width is defined as the maximum
distance between the two highest bulging points along the same
compression stack axis of the absorbent article package 1000.
In-Bag Stack Height=(Package Width/Pad Count Per Stack).times.10
absorbent articles.
Test Procedure
[0307] Absorbent article packages are equilibrated at
23.+-.2.degree. C. and 50.+-.5% relative humidity prior to
measurement.
[0308] The horizontal sliding plate is raised and an absorbent
article package is placed centrally under the horizontal sliding
plate in such a way that the absorbent articles within the package
are in a horizontal orientation (see FIG. 37). Any handle or other
packaging feature on the surfaces of the package that would contact
either of the plates is folded flat against the surface of the
package so as to minimize their impact on the measurement. The
horizontal sliding plate is lowered slowly until it contacts the
top surface of the package and then released. The gap between the
horizontal plates is measured to within .+-.0.5 mm ten seconds
after releasing the horizontal sliding plate. Five identical
packages (same size packages and same absorbent articles counts)
are measured and the arithmetic mean is reported as the package
width. The "In-Bag Stack Height"=(package width/absorbent article
count per stack).times.10 is calculated and reported to within
.+-.0.5 mm.
[0309] 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".
[0310] All documents cited herein, including any cross referenced
or related patent, patent publication, or patent application, is
hereby incorporated by reference in its entirety unless expressly
excluded or otherwise limited. The citation of any document is not
an admission that it is prior art with respect to any invention
disclosed or claimed herein or that it alone, or in any combination
with any other reference or references, teaches, suggests, or
discloses any such invention. Further, to the extent that any
meaning or definition of a term in this document conflicts with any
meaning or definition of the same term in a document incorporated
by reference, the meaning or definition assigned to that term in
this document shall govern.
[0311] While particular forms of the present disclosure have been
illustrated and described, those of skill in the art will recognize
that various other changes and modifications can be made without
departing from the spirit and scope of the invention. It is
therefore intended to cover in the appended claims all such changes
and modifications that are within the scope of the present
disclosure.
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