U.S. patent application number 16/378815 was filed with the patent office on 2019-08-01 for multi-component topsheets.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to George Christopher DOBRIN, Theresa Lynn GALIE, Olaf Erik Alexander ISELE, Amy Lynn TALLY.
Application Number | 20190231613 16/378815 |
Document ID | / |
Family ID | 52669681 |
Filed Date | 2019-08-01 |
View All Diagrams
United States Patent
Application |
20190231613 |
Kind Code |
A1 |
TALLY; Amy Lynn ; et
al. |
August 1, 2019 |
MULTI-COMPONENT TOPSHEETS
Abstract
A multi-component topsheet for an absorbent article includes a
first discrete substrate forming about 80% or more of an outer
perimeter of the topsheet and a second discrete substrate wherein
about 80% or more of an outer perimeter of the second discrete
substrate is joined to the first discrete substrate, wherein the
topsheet has a single layer of substrate in about 75% or more of
the total area of the topsheet and a dual layer of substrate in
about 25% or less of the total area of the topsheet.
Inventors: |
TALLY; Amy Lynn; (Cold
Spring, KY) ; GALIE; Theresa Lynn; (Cincinnati,
OH) ; DOBRIN; George Christopher; (Mason, OH)
; ISELE; Olaf Erik Alexander; (West Chester, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
52669681 |
Appl. No.: |
16/378815 |
Filed: |
April 9, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14634985 |
Mar 2, 2015 |
10285874 |
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16378815 |
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61948872 |
Mar 6, 2014 |
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61948692 |
Mar 6, 2014 |
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62112337 |
Feb 5, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F 13/512 20130101;
A61F 2013/51178 20130101; A61F 13/5121 20130101; A61F 2013/51333
20130101; A61F 13/51104 20130101; A61F 2013/8491 20130101; A61F
13/51305 20130101 |
International
Class: |
A61F 13/512 20060101
A61F013/512; A61F 13/513 20060101 A61F013/513; A61F 13/511 20060101
A61F013/511 |
Claims
1. An absorbent article comprising: a central longitudinal axis; a
liquid permeable topsheet; a liquid impermeable backsheet; and an
absorbent core positioned at least partially intermediate the
topsheet and the backsheet, wherein the absorbent core comprises an
absorbent material; the topsheet comprising: a first layer
comprising a hydrophobic nonwoven material, wherein the hydrophobic
nonwoven material overlaps the central longitudinal axis of the
absorbent article, and wherein the first layer comprises carded
fibers; and a second layer comprising a hydrophilic nonwoven
material, wherein the first layer is joined to the second layer,
and wherein the second layer comprises carded fibers; wherein the
topsheet comprises a plurality of recesses, a plurality of
projections forming a portion of a wearer-facing surface of the
topsheet, and a plurality of land areas, wherein the land areas
surround at least a majority of the plurality of projections and a
plurality of the recesses, wherein the plurality of recesses, the
plurality projections, and the plurality of land areas, together
form a first three-dimensional surface on a first side of the
topsheet and a second three-dimensional surface on a second side of
the topsheet, wherein a majority of the projections have a
z-directional height in the range of about 500 .mu.m to about 4000
.mu.m, according to the Projection Height Test, wherein a majority
of the recesses define an aperture at a location most distal from a
top peak of an adjacent projection and defined at a lowermost plane
of the topsheet, and wherein the majority of the recesses have a
z-directional height in the range of about 500 .mu.m to about 2000
.mu.m, according to the Recess Height Test; wherein the topsheet
has an overall z-directional height in the range of about 1000
.mu.m to about 6000 .mu.m, according to the Overall Substrate
Height Test; wherein the apertures are formed through the first
layer and the second layer; and wherein the topsheet comprises
cotton fibers.
2. The absorbent article of claim 1, wherein the first layer forms
a central longitudinal portion of the wearer-facing surface of the
topsheet, and wherein the second layer forms a central longitudinal
portion of a garment-facing surface of the topsheet.
3. The absorbent article of claim 1, wherein a majority of the
apertures have an effective aperture area in the range of about 0.5
mm.sup.2 to about 3 mm.sup.2, according to the Aperture Test.
4. The absorbent article of claim 1, wherein the projections and
the recesses are each formed by portions of the first layer and
portions of the second layer.
5. The absorbent article of claim 1, wherein the first layer is
joined to the second layer by adhesive bonding or mechanical
bonding.
6. The absorbent article of claim 1, wherein the first layer
comprises a plurality of first fibers, wherein the second layer
comprises a plurality of second fibers, and wherein the first and
second fibers are the same.
7. The absorbent article of claim 1, wherein four apertures are
formed around each projection, and wherein four projections are
formed around each aperture.
8. The absorbent article of claim 1, wherein two adjacent apertures
are separated by a projection and a land area along a lateral axis
of the topsheet, and wherein two adjacent projections are separated
by an aperture and a land area along the lateral axis of the
topsheet.
9. The absorbent article of claim 1, wherein two adjacent apertures
are separated by a projection and a land area along a longitudinal
axis of the topsheet, and wherein two adjacent projections are
separated by an aperture and a land area along the longitudinal
axis of the topsheet.
10. The absorbent article of claim 1, wherein substantially all of
the recesses define an aperture at the lowermost plane of the
topsheet.
11. The absorbent article of claim 1, wherein substantially all of
the projections comprise a hollow arched portion.
12. The absorbent article of claim 1, wherein the apertures
comprise a first set of apertures together forming a first line in
the topsheet and a second set of apertures together forming a
second line in the topsheet, and wherein the first line is
generally parallel with the second line.
13. The absorbent article of claim 1, wherein the topsheet has a %
effective open area in the range of about 5% to about 25%,
according to the Aperture Test.
14. The absorbent article of claim 1, wherein top peaks of the
majority of the projections form a topmost plane of the topsheet,
and wherein the land areas are positioned intermediate the
lowermost plane and the topmost plane.
15. The absorbent article of claim 1, wherein the first
three-dimensional surface has a geometric roughness value in the
range of about 3.0 to about 3.6, according to the Descriptive
Analysis Roughness Test.
16. A package comprising a plurality of the absorbent articles of
claim 1, wherein the package has an in-bag stack height from about
70 mm to about 95, according to the In-Bag Stack Height Test,
wherein the absorbent article has a relative humidity from about
50% to about 70%, according to the Humidity Test.
17. An absorbent article comprising: a central longitudinal axis; a
liquid permeable topsheet; a liquid impermeable backsheet; and an
absorbent core positioned at least partially intermediate the
topsheet and the backsheet, wherein the absorbent core comprises an
absorbent material comprising superabsorbent polymers; the topsheet
comprising: a first layer comprising a hydrophobic nonwoven
material; and a second layer comprising a hydrophilic nonwoven
material, wherein the first layer is joined to the second layer,
and wherein the first layer and the second layer comprise carded
fibers; wherein the topsheet comprises a plurality of recesses, a
plurality of dome-shaped projections forming a portion of a
wearer-facing surface of the absorbent article, and a plurality of
land areas, wherein the land areas surround at least a majority of
the plurality of dome-shaped projections and a plurality of the
recesses, wherein the plurality of recesses, the plurality of
dome-shaped projections, and the plurality of land areas, together
form a first three-dimensional surface on a first side of the
topsheet and a second three-dimensional surface on a second side of
the topsheet, wherein a majority of the dome-shaped projections
have a z-directional height in the range of about 500 .mu.m to
about 4000 .mu.m, according to the Projection Height Test, wherein
a majority of the recesses define an aperture at a location most
distal from a top peak of an adjacent dome-shaped projection, and
wherein the majority of the recesses have a z-directional height in
the range of about 500 .mu.m to about 2000 .mu.m, according to the
Recess Height Test; wherein the topsheet has an overall
z-directional height in the range of about 1000 .mu.m to about 6000
.mu.m, according to the Overall Substrate Height Test; wherein the
dome-shaped projections and the recesses are formed by portions of
the first layer and portions of the second layer; and wherein the
apertures are formed through the first layer and through the
second.
18. A package comprising a plurality of the absorbent articles of
claim 17, wherein the package has an in-bag stack height from about
70 mm to about 95, according to the In-Bag Stack Height Test,
wherein the absorbent article has a relative humidity from about
50% to about 70%, according to the Humidity Test.
19. An absorbent article comprising: a central longitudinal axis; a
central lateral axis extending in a direction perpendicular to the
central longitudinal axis; an absorbent core; a liquid impermeable
backsheet; a liquid permeable topsheet, wherein the absorbent core
is positioned at least partially intermediate the liquid permeable
topsheet and the liquid impermeable backsheet, wherein the
absorbent core comprises an absorbent material, and wherein the
liquid permeable topsheet comprises: a first layer comprising a
hydrophobic nonwoven material, wherein the hydrophobic nonwoven
material overlaps the central longitudinal axis; and a second layer
comprising a hydrophilic nonwoven material, wherein the first layer
is joined to the second layer, and wherein the hydrophilic nonwoven
material overlaps the central longitudinal axis; wherein the
topsheet comprises a plurality of recesses, a plurality of dome
shaped projections forming a portion of a wearer-facing surface of
the topsheet, and a plurality of land areas, wherein the land areas
surround at least a majority of the plurality of dome-shaped
projections and a plurality of the recesses, wherein the plurality
of recesses, the plurality of dome-shaped projections, and the
plurality of land areas, together form a first three-dimensional
surface on a first side of the topsheet and a second
three-dimensional surface on a second side of the topsheet, wherein
a majority of the dome-shaped projections have a z-directional
height in the range of about 500 .mu.m to about 4000 .mu.m,
according to the Projection Height Test, wherein a majority of the
recesses define an aperture at a location most distal from a top
peak of an adjacent dome-shaped projection, wherein the aperture is
defined at a lowermost plane of the topsheet, wherein top peaks of
the dome-shaped projections form a topmost plane of the topsheet,
wherein the land areas are positioned intermediate the lowermost
plane and the topmost plane, and wherein the majority of the
recesses have a z-directional height in the range of about 500
.mu.m to about 2000 .mu.m, according to the Recess Height Test; and
wherein the topsheet has an overall z-directional height in the
range of about 1000 .mu.m to about 6000 .mu.m, according to the
Overall Substrate Height Test; and wherein the first
three-dimensional surface has a geometric roughness value in the
range of about 3.0 to about 3.6, according to the Descriptive
Analysis Roughness Test.
20. The absorbent article of claim 19, wherein the topsheet
comprises carded fibers.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of, and claims priority
under 35 U.S.C. .sctn. 120 to, U.S. patent application Ser. No.
14/634,985, filed on Mar. 2, 2015, which claims the benefit, under
35 U.S.C. .sctn. 119(e), to U.S. Provisional Patent Application
Ser. Nos. 61/948,872, filed on Mar. 6, 2014, 61/948,692, filed on
Mar. 6, 2014, and 62/112,337, filed on Feb. 5, 2015, the entire
disclosures of all of which are fully incorporated by reference
herein.
FIELD
[0002] The present disclosure is generally related to
multi-component topsheets, and is more specifically related to
multi-component topsheets for absorbent articles and/or absorbent
articles comprising multi-component topsheets.
BACKGROUND
[0003] Absorbent articles for personal hygiene, such as disposable
diapers for infants, training pants for toddlers, adult
incontinence undergarments, and/or sanitary napkins are designed to
absorb and contain body exudates, in particular large quantities of
urine, runny BM, and/or menses (together the "fluids"). These
absorbent articles may comprise several layers providing different
functions, for example, a topsheet, a backsheet, and an absorbent
core disposed between the topsheet and the backsheet, among other
layers (e.g., acquisition layer, distribution layer, etc.), if
desired.
[0004] The topsheet is generally liquid permeable and is configured
to receive the fluids being excreted from the body and aid in
directing the fluids toward an acquisition system, a distribution
system, and/or the absorbent core. In general, topsheets may be
made to be hydrophilic via a surfactant treatment applied thereto
so that the fluids are attracted to the topsheet to then be
channeled into the underlying acquisition system, distribution
system, and/or the absorbent core. One of the important qualities
of a topsheet is the ability to reduce ponding of the fluids on the
topsheets before the fluids are able to be absorbed by the
absorbent article. Stated another way, one design criteria of
topsheets is to reduce the amount of time the fluids spend on
topsheet prior to being absorbed by the absorbent article. If
fluids remain on the surface of a topsheet for too long of a period
of time, the wearer may not feel dry and skin discomfort may
increase.
[0005] To solve the problem of the skin feeling wet during, for
example, urination, because of prolonged fluid residency on the
topsheets, apertured topsheets have been used to allow for faster
fluid penetration. Although apertured topsheets have generally
reduced fluid pendency on topsheets, topsheets can still be further
improved by providing three-dimensional substrates that further
reduce skin/fluid contact and/or skin/fluid contact time during,
for example, a urination event.
[0006] Moreover, three-dimensional substrates, or other improved
apertured topsheet materials, can be relatively expensive when
compared to traditional topsheet materials. Accordingly, it is of
continued interest to be able to attain the benefits of using
three-dimensional substrates as topsheet materials, while limiting
the added expense of employing such materials.
SUMMARY
[0007] The present disclosure is generally related, in part, to
three-dimensional substrates that may be applied to topsheets of
absorbent articles, form portions of, or all of, the topsheets, or
form other portions of absorbent articles. The three-dimensional
substrates may be liquid permeable substrates. The
three-dimensional substrates of the present disclosure may reduce
fluid/skin contact and/or fluid/skin contact time by providing
first elements having a first z-directional height and at least
second elements having a second z-directional height. These
substrates may also comprise apertures. The first z-directional
height may generally be higher than the second z-directional
height. Such a structure creates a substrate having a plurality of
heights. These three-dimensional substrates may allow fluids,
during a urination event, for example, to be received onto the
substrate and moved into the second elements having the second
z-directional height (lower) and/or into and through the apertures
to at least reduce the amount of fluid in contact with the skin
and/or to at least reduce the fluid/skin contact time. Stated
another way, the first elements having the first z-directional
height (higher) may be in contact with the skin, while the fluids
moves via gravity into the second elements having the second
z-directional height (lower height) and/or into and through the
apertures. Upon information and belief, such three-dimensional
structures reduce the amount of fluid on skin, give the wearer a
drier, more comfortable feel, and/or reduce the pendency of
fluid/skin contact. The first elements having the first
z-directional height (higher) essentially serve to provide a spacer
between the skin and the fluids while the substrates are channeling
the fluids into the acquisition and/or distribution system and/or
the absorbent core.
[0008] In one embodiment, a multi-component topsheet for an
absorbent article includes a first discrete substrate forming about
80% or more of an outer perimeter of the topsheet and a second
discrete substrate wherein about 80% or more of an outer perimeter
of the second discrete substrate is joined to the first discrete
substrate, wherein the topsheet has a single layer of substrate in
about 75% or more of the total area of the topsheet and a dual
layer of substrate in about 25% or less of the total area of the
topsheet, wherein the dual layer of substrate is formed from an
overlap between the first discrete substrate and the second
discrete substrate, wherein the second discrete substrate comprises
a plurality of recesses and projections, wherein the plurality of
recesses and projections together form a first three-dimensional
surface on a first side of the second discrete substrate and a
second three-dimensional surface on a second side of the substrate,
wherein a majority of the projections have, according to the
Projection Height Test, a z-dimensional height of between about 500
.mu.m and about 4000 .mu.m, and wherein a majority of the recesses
define an aperture at a location most distal from a top surface of
an adjacent projection, a majority of the recesses having,
according to the Recess Height Test, a z-directional height of
between about 500 .mu.m and about 2000 .mu.m.
[0009] In another embodiment, a multi-component topsheet for an
absorbent article includes a first discrete substrate forming about
80% or more of an outer perimeter of the topsheet and a second
discrete substrate wherein about 80% or more of an outer perimeter
of the second discrete substrate is joined to the first discrete
substrate, wherein the topsheet has a single layer of substrate in
about 75% or more of the total area of the topsheet and a dual
layer of substrate in about 25% or less of the total area of the
topsheet, wherein the dual layer of substrate is formed from an
overlap between the first discrete substrate and the second
discrete substrate, wherein the second discrete substrate comprises
a plurality of recesses and projections, wherein the plurality of
recesses and projections together form a first three-dimensional
surface on a first side of the second discrete substrate and a
second three-dimensional surface on a second side of the substrate,
wherein a majority of the projections have, according to the
Projection Height Test, a z-dimensional height of between about 500
.mu.m and about 4000 .mu.m, and wherein a majority of the recesses
define an aperture at a location most distal from a top surface of
an adjacent projection, a majority of the recesses having,
according to the Recess Height Test, a z-directional height of
between about 500 .mu.m and about 2000 .mu.m.
[0010] In another embodiment, an absorbent article includes a
multi-component topsheet for an absorbent article includes a first
discrete substrate forming about 80% or more of an outer perimeter
of the topsheet, and a second discrete substrate wherein about 80%
or more of an outer perimeter of the second discrete substrate is
joined to the first discrete substrate, wherein the topsheet has a
single layer of substrate in about 75% or more of the total area of
the topsheet and a dual layer of substrate in about 25% or less of
the total area of the topsheet, wherein the dual layer of substrate
is formed from an overlap between the first discrete substrate and
the second discrete substrate, wherein the second discrete
substrate comprises a plurality of recesses and projections,
wherein the plurality of recesses and projections together form a
first three-dimensional surface on a first side of the second
discrete substrate and a second three-dimensional surface on a
second side of the substrate, wherein a majority of the projections
have, according to the Projection Height Test, a z-dimensional
height of between about 500 .mu.m and about 4000 .mu.m, and wherein
a majority of the recesses define an aperture at a location most
distal from a top surface of an adjacent projection, a majority of
the recesses having, according to the Recess Height Test, a
z-directional height of between about 500 .mu.m and about 2000
.mu.m.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above-mentioned and other features and advantages of the
present disclosure, and the manner of attaining them, will become
more apparent and the disclosure itself will be better understood
by reference to the following description of non-limiting forms of
the disclosure taken in conjunction with the accompanying drawings,
wherein:
[0012] FIG. 1 is a top view of an absorbent article, wearer-facing
surface facing the viewer, with some layers partially removed in
accordance with the present disclosure;
[0013] FIG. 2 is a cross-sectional view of the absorbent article
taken about line 2-2 of FIG. 1 in accordance with the present
disclosure;
[0014] FIG. 3 is a cross-sectional view of the absorbent article
taken about line 2-2 of FIG. 2 where the absorbent article has been
loaded with fluid in accordance with the present disclosure;
[0015] FIG. 4 is a top view of another absorbent article,
wearer-facing surface facing the viewer, with some layers partially
removed in accordance with the present disclosure;
[0016] FIG. 5 is a cross-sectional view of the absorbent article
taken about line 5-5 of FIG. 4 in accordance with the present
disclosure;
[0017] FIG. 6 is a top view of an absorbent core of the absorbent
article of FIG. 4 with some layers partially removed in accordance
the present disclosure;
[0018] FIG. 7 is a cross-sectional view of the absorbent core taken
about line 7-7 of FIG. 6 in accordance with the present
disclosure;
[0019] FIG. 8 is a cross-sectional view of the absorbent core taken
about line 8-8 of FIG. 6 in accordance with the present
disclosure;
[0020] FIG. 9 is a top view of an absorbent article, wearer-facing
surface facing the viewer, that is a sanitary napkin with some of
the layers cut away in accordance with the present disclosure;
[0021] FIG. 10 is a top view of an absorbent article, wearer-facing
surface facing the viewer, that comprises a three-dimensional,
liquid permeable substrate in accordance with the present
disclosure;
[0022] FIG. 11 is a perspective view of an absorbent article of
FIG. 10 in accordance with the present disclosure;
[0023] FIG. 12 is an enlarged top view of a portion of the liquid
permeable substrate of FIG. 10 in accordance with the present
disclosure;
[0024] FIG. 13 is another enlarged top view of a portion of the
liquid permeable substrate of FIG. 10 in accordance with the
present disclosure;
[0025] FIG. 14 is a schematic illustration of a three-dimensional,
liquid permeable substrate positioned on and/or joined to a
topsheet for an absorbent article in accordance with the present
disclosure;
[0026] FIG. 15 is another schematic illustration of a
three-dimensional, liquid permeable substrate positioned on and/or
joined to a topsheet for an absorbent article in accordance with
the present disclosure;
[0027] FIG. 16 is another schematic illustration of a
three-dimensional, liquid permeable substrate positioned on and/or
joined to a topsheet for an absorbent article in accordance with
the present disclosure;
[0028] FIG. 17 is a front view of a portion of a three-dimensional,
liquid permeable substrate, wearer-facing surface facing the viewer
in accordance with the present disclosure;
[0029] FIG. 18 is a front perspective view of the portion of the
three-dimensional, liquid permeable substrate of FIG. 17 in
accordance with the present disclosure;
[0030] FIG. 19 is another front view of a portion of a
three-dimensional, liquid permeable substrate, wearer-facing
surface facing the viewer in accordance with the present
disclosure;
[0031] FIG. 20 is a front perspective view of the portion of the
liquid permeable substrate of FIG. 19 in accordance with the
present disclosure;
[0032] FIG. 21 is a back view of a portion of a three-dimensional,
liquid permeable substrate, wearer-facing surface facing the viewer
in accordance with the present disclosure;
[0033] FIG. 22 is a back perspective view of the portion of the
three-dimensional, liquid permeable substrate of FIG. 21 in
accordance with the present disclosure;
[0034] FIG. 23 is another back view of a portion of a
three-dimensional, liquid permeable substrate, wearer-facing
surface facing the viewer in accordance with the present
disclosure;
[0035] FIG. 24 is a back perspective view of the portion of the
liquid permeable substrate of FIG. 23 in accordance with the
present disclosure;
[0036] FIG. 25 is a cross sectional view of the liquid permeable
substrate in accordance with the present disclosure;
[0037] FIG. 26 is a schematic illustration of one example process
for forming the substrates of the present disclosure;
[0038] FIG. 27 is a view of intermeshing engagement of portions of
first and second rolls in accordance with the present
disclosure;
[0039] FIG. 28 is a view of a portion of the first roll in
accordance with the present disclosure;
[0040] FIG. 29 is a view of a portion of the second roll in
accordance with the present disclosure;
[0041] FIG. 30 is a schematic illustration of atop view of a
multi-component topsheet in accordance with the present
disclosure;
[0042] FIG. 31 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 30;
[0043] FIG. 32 is a schematic illustration of atop view of a
multi-component topsheet in accordance with the present
disclosure;
[0044] FIG. 33 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 32;
[0045] FIG. 34 is a schematic illustration of atop view of a
multi-component topsheet in accordance with the present
disclosure;
[0046] FIG. 35 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 34;
[0047] FIG. 36 is a schematic illustration of atop view of a
multi-component topsheet in accordance with the present
disclosure;
[0048] FIG. 37 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 36;
[0049] FIG. 38 is a schematic illustration of atop view of a
multi-component topsheet in accordance with the present
disclosure;
[0050] FIG. 39 is a schematic illustration of atop view of a
multi-component topsheet in accordance with the present
disclosure;
[0051] FIG. 40 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0052] FIG. 41 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0053] FIG. 42 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0054] FIG. 43 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0055] FIG. 44 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0056] FIG. 45 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0057] FIG. 46 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0058] FIG. 47 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 46;
[0059] FIG. 48 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0060] FIG. 49 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 48;
[0061] FIG. 50 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0062] FIG. 51 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 50;
[0063] FIG. 52 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 50;
[0064] FIG. 53 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0065] FIG. 54 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 53;
[0066] FIG. 55 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0067] FIG. 56 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 55;
[0068] FIG. 57 is a schematic illustration of a cross-sectional
view of the multi-component topsheet of FIG. 55;
[0069] FIG. 58 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0070] FIG. 59 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0071] FIG. 60 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0072] FIG. 61 is a schematic illustration of a top view of a
multi-component topsheet in accordance with the present
disclosure;
[0073] FIG. 62 is a schematic illustration of a cross-sectional
view of a multi-component topsheet in accordance with the present
disclosure;
[0074] FIG. 63 is a schematic illustration of a cross-sectional
view of a multi-component topsheet in accordance with the present
disclosure;
[0075] FIG. 64 is a schematic illustration of a cross-sectional
view of a multi-component topsheet in accordance with the present
disclosure;
[0076] FIG. 65 is a schematic illustration of a cross-sectional
view of a multi-component topsheet in accordance with the present
disclosure;
[0077] FIG. 66 is a schematic illustration of an absorbent article
in accordance with the present disclosure;
[0078] FIG. 67 is a schematic illustration of an absorbent article
in accordance with the present disclosure; and
[0079] FIG. 68 is a schematic illustration of an absorbent article
in accordance with the present disclosure.
DETAILED DESCRIPTION
[0080] 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
three-dimension substrates disclosed herein. One or more examples
of these non-limiting embodiments are illustrated in the
accompanying drawings. Those of ordinary skill in the art will
understand that the three-dimensional substrates 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.
Introduction
[0081] As used herein, the term "absorbent article" refers to
disposable devices such as infant, child, or adult diapers, adult
incontinence products, training pants, sanitary napkins, and the
like which are placed against or in proximity to a body of a wearer
to absorb and contain the various fluids (urine, menses, and/or
runny BM) or bodily exudates (generally solid BM) discharged from
the body. Typically, these absorbent articles comprise a topsheet,
backsheet, an absorbent core, optionally an acquisition system
and/or a distribution system (which may be comprised of one or
several layers), and typically other components, with the absorbent
core normally placed at least partially between the backsheet and
the acquisition and/or distribution system or between the topsheet
and the backsheet. The absorbent articles comprising
three-dimensional, liquid permeable substrates of the present
disclosure will be further illustrated in the below description and
in the Figures in the form of one or more components of taped
diaper. Nothing in this description should be, however, considered
limiting the scope of the claims. As such the present disclosure
applies to any suitable form of absorbent articles (e.g., diapers,
training pants, adult incontinence products, sanitary napkins).
[0082] As used herein, the term "nonwoven web" means a manufactured
sheet, web, or batt of directionally or randomly orientated fibers,
bonded by friction, and/or cohesion, and/or adhesion, excluding
paper and products which are woven, knitted, tufted, stitch-bonded
incorporating binding yarns or filaments, or felted by wet-milling,
whether or not additionally needled. The fibers may be of natural
or man-made origin and may be staple or continuous filaments or be
formed in situ. Commercially available fibers may have diameters
ranging from less than about 0.001 mm to more than about 0.2 mm and
may come in several different forms such as short fibers (known as
staple, or chopped), continuous single fibers (filaments or
monofilaments), untwisted bundles of continuous filaments (tow),
and twisted bundles of continuous filaments (yam). Nonwoven webs
may be formed by many processes such as meltblowing, spunbonding,
solvent spinning, electrospinning, carding, and airlaying. The
basis weight of nonwoven webs is usually expressed in grams per
square meter (g/m.sup.2 or gsm).
[0083] As used herein, the terms "joined", "bonded", or "attached"
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.
[0084] As used herein, the term "machine direction" or "MD" is the
direction that is substantially parallel to the direction of travel
of a substrate as it is made. The "cross direction" or "CD" is the
direction substantially perpendicular to the MD and in the plane
generally defined by the substrate.
[0085] As used herein, the term "hydrophilic", refers to a material
having a contact angle less than or equal to 90.degree. according
to The American Chemical Society Publication "Contact Angle,
Wettability, and Adhesion," edited by Robert F. Gould and
copyrighted in 1964.
[0086] As used herein, the term "hydrophobic", refers to a material
or layer having a contact angle greater than or equal to 90.degree.
according to The American Chemical Society Publication "Contact
Angle, Wettability, and Adhesion," edited by Robert F. Gould and
copyrighted in 1964.
General Description of the Absorbent Article
[0087] An example absorbent article in the form of a diaper 20 is
represented in FIGS. 1-3. FIG. 1 is a plan view of the example
diaper 20, in a flat-out state, with portions of the structure
being cut-away to more clearly show the construction of the diaper
20. The wearer-facing surface of the diaper 20 of FIG. 1 is facing
the viewer. This diaper 20 is shown for illustration purpose only
as the three-dimensional substrates of the present disclosure may
be used as one or more components of an absorbent article.
[0088] The absorbent article 20 may comprise a liquid permeable
topsheet 24, a liquid impermeable backsheet 25, an absorbent core
28 positioned at least partially intermediate the topsheet 24 and
the backsheet 25, and barrier leg cuffs 34. The absorbent article
may also comprise an acquisition and/or distribution system ("ADS")
50, which in the example represented comprises a distribution layer
54 and an acquisition layer 52, which will be further detailed
below. The absorbent article may also comprise elasticized
gasketing cuffs 32 comprising elastics 33 joined to a chassis of
the absorbent article, typically via the topsheet and/or backsheet,
and substantially planar with the chassis of the diaper.
[0089] The figures also show typical taped diaper components such
as a fastening system comprising tabs 42 attached towards the rear
edge of the article and cooperating with a landing zone 44 on the
front of the absorbent article. The absorbent article may also
comprise other typical elements, which are not represented, such as
a rear elastic waist feature, a front elastic waist feature,
transverse barrier cuff(s), and/or a lotion application, for
example.
[0090] The absorbent article 20 comprises a front waist edge 10, a
rear waist edge 12 longitudinally opposing the front waist edge 10,
a first side edge 3, and a second side edge 4 laterally opposing
the first side edge 3. The front waist edge 10 is the edge of the
article which is intended to be placed towards the front of the
user when worn, and the rear waist edge 12 is the opposite edge.
The absorbent article may have a longitudinal axis 80 extending
from the lateral midpoint of the front waist edge 10 to a lateral
midpoint of the rear waist edge 12 of the article and dividing the
article in two substantially symmetrical halves relative to the
longitudinal axis 80, with the article placed flat and viewed from
above as in FIG. 1. The absorbent article may also have a lateral
axis 90 extending from the longitudinal midpoint of the first side
edge 3 to the longitudinal midpoint of the second side edge 4. The
length, L, of the article may be measured along the longitudinal
axis 80 from the front waist edge 10 to the rear waist edge 12. The
width, W, of the article may be measured along the lateral axis 90
from the first side edge 3 to the second side edge 4. The article
may comprise a crotch point C defined herein as the point placed on
the longitudinal axis at a distance of two fifth ( ) of L starting
from the front edge 10 of the article 20. The article may comprise
a front waist region 5, a rear waist region 6, and a crotch region
7. The front waist region 5, the rear waist region 6, and the
crotch region 7 each define 1/3 of the longitudinal length, L, of
the absorbent article.
[0091] The topsheet 24, the backsheet 25, the absorbent core 28,
and the other article components may be assembled in a variety of
configurations, in particular by gluing or heat embossing, for
example. Example absorbent article configurations are described
generally in U.S. Pat. Nos. 3,860,003, 5,221,274, 5,554,145,
5,569,234, 5,580,411, and 6,004,306.
[0092] The absorbent core 28 may comprise an absorbent material
comprising at least 80% by weight, at least 90% by weight, at least
95% by weight, or at least 99% by weight of superabsorbent polymers
and a core wrap enclosing the superabsorbent polymers. The core
wrap may typically comprise two materials, substrates, or nonwoven
materials 16 and 16' for the top side and bottom side of the core.
The core may comprises one or more channels, represented in FIG. 1
as the four channels 26, 26' and 27, 27'. The channels 26, 26', 27,
and 27' are optional features. Instead, the core may not have any
channels or may have any number of channels.
[0093] These and other components of the example absorbent article
will now be discussed in more details.
Topsheet
[0094] In the present disclosure, the topsheet (the portion of the
absorbent article that contacts the wearer's skin and receives the
fluids) may be formed of a portion of, or all of, one or more of
the three-dimensional substrates described herein and/or have one
or more three-dimensional substrates positioned thereon and/or
joined thereto, so that the three-dimensional substrate(s)
contact(s) the wearer's skin. Other portions of the topsheet (other
than the three-dimensional substrates) may also contact the
wearer's skin. A typical topsheet is described below, although it
will be understood that this topsheet 24, or portions thereof, may
be replaced by the three-dimensional substrates described herein.
Alternatively, the three-dimensional substrates may be positioned
as a strip or a patch on top of the typical topsheet 24, as is
described herein.
[0095] The topsheet 24 may be the part of the absorbent article
that is in contact with the wearer's skin. The topsheet 24 may be
joined to the backsheet 25, the core 28 and/or any other layers as
is known to those of skill in the art. Usually, the topsheet 24 and
the backsheet 25 are joined directly to each other in some
locations (e.g., on or close to the periphery of the absorbent
article) and are indirectly joined together in other locations by
directly joining them to one or more other elements of the article
20.
[0096] The topsheet 24 may be compliant, soft-feeling, and
non-irritating to the wearer's skin. Further, a portion of, or all
of, the topsheet 24 may be liquid permeable, permitting liquids to
readily penetrate through its thickness. A suitable topsheet may be
manufactured from a wide range of materials, such as porous foams,
reticulated foams, apertured plastic films, or woven or nonwoven
materials of natural fibers (e.g., wood or cotton fibers),
synthetic fibers or filaments (e.g., polyester or polypropylene or
bicomponent PE/PP fibers or mixtures thereof), or a combination of
natural and synthetic fibers. If the topsheet 24 includes fibers,
the fibers may be spunbond, carded, wet-laid, meltblown,
hydroentangled, or otherwise processed as is known in the art. A
suitable topsheet comprising a web of spunbond polypropylene
(topically treated with a hydrophilic surfactant) is manufactured
by Polymer Group, Inc., of Charlotte, N.C. under the designation
P-10.
[0097] Any portion of the topsheet 24 may be coated with a lotion
and/or a skin care composition as is generally disclosed in the
art. The topsheet 24 may also comprise or be treated with
antibacterial agents, some examples of which are disclosed in PCT
Publication WO95/24173. Further, the topsheet 24, the backsheet 25
or any portion of the topsheet or backsheet may be embossed and/or
matte finished to provide a more cloth like appearance.
[0098] The topsheet 24 may comprise one or more apertures to ease
penetration of fluids therethrough. The size of at least the
primary apertures is important in achieving the desired fluid
encapsulation performance. If the primary apertures are too small,
the fluids may not pass through the apertures, either due to poor
alignment of the fluid source and the aperture location or due to
runny fecal masses, for example, having a diameter greater than the
apertures. If the apertures are too large, the area of skin that
may be contaminated by "rewet" from the article is increased.
Typically, the total area of the apertures at the surface of a
diaper may have an area of between about 10 cm.sup.2 and about 50
cm.sup.2 or between about 15 cm.sup.2 and 35 cm.sup.2. Examples of
apertured topsheets are disclosed in U.S. Pat. No. 6,632,504,
assigned to BBA NONWOVENS SIMPSONVILLE. Typical diaper topsheets
have a basis weight of from about 10 to about 50 gsm or from about
12 to about 30 gsm, but other basis weights are within the scope of
the present disclosure.
Backsheet
[0099] The backsheet 25 is generally that portion of the absorbent
article 20 positioned adjacent the garment-facing surface of the
absorbent core 28 and which prevents, or at least inhibits, the
fluids and bodily exudates absorbed and contained therein from
soiling articles such as bedsheets and undergarments. The backsheet
25 is typically impermeable, or at least substantially impermeable,
to fluids (e.g., urine). The backsheet may, for example, be or
comprise a thin plastic film such as a thermoplastic film having a
thickness of about 0.012 mm to about 0.051 mm. Example backsheet
films include those manufactured by Tredegar Corporation, based in
Richmond, Va., and sold under the trade name CPC2 film. Other
suitable backsheet materials may include breathable materials which
permit vapors to escape from the absorbent article 20 while still
preventing, or at least inhibiting, fluids from passing through the
backsheet 25. Example breathable materials may include materials
such as woven webs, nonwoven webs, composite materials such as
film-coated nonwoven webs, microporous films such as manufactured
by Mitsui Toatsu Co., of Japan under the designation ESPOIR NO and
by Tredegar Corporation of Richmond, Va., and sold under the
designation EXAIRE, and monolithic films such as manufactured by
Clopay Corporation, Cincinnati, Ohio under the name HYTREL blend
P18-3097.
[0100] The backsheet 25 may be joined to the topsheet 24, the
absorbent core 28, and/or any other element of the absorbent
article 20 by any attachment methods known to those of skill in the
art. Suitable attachment methods are described above with respect
to methods for joining the topsheet 24 to other elements of the
article 20.
[0101] An outer cover 23 may cover at least a portion of, or all
of, the backsheet 25 to form a soft garment-facing surface of the
absorbent article. The outer cover 23 may be formed of one or more
nonwoven materials. The outer cover 23 is illustrated in dash in
FIG. 2, as an example. The outer cover 23 may be joined to at least
a portion of the backsheet 25 through mechanical bonding, adhesive
bonding, or other suitable methods of attachment.
Absorbent Core
[0102] As used herein, the term "absorbent core" refers to the
component of the absorbent article having the most absorbent
capacity and comprising an absorbent material and a core wrap or
core bag enclosing the absorbent material. The term "absorbent
core" does not include the acquisition and/or distribution system
or any other components of the article which are not either
integral part of the core wrap or core bag or placed within the
core wrap or core bag. The absorbent core may comprise, consist
essentially of, or consist of, a core wrap, an absorbent material
(e.g., superabsorbent polymers) as discussed, and glue.
[0103] The absorbent core 28 may comprise an absorbent material
with a high amount of superabsorbent polymers (herein abbreviated
as "SAP") enclosed within the core wrap. The SAP content may
represent 70%-100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99%,
or 100%, by weight of the absorbent material, contained in the core
wrap. The core wrap is not considered as absorbent material for the
purpose of assessing the percentage of SAP in the absorbent core.
The core may also contain airfelt or cellulosic fibers with or
without SAP.
[0104] By "absorbent material" it is meant a material which has
some absorbency property or liquid retaining properties, such as
SAP, cellulosic fibers as well as synthetic fibers. Typically,
glues used in making absorbent cores have no or little absorbency
properties and are not considered as absorbent material. The SAP
content may be higher than 80%, for example at least 85%, at least
90%, at least 95%, at least 99%, and even up to and including 100%
of the weight of the absorbent material contained within the core
wrap. This provides a relatively thin core compared to a
conventional core typically comprising between 40-60% SAP and high
content of cellulose fibers. The conventional cores are also within
the scope of the present disclosure. The absorbent material may in
particular comprises less than 15% weight percent or less than 10%
weight percent of natural, cellulosic, or synthetic fibers, less
than 5% weight percent, less than 3% weight percent, less than 2%
weight percent, less than 1% weight percent, or may even be
substantially free of natural, cellulosic, and/or synthetic
fibers.
[0105] The example absorbent core 28 of the absorbent article 20 of
FIGS. 4-5 is shown in isolation in FIGS. 6-8. The absorbent core 28
may comprises 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 28 may also comprise a generally
planar top side and a generally planar bottom side. The front side
280 of the core is the side of the core intended to be placed
towards the front waist edge 10 of the absorbent article. The core
28 may have a longitudinal axis 80' corresponding substantially to
the longitudinal axis 80 of the absorbent article 20, as seen from
the top in a planar view as in FIG. 1. The absorbent material may
be distributed in higher amount towards the front side 280 than
towards the rear side 282 as more absorbency may be required at the
front in particular absorbent articles. The front and rear sides
280 and 282 of the core may be shorter than the longitudinal sides
284 and 286 of the core. The core wrap may be formed by two
nonwoven materials, substrates, laminates, or other materials, 16,
16' which may be at least partially sealed along the sides 284, 286
of the absorbent core 28. The core wrap may be at least partially
sealed along its front side 280, rear side 282, and two
longitudinal sides 284, 286 so that substantially no absorbent
material leaks out of the absorbent core wrap. The first material,
substrate, or nonwoven 16 may at least partially surround the
second material, substrate, or nonwoven 16' to form the core wrap,
as illustrated in FIG. 7. The first material 16 may surround a
portion of the second material 16' proximate to the first and
second side edges 284 and 286.
[0106] The absorbent core may comprise adhesive, for example, to
help immobilizing the SAP within the core wrap and/or to ensure
integrity of the core wrap, in particular when the core wrap is
made of two or more substrates. The adhesive may be a hot melt
adhesive, supplied, by H.B. Fuller, for example. The core wrap may
extend to a larger area than strictly needed for containing the
absorbent material within.
[0107] Cores comprising relatively high amount of SAP with various
core designs are disclosed in U.S. Pat. No. 5,599,335 (Goldman), EP
1,447,066 (Busam), WO 95/11652 (Tanzer), U.S. Pat. Publ. No.
2008/0312622A1 (Hundorf), and WO 2012/052172 (Van Malderen).
[0108] The absorbent material may be a continuous layer present
within the core wrap. Alternatively, the absorbent material may be
comprised of individual pockets or stripes of absorbent material
enclosed within the core wrap. In the first case, the absorbent
material may be, for example, obtained by the application of a
single continuous layer of absorbent material. The continuous layer
of absorbent material, in particular of SAP, may also be obtained
by combining two absorbent layers having discontinuous absorbent
material application patterns, wherein the resulting layer is
substantially continuously distributed across the absorbent
particulate polymer material area, as disclosed in U.S. Pat. Appl.
Pub. No. 2008/0312622A1 (Hundorf), for example. The absorbent core
28 may comprise a first absorbent layer and a second absorbent
layer. The first absorbent layer may comprise the first material 16
and a first layer 61 of absorbent material, which may be 100% or
less of SAP. The second absorbent layer may comprise the second
material 16' and a second layer 62 of absorbent material, which may
also be 100% or less of SAP. The absorbent core 28 may also
comprise a fibrous thermoplastic adhesive material 51 at least
partially bonding each layer of absorbent material 61, 62 to its
respective material 16 or 16'. This is illustrated in FIGS. 7-8, as
an example, where the first and second SAP layers have been applied
as transversal stripes or "land areas" having the same width as the
desired absorbent material deposition area on their respective
substrate before being combined. The stripes may comprise different
amounts of absorbent material (SAP) to provide a profiled basis
weight along the longitudinal axis of the core 80. The first
material 16 and the second material 16' may form the core wrap.
[0109] The fibrous thermoplastic adhesive material 51 may be at
least partially in contact with the absorbent material 61, 62 in
the land areas and at least partially in contact with the materials
16 and 16' in the junction areas. This imparts an essentially
three-dimensional structure to the fibrous layer of thermoplastic
adhesive material 51, which in itself is essentially a
two-dimensional structure of relatively small thickness, as
compared to the dimension in length and width directions. Thereby,
the fibrous thermoplastic adhesive material may provide cavities to
cover the absorbent material in the land areas, and thereby
immobilizes this absorbent material, which may be 100% or less of
SAP.
[0110] The thermoplastic adhesive used for the fibrous layer may
have elastomeric properties, such that the web formed by the fibers
on the SAP layer is able to be stretched as the SAP swell.
Elastomeric, hot-melt adhesives of these types are described in
more detail in U.S. Pat. No. 4,731,066 issued to Korpman on Mar.
15, 1988. The thermoplastic adhesive material may be applied as
fibers.
Superabsorbent Polymer (SAP)
[0111] "Superabsorbent polymers" ("SAP"), as used herein, refer to
absorbent materials which are cross-linked polymeric materials that
can absorb at least 10 times their weight of an aqueous 0.9% saline
solution as measured using the Centrifuge Retention Capacity (CRC)
test (EDANA method WSP 241.2-05E). The SAP used may have a CRC
value of more than 20 g/g, more than 24 g/g, from 20 to 50 g/g,
from 20 to 40 g/g, or from 24 to 30 g/g, specifically reciting all
0.1 g/g increments within the above-specified ranges and any ranges
created therein or thereby. The SAP useful with the present
disclosure may include a variety of water-insoluble, but
water-swellable polymers capable of absorbing large quantities of
fluids.
[0112] The superabsorbent polymer may be in particulate form so as
to be flowable in the dry state. Particulate absorbent polymer
materials may be made of poly(meth)acrylic acid polymers. However,
starch-based particulate absorbent polymer material may also be
used, as well as polyacrylamide copolymer, ethylene maleic
anhydride copolymer, cross-linked carboxymethylcellulose, polyvinyl
alcohol copolymers, cross-linked polyethylene oxide, and starch
grafted copolymer of polyacrylonitrile.
[0113] The SAP may be of numerous shapes. The term "particles"
refers to granules, fibers, flakes, spheres, powders, platelets and
other shapes and forms known to persons skilled in the art of
superabsorbent polymer particles. The SAP particles may be in the
shape of fibers, i.e., elongated, acicular superabsorbent polymer
particles. The fibers may also be in the form of a long filament
that may be woven. SAP may be spherical-like particles. The
absorbent core may comprise one or more types of SAP.
[0114] For most absorbent articles, liquid discharges from a wearer
occur predominately in the front half of the absorbent article, in
particular for a diaper. The front half of the article (as defined
by the region between the front edge and a transversal line placed
at a distance of half L from the front waist edge 10 or rear waist
edge 12 may therefore may comprise most of the absorbent capacity
of the core. Thus, at least 60% of the SAP, or at least 65%, 70%,
75%, 80%, or 85% of the SAP may be present in the front half of the
absorbent article, while the remaining SAP may be disposed in the
rear half of the absorbent article. Alternatively, the SAP
distribution may be uniform through the core or may have other
suitable distributions.
[0115] The total amount of SAP present in the absorbent core may
also vary according to expected user. Diapers for newborns may
require less SAP than infant, child, or adult incontinence diapers.
The amount of SAP in the core may be about 5 to 60 g or from 5 to
50 g, specifically reciting all 0.1 increments within the specified
ranges and any ranged formed therein or thereby. The average SAP
basis weight within the (or "at least one", if several are present)
deposition area 8 of the SAP may be at least 50, 100, 200, 300,
400, 500 or more g/m.sup.2. The areas of the channels (e.g., 26,
26', 27, 27') present in the absorbent material deposition area 8
are deduced from the absorbent material deposition area to
calculate this average basis weight.
Core Wrap
[0116] The core wrap may be made of a single substrate, material,
or nonwoven folded around the absorbent material, or may comprise
two (or more) substrates, materials, or nonwovens which are
attached to another. Typical attachments are the so-called C-wrap
and/or sandwich wrap. In a C-wrap, as illustrated, for example, in
FIGS. 2 and 7, the longitudinal and/or transversal edges of one of
the substrates are folded over the other substrate to form flaps.
These flaps are then bonded to the external surface of the other
substrate, typically by gluing.
[0117] The core wrap may be formed by any materials suitable for
receiving and containing the absorbent material. Typical substrate
materials used in the production of conventional cores may be used,
in particular paper, tissues, films, wovens or nonwovens, or
laminates or composites of any of these.
[0118] The substrates may also be air-permeable (in addition to
being liquid or fluid permeable). Films useful herein may therefore
comprise micro-pores.
[0119] The core wrap may be at least partially sealed along all the
sides of the absorbent core so that substantially no absorbent
material leaks out of the core. By "substantially no absorbent
material" it is meant that less than 5%, less than 2%, less than
1%, or about 0% by weight of absorbent material escape the core
wrap. The term "seal" is to be understood in a broad sense. The
seal does not need to be continuous along the whole periphery of
the core wrap but may be discontinuous along part or the whole of
it, such as formed by a series of seal points spaced on a line. A
seal may be formed by gluing and/or thermal bonding.
[0120] If the core wrap is formed by two substrates 16, 16', four
seals may be used to enclose the absorbent material 60 within the
core wrap. For example, a first substrate 16 may be placed on one
side of the core (the top side as represented in the Figures) and
extend around the core's longitudinal edges to at least partially
wrap the opposed bottom side of the core. The second substrate 16'
may be present between the wrapped flaps of the first substrate 16
and the absorbent material 60. The flaps of the first substrate 16
may be glued to the second substrate 16' to provide a strong seal.
This so called C-wrap construction may provide benefits such as
improved resistance to bursting in a wet loaded state compared to a
sandwich seal. The front side and rear side of the core wrap may
then also be sealed by gluing the first substrate and second
substrate to another to provide complete encapsulation of the
absorbent material across the whole of the periphery of the core.
For the front side and rear side of the core, the first and second
substrates may extend and may be joined together in a substantially
planar direction, forming for these edges a so-called sandwich
construction. In the so-called sandwich construction, the first and
second substrates may also extend outwardly on all sides of the
core and be sealed flat, or substantially flat, along the whole or
parts of the periphery of the core typically by gluing and/or
heat/pressure bonding. In an example, neither the first nor the
second substrates need to be shaped, so that they may be
rectangularly cut for ease of production but other shapes are
within the scope of the present disclosure.
[0121] The core wrap may also be formed by a single substrate which
may enclose as in a parcel wrap the absorbent material and be
sealed along the front side and rear side of the core and one
longitudinal seal.
SAP Deposition Area
[0122] The absorbent material deposition area 8 may be defined by
the periphery of the layer formed by the absorbent material 60
within the core wrap, as seen from the top side of the absorbent
core. The absorbent material deposition area 8 may have various
shapes, in particular, a so-called "dog bone" or "hour-glass"
shape, which shows a tapering along its width towards the middle or
"crotch" region of the core. In this way, the absorbent material
deposition area 8 may have a relatively narrow width in an area of
the core intended to be placed in the crotch region of the
absorbent article, as illustrated in FIG. 1. This may provide
better wearing comfort. The absorbent material deposition area 8
may also be generally rectangular, for example as shown in FIGS.
4-6, but other deposition areas, such as a rectangular, "T," "Y,"
"sand-hour," or "dog-bone" shapes are also within the scope of the
present disclosure. The absorbent material may be deposited using
any suitable techniques, which may allow relatively precise
deposition of SAP at relatively high speed.
Channels
[0123] The absorbent material deposition area 8 may comprise at
least one channel 26, which is at least partially oriented in the
longitudinal direction of the article 80 (i.e., has a longitudinal
vector component). Other channels may be at least partially
oriented in the lateral direction (i.e., has a lateral vector
component) or in any other direction. In the following, the plural
form "channels" will be used to mean "at least one channel". The
channels may have a length L' projected on the longitudinal axis 80
of the article that is at least 10% of the length L of the article.
The channels may be formed in various ways. For example, the
channels may be formed by zones within the absorbent material
deposition area 8 which may be substantially free of, or free of,
absorbent material, in particular SAP. In addition or
alternatively, the channel(s) may also be formed by continuously or
discontinuously bonding the top side of the core wrap to the bottom
side of the core wrap through the absorbent material deposition
area 8. The channels may be continuous but it is also envisioned
that the channels may be intermittent. The acquisition-distribution
system or layer 50, or another layer of the article, may also
comprise channels, which may or not correspond to the channels of
the absorbent core.
[0124] In some instances, the channels may be present at least at
the same longitudinal level as the crotch point C or the lateral
axis 60 in the absorbent article, as represented in FIG. 1 with the
two longitudinally extending channels 26, 26'. The channels may
also extend from the crotch region 7 or may be present in the front
waist region 5 and/or in the rear waist region 6 of the
article.
[0125] The absorbent core 28 may also comprise more than two
channels, for example, at least 3, at least 4, at least 5, or at
least 6 or more. Shorter channels may also be present, for example
in the rear waist region 6 or the front waist region 5 of the core
as represented by the pair of channels 27, 27' in FIG. 1 towards
the front of the article. The channels may comprise one or more
pairs of channels symmetrically arranged, or otherwise arranged
relative to the longitudinal axis 80.
[0126] The channels may be particularly useful in the absorbent
core when the absorbent material deposition area is rectangular, as
the channels may improve the flexibility of the core to an extent
that there is less advantage in using a non-rectangular (shaped)
core. Of course channels may also be present in a layer of SAP
having a shaped deposition area.
[0127] The channels may be completely oriented longitudinally and
parallel to the longitudinal axis or completely oriented
transversely and parallel to the lateral axis, but also may have at
least portions that are curved.
[0128] In order to reduce the risk of fluid leakages, the
longitudinal main channels may not extend up to any of the edges of
the absorbent material deposition area 8, and may therefore be
fully encompassed within the absorbent material deposition area 8
of the core. The smallest distance between a channel and the
closest edge of the absorbent material deposition area 8 may be at
least 5 mm.
[0129] The channels may have a width We along at least part of
their length which is at least 2 mm, at least 3 mm, at least 4 mm,
up to for example 20 mm, 16 mm, or 12 mm, for example. The width of
the channel(s) may be constant through substantially the whole
length of the channel or may vary along its length. When the
channels are formed by absorbent material-free zone within the
absorbent material deposition area 8, the width of the channels is
considered to be the width of the material free zone, disregarding
the possible presence of the core wrap within the channels. If the
channels are not formed by absorbent material free zones, for
example mainly though bonding of the core wrap through the
absorbent material zone, the width of the channels is the width of
this bonding.
[0130] At least some or all of the channels may be permanent
channels, meaning their integrity is at least partially maintained
both in the dry state and in the wet state. Permanent channels may
be obtained by provision of one or more adhesive materials, for
example, the fibrous layer of adhesive material or construction
glue that helps adhere a substrate with an absorbent material
within the walls of the channel. Permanent channels may also be
formed by bonding the upper side and lower side of the core wrap
(e.g., the first substrate 16 and the second substrate 16') and/or
the topsheet 24 to the backsheet 25 together through the channels.
Typically, an adhesive may be used to bond both sides of the core
wrap or the topsheet and the backsheet through the channels, but it
is possible to bond via other known processes, such as pressure
bonding, ultrasonic bonding, heat bonding, or combination thereof.
The core wrap or the topsheet 24 and the backsheet 25 may be
continuously bonded or intermittently bonded along the channels.
The channels may advantageously remain or become visible at least
through the topsheet and/or backsheet when the absorbent article is
fully loaded with a fluid. This may be obtained by making the
channels substantially free of SAP, so they will not swell, and
sufficiently large so that they will not close when wet.
Furthermore, bonding the core wrap to itself or the topsheet to the
backsheet through the channels may be advantageous.
Barrier Leg Cuffs
[0131] The absorbent article may comprise a pair of barrier leg
cuffs 34. Each barrier leg cuff may be formed by a piece of
material which is bonded to the article so it may extend upwards
from a wearer-facing surface of the absorbent article and provide
improved containment of fluids and other body exudates
approximately at the junction of the torso and legs of the wearer.
The barrier leg cuffs are delimited by a proximal edge 64 joined
directly or indirectly to the topsheet 24 and/or the backsheet 25
and a free terminal edge 66, which is intended to contact and form
a seal with the wearer's skin. The barrier leg cuffs 34 extend at
least partially between the front waist edge 10 and the rear waist
edge 12 of the absorbent article on opposite sides of the
longitudinal axis 80 and are at least present at the level of the
crotch point (C) or crotch region. The barrier leg cuffs may be
joined at the proximal edge 64 with the chassis of the article by a
bond 65 which may be made by gluing, fusion bonding, or a
combination of other suitable bonding processes. The bond 65 at the
proximal edge 64 may be continuous or intermittent. The bond 65
closest to the raised section of the leg cuffs delimits the
proximal edge 64 of the standing up section of the leg cuffs.
[0132] The barrier leg cuffs may be integral with the topsheet 24
or the backsheet 25 or may be a separate material joined to the
article's chassis. Each barrier leg cuff 34 may comprise one, two
or more elastic strings 35 close to the free terminal edge 66 to
provide a better seal.
[0133] In addition to the barrier leg cuffs 34, the article may
comprise gasketing cuffs 32, which are joined to the chassis of the
absorbent article, in particular to the topsheet 24 and/or the
backsheet 25 and are placed externally relative to the barrier leg
cuffs. The gasketing cuffs 32 may provide a better seal around the
thighs of the wearer. Each gasketing leg cuff may comprise one or
more elastic strings or elastic elements 33 in the chassis of the
absorbent article between the topsheet 24 and backsheet 25 in the
area of the leg openings. All, or a portion of, the barrier leg
cuffs and/or gasketing cuffs may be treated with a lotion or
another skin care composition.
Acquisition-Distribution System
[0134] The absorbent articles of the present disclosure may
comprise an acquisition-distribution layer or system 50 ("ADS").
One function of the ADS is to quickly acquire one or more of the
fluids and distribute them to the absorbent core in an efficient
manner. The ADS may comprise one, two or more layers, which may
form a unitary layer or may remain as discrete layers which may be
attached to each other. In an example, the ADS may comprise two
layers: a distribution layer 54 and an acquisition layer 52
disposed between the absorbent core and the topsheet, but the
present disclosure is not so limited.
[0135] The ADS may comprise SAP as this may slow the acquisition
and distribution of the fluids. Suitable ADS are described in WO
2000/59430 (Daley), WO 95/10996 (Richards), U.S. Pat. No. 5,700,254
(McDowall), and WO 02/067809 (Graef), for example.
[0136] In one example, the ADS may not be provided, or only one
layer of the ADS may be provided, such as the distribution layer
only or the acquisition layer only. When one of the
three-dimensional, liquid permeable substrates of the present
disclosure is used as a portion of, or all of, a topsheet, or
positioned on a topsheet, dryness performance of the liquid
permeable substrates may be improved if only one or no layers of
the ADS are present. This is owing to the fact that fluids (e.g.,
urine) are easily able to wick through the liquid permeable
substrates directly into the absorbent core 28 and/or into one
layer of the ADS.
Distribution Layer
[0137] The distribution layer of the ADS may comprise at least 50%
by weight of cross-linked cellulose fibers. The cross-linked
cellulosic fibers may be crimped, twisted, or curled, or a
combination thereof including crimped, twisted, and curled. This
type of material is disclosed in U.S. Pat. Publ. No. 2008/0312622
A1 (Hundorf). The cross-linked cellulosic fibers provide higher
resilience and therefore higher resistance to the first absorbent
layer against the compression in the product packaging or in use
conditions, e.g., under wearer weight. This may provide the core
with a higher void volume, permeability, and liquid absorption, and
hence reduced leakage and improved dryness.
[0138] The distribution layer comprising the cross-linked cellulose
fibers of the present disclosure may comprise other fibers, but
this layer may advantageously comprise at least 50%, or 60%, or
70%, or 80%, or 90%, or even up to 100%, by weight of the layer, of
cross-linked cellulose fibers (including the cross-linking agents).
Examples of such mixed layer of cross-linked cellulose fibers may
comprise about 70% by weight of chemically cross-linked cellulose
fibers, about 10% by weight polyester (PET) fibers, and about 20%
by weight untreated pulp fibers. In another example, the layer of
cross-linked cellulose fibers may comprise about 70% by weight
chemically cross-linked cellulose fibers, about 20% by weight
lyocell fibers, and about 10% by weight PET fibers. In still
another example, the layer may comprise about 68% by weight
chemically cross-linked cellulose fibers, about 16% by weight
untreated pulp fibers, and about 16% by weight PET fibers. In yet
another example, the layer of cross-linked cellulose fibers may
comprise from about 90 to about 100% by weight chemically
cross-linked cellulose fibers.
Acquisition Layer
[0139] The ADS 50 may comprise an acquisition layer 52. The
acquisition layer may be disposed between the distribution layer 54
and the topsheet 24. The acquisition layer 52 may be or may
comprise a nonwoven material, such as a hydrophilic SMS or SMMS
material, comprising a spunbonded, a melt-blown and a further
spunbonded layer or alternatively a carded staple fiber
chemical-bonded nonwoven. The nonwoven material may be latex
bonded.
[0140] A further acquisition layer may be used in addition to a
first acquisition layer described above. For example, a tissue
layer may be placed between the first acquisition layer and the
distribution layer. The tissue may have enhanced capillarity
distribution properties compared to the acquisition layer described
above.
Fastening System
[0141] The absorbent article may include a fastening system. The
fastening system may be used to provide lateral tensions about the
circumference of the absorbent article to hold the absorbent
article on the wearer as is typical for taped diapers. This
fastening system may not be necessary for training pant articles
since the waist region of these articles is already bonded. The
fastening system may comprise a fastener such as tape tabs, hook
and loop fastening components, interlocking fasteners such as tabs
& slots, buckles, buttons, snaps, and/or hermaphroditic
fastening components, although any other suitable fastening
mechanisms are also within the scope of the present disclosure. A
landing zone 44 is normally provided on the garment-facing surface
of the front waist region 5 for the fastener to be releasably
attached thereto.
Front and Rear Ears
[0142] The absorbent article may comprise front ears 46 and rear
ears 40. The ears may be an integral part of the chassis, such as
formed from the topsheet 24 and/or backsheet 26 as side panels.
Alternatively, as represented on FIG. 1, the ears may be separate
elements attached by gluing, heat embossing, and/or pressure
bonding. The rear ears 40 may be stretchable to facilitate the
attachment of the tabs 42 to the landing zone 44 and maintain the
taped diapers in place around the wearer's waist. The rear ears 40
may also be elastic or extensible to provide a more comfortable and
contouring fit by initially conformably fitting the absorbent
article to the wearer and sustaining this fit throughout the time
of wear well past when absorbent article has been loaded with
fluids or other bodily exudates since the elasticized ears allow
the sides of the absorbent article to expand and contract.
Elastic Waist Feature
[0143] The absorbent article 20 may also comprise at least one
elastic waist feature (not represented) that helps to provide
improved fit and containment. The elastic waist feature is
generally intended to elastically expand and contract to
dynamically fit the wearer's waist. The elastic waist feature may
extend at least longitudinally outwardly from at least one waist
edge of the absorbent core 28 and generally forms at least a
portion of the end edge of the absorbent article. Disposable
diapers may be constructed so as to have two elastic waist
features, one positioned in the front waist region and one
positioned in the rear waist region.
Relations between the Layers
[0144] Typically, adjacent layers and components may be joined
together using conventional bonding methods, such as adhesive
coating via slot coating or spraying on the whole or part of the
surface of the layer, thermo-bonding, pressure bonding, or
combinations thereof. This bonding is not represented in the
Figures (except for the bonding between the raised element of the
leg cuffs 65 with the topsheet 24) for clarity and readability, but
bonding between the layers of the article should be considered to
be present unless specifically excluded. Adhesives may be used to
improve the adhesion of the different layers between the backsheet
25 and the core wrap. The glue may be any suitable hotmelt glue
known in the art.
Sanitary Napkin
[0145] The three-dimensional substrates of the present disclosure
may form a portion of a topsheet, form the topsheet, form a portion
of, or all of a secondary topsheet, or be positioned on or joined
to at least a portion of the topsheet of a sanitary napkin.
Referring to FIG. 9, the absorbent article may comprise a sanitary
napkin 300. The sanitary napkin 300 may comprise a liquid permeable
topsheet 314, a liquid impermeable, or substantially liquid
impermeable, backsheet 316, and an absorbent core 308. The
absorbent core 308 may have any or all of the features described
herein with respect to the absorbent cores 28 and, in some forms,
may have a secondary topsheet instead of the
acquisition-distribution system disclosed above. The sanitary
napkin 300 may also comprise wings 320 extending outwardly with
respect to a longitudinal axis 380 of the sanitary napkin 300.
[0146] The sanitary napkin 300 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 308. The sanitary napkin 300 may
also comprise a front edge 322, a rear edge 324 longitudinally
opposing the front edge 322, a first side edge 326, and a second
side edge 328 longitudinally opposing the first side edge 326. The
longitudinal axis 380 may extend from a midpoint of the front edge
322 to a midpoint of the rear edge 324. The lateral axis 390 may
extend from a midpoint of the first side edge 326 to a midpoint of
the second side edge 328. The sanitary napkin 300 may also be
provided with additional features commonly found in sanitary
napkins as is generally known in the art, such as a secondary
topsheet 319, for example.
Three-Dimensional Substrates
[0147] The three-dimensional, liquid permeable substrates of the
present disclosure may comprise substrates that have first elements
(e.g., projections) that have a first z-directional height and at
least second elements (e.g., land areas) that have a second
z-directional height. The substrates may also have a plurality of
apertures. The substrates may also have at least third elements
having at least a third z-directional height. Owing to such
structures, fluids may be quickly moved away from the skin of a
wearer, leaving primarily the first elements having the first
z-directional heights contacting the skin of the wearer, thereby
making the wearer feel dryer. The fluids may flow via gravity or
via capillary gradient into the second elements having the second
z-directional heights and/or into and through the apertures, so
that the fluids may be absorbed into the absorbent articles. By
providing the three-dimensional substrates of the present
disclosure, fluid/skin contact and the time that fluids are in
contact with the skin of a wearer may be reduced. Further, the
first elements having the first z-directional heights may act as a
spacer between the fluids and the skin of the wearer while the
fluids are being absorbed into the absorbent article.
[0148] Referring to FIGS. 10-13, a three-dimensional, liquid
permeable substrate 400 (referred to herein both as a
three-dimensional substrate or a liquid permeable substrate) is
illustrated an on absorbent article 402. FIG. 10 is a top view of
the absorbent article 402 with the wearer-facing surface facing the
viewer. FIG. 11 is a perspective view of the absorbent article 402
with the wearer-facing surface facing the viewer. FIG. 12 is a top
view of a portion of the liquid preamble substrate 400 on the
absorbent article with the wearer-facing surface facing the viewer.
FIG. 13 is another top view of a portion of the liquid permeable
substrate 400 on the absorbent article 402 with the wearer-facing
surface facing the viewer.
[0149] In one form, the liquid permeable substrate 400, or other
liquid permeable substrates described herein, may comprise a patch
or strip positioned on and/or joined to a topsheet of the absorbent
article 402. The patch or strip may be bonded to the topsheet,
adhesively attached to the topsheet, cold-pressure welded to the
topsheet, ultrasonically bonded to the topsheet, and/or otherwise
joined to the topsheet. Alternatively, the liquid permeable
substrates of the present disclosure may comprise the topsheet
(e.g., topsheet 24), form all of the topsheet, or form a portion of
the topsheet. Also, the topsheet 24 may be comprised only of one or
more of the liquid permeable substrates of the present disclosure.
In any of the various configurations, the liquid permeable
substrates of the present disclosure are intended to form at least
a portion of the wearer-facing surface of an absorbent article and
be in at least partial contact with the skin of a wearer.
[0150] Referring to FIGS. 14-16, the liquid permeable substrate
400, or other liquid permeable substrates described herein, in a
patch or strip form joined to the topsheet 24, may have a cross
machine directional width of W1, while the topsheet 24 may have a
cross machine directional width of W2. W1 may be less than, the
same as, substantially the same as, or greater than (not
illustrated) the width W2. The width W1 may also vary or be
constant throughout a longitudinal length of the liquid permeable
substrates. Still referring to FIGS. 14-16, the liquid permeable
substrate 400, or other liquid permeable substrates described
herein, in a patch or strip form, may have a machine directional
length of L1, while the topsheet 24 may have a machine directional
length of L2. L1 may be less than, the same as, substantially the
same as, or greater than (not illustrated) the length L2. The
length L1 may vary or be constant across the width W1 of the liquid
permeable substrates. Although not illustrated in FIGS. 14-16, the
lengths and widths of the topsheet 24 and the liquid permeable
substrates may be the same, or substantially the same.
[0151] Although the patch or strip of the liquid permeable
substrate 400 is illustrated as being rectangular in FIGS. 14-16,
the liquid permeable substrates of the present disclosure may also
have any other suitable shapes, such a front/back profiled shape
(i.e., wider in the front, wider in the back, and/or narrower in
the crotch), a square shape, an ovate shape, or other suitable
shape. The side edges 404 and/or the end edge 406 of the liquid
permeable substrate 400 may have one or more arcuate portions,
designs, and/or shapes cut out from them to provide an
aesthetically pleasing look to the liquid permeable substrate 400.
One side edge 404 may be symmetrical or asymmetrical to another
side edge 404 about a longitudinal axis, 408, of the topsheet 24.
Likewise, one end edge 406 may be symmetrical or asymmetrical to
another side edge 406 about a lateral axis, 410 of the topsheet
24.
[0152] The liquid permeable substrate 400 may comprise one or more
layers. If more than one layer is provided, the layers may be
joined together or attached to each other through mechanical
bonding, adhesive bonding, pressure bonding, heat bonding, passing
heated air through both layers, or by other methods of joining to
form the multilayer substrate 400. Alternatively the layers are
formed in subsequent fiber laydown steps such as a first and a
second carding operation for a first type and a second type of
staple fibers or two subsequent beams of spunlaying polymeric
filaments including additives. The first layer may comprise one or
more hydrophobic materials, or may be fully hydrophobic, and the
second layer may comprise one or more hydrophilic materials, or may
be fully hydrophilic. Instead of one layer comprising a hydrophobic
material and the other layer comprising a hydrophilic material, one
layer may comprise a material that is more hydrophobic or more
hydrophilic than the material that comprises the other layer (e.g.,
both layers are hydrophilic, but one layer is more hydrophilic or
both layers are hydrophobic, but one layer is more hydrophobic).
The first layer may comprise a hydrophobic layer and the second
layer may comprise a hydrophilic layer or vice versa. The first
layer may be used as a portion of, or all of, the wearer-facing
surface of the absorbent article. Alternatively, the second layer
may be used as a portion of, or all of, the wearer-facing surface
of the absorbent article.
[0153] The rationale for having the first layer (or wearer-facing
layer) being comprised of a hydrophobic material is twofold. First,
if the liquid permeable substrate is apertured, the hydrophobic
layer will not retain as much liquid as the hydrophilic second
layer and thus, there will be less fluid (e.g., urine) in direct
contact with the skin of a wearer. Second, projections (described
below) in the first and second layers generally form hollow
portions or arches on a garment-facing side of the liquid permeable
substrate that do not have direct contact with the ADS or core, so
fluids can get caught in the hollow arches. Without good
connectivity of the hollow arches to the ADS or the core, the
liquid permeable substrate may retain more fluid and feel wetter to
the wearer. With a hydrophobic first layer, however, any liquid
that is wicked into the hollow arches will be mostly on the
garment-facing, or downward-facing hydrophilic side of the liquid
permeable substrate, thereby leaving the first hydrophobic layer
dryer. In principle, this may be achieved with a hydrophilic or
capillary gradient from the first layer to the second layer (e.g.
finer fibers in the second layer with same hydrophilic properties
(i.e., contact angle with the liquid)). The apertures in the
substrate may play an important role to enable initial and fast
fluid flow (strike-through) despite the first hydrophobic layer.
Therefore, the first hydrophobic layer works in concert with the
protrusions, hollow arches, and the apertures to reduce wetness on
the wearer-facing surface of the liquid permeable substrate. In
other instances, the second layer may be used as a portion of the
wearer-facing surface.
[0154] The first layer may comprise a plurality of first fibers
and/or filaments (hereafter together referred to as fibers). The
plurality of first fibers may comprise fibers that are the same,
substantially the same, or different in size, shape, composition,
denier, fiber diameter, fiber length, and/or weight. The second
layer may comprise a plurality of second fibers. The plurality of
second fibers may comprise fibers that are the same, substantially
the same, or different in size, shape, composition, denier, fiber
diameter, fiber length, and/or weight. The plurality of first
fibers may be the same as, substantially the same as, or different
than the plurality of second fibers. Additional layers may have the
same or different configurations.
[0155] The first layer and/or the second layer may comprise
bicomponent fibers having a sheath and a core. The sheath may
comprise polyethylene and the core may comprise polyethylene
terephthalate (PET). The sheath and the core may also comprise any
other suitable materials known to those of skill in the art. The
sheath and the core may each comprise about 50% of the fibers by
weight of the fibers, although other variations (e.g., sheath 60%,
core 40%; sheath 30%, core 70% etc.) are also within the scope of
the present disclosure. The bicomponent fibers or other fibers that
make up the first and/or second layers may have a denier in the
range of about 0.5 to about 4, about 1.0 to about 3, about 1.5 to
about 2.5, or about 2, specifically including all 0.1 denier
increments within the specified ranges and all ranges formed
therein or thereby. Denier is defined as the mass in grams per 9000
meters of a fiber length.
[0156] The plurality of first and second fibers may also comprise
any other suitable types of fibers, such as polypropylene fibers,
other polyolefins, other polyesters besides PET such as polylactic
acid, thermoplastic starch-containing sustainable resins, other
sustainable resins, bio-PE, bio-PP, and Bio-PET, viscose fibers,
rayon fibers, or other suitable nonwoven fibers, for example. These
fibers may have any suitable deniers or denier ranges and/or fiber
lengths or fiber length ranges.
[0157] In an instance where the plurality of first and second
fibers are the same or substantially the same, the plurality of
second fibers may be treated with a hydrophilic agent, such as a
surfactant, to cause the plurality of second fibers to become
hydrophilic or at least less hydrophobic. The plurality of first
fibers may not be treated with the surfactant such that they remain
in their natural hydrophobic state or the plurality of first fibers
may be treated with a surfactant to become less hydrophobic.
[0158] The first layer may have a basis weight in the range of
about 10 gsm to about 25 gsm. The second layer may have a basis
weight in the range of about 10 gsm to about 45 gsm. The basis
weight of the substrate (both first and second layers) may be in
the range of about 20 gsm to about 70 gsm, about 20 gsm to about 60
gsm, about 25 gsm to about 50 gsm, about 30 gsm to about 40 gsm,
about 30 gsm, about 35 gsm, or about 40 gsm.
[0159] In an example, the basis weight of the substrate may be
about 30 gsm to about 40 gsm or about 35 gsm. In such an example,
the first layer may have a basis weight in the range of about 10
gsm to about 20 gsm, or about 15 gsm, and the second layer may have
a basis weight in the range of about 15 gsm to about 25 gsm, or
about 20 gsm. In another example, the basis weight of the substrate
may be about 20 gsm. In such an example, the first layer may have a
basis weight of about 10 gsm and the second layer may have a basis
weight of about 10 gsm. In still another example, the basis weight
of the substrate may be about 60 gsm. In such an example, the first
layer may have a basis weight of about 24 gsm, and the second layer
may have a basis weight of 36 gsm. All other suitable basis weight
ranges for the first and second layers and the substrates are
within the scope of the present disclosure. Accordingly, the basis
weight of the layers and the substrates may be designed for
specific product requirements.
[0160] Specifically recited herein are all 0.1 gsm increments
within the above-specified ranges of basis weight and all ranges
formed therein or thereby.
[0161] The liquid permeable substrates of the present disclosure
may also form a portion of, or all of, the outer cover 23 which is
joined to at least a portion of the backsheet 25. In other
instances, the outer cover 23 may comprise a pattern (e.g.,
embossed pattern, printed pattern) and/or three-dimensional
structure that is the same as, or similar in appearance to, the
liquid permeable substrates of the present disclosure. In general,
the appearance of at least a portion of a liquid permeable
substrate on the wearer-facing surface may match, or substantially
match, at least a portion of the outer cover 23 or another portion
of absorbent article.
[0162] FIG. 17 is a front view of a portion of a three-dimensional,
liquid permeable substrate, wearer-facing surface facing the
viewer. FIG. 18 is a front perspective view of the portion of the
three-dimensional, liquid permeable substrate of FIG. 17. FIG. 19
is another front view of a portion of a three-dimensional, liquid
permeable substrate, wearer-facing surface facing the viewer. FIG.
20 is a front perspective view of the portion of the liquid
permeable substrate of FIG. 19. FIG. 21 is a back view of a portion
of a three-dimensional, liquid permeable substrate, wearer-facing
surface facing the viewer. FIG. 22 is a back perspective view of
the portion of the three-dimensional, liquid permeable substrate of
FIG. 21. FIG. 23 is another back view of a portion of a
three-dimensional, liquid permeable substrate, wearer-facing
surface facing the viewer. FIG. 24 is a back perspective view of
the portion of the liquid permeable substrate of FIG. 23. FIG. 25
is a cross-sectional view of the liquid permeable substrate.
[0163] Referring generally to FIGS. 17-25, the liquid permeable
substrate 400 may comprise a first layer and a second layer, or
more than two layers or one layer. The substrate 400 may comprise a
plurality of land areas 412, a plurality of recesses 414, and a
plurality of projections 416. The plurality of projections 416 may
form the first elements having the first z-directional height, and
the land areas 412 may form the second elements having the second
z-direction height, as described above. The plurality of land areas
412, the plurality of recesses 414, and the plurality of
projections 416 may together form a first three-dimensional surface
on a first side 418 of the substrate 400. The plurality of land
areas 412, the plurality of recesses 414, and the plurality of
projections 416 may also form a second three-dimensional surface on
a second side 420 of the substrate 400. The projections 416 may be
generally dome shaped on a wearer-facing surface of the liquid
permeable substrate 400 and may be hollow arch-shaped on the
garment-facing surface of the substrate 400. All of, or a majority
of (i.e., more than 50% of, or more than 75% of), or substantially
all of, the recesses 414 may define an aperture 422 therein at a
location most distal from a top peak 425 of an adjacent projection
416. A perimeter 423 of a majority of, or all of, the apertures 422
may form a bottommost portion or plane of the substrate 400, while
the top peak 425 (i.e., uppermost portion) of a majority of, or all
of, the projections 416 may form a topmost portion or plane of the
substrate 400. In other instances, the substrate may not have
apertures within the recesses 414 and the portion of the recesses
414 most distal from the top peaks 425 of the projections 416 may
form the bottommost portion or plane of the substrate 400. The
apertures 422 may extend through the first and the second layers of
the substrate 400.
[0164] The land areas 412 may be positioned intermediate: (1)
adjacent projections 416, (2) adjacent recesses 414 and/or adjacent
apertures 422. The land areas 412 may also surround at least a
portion of, or all of, a majority of, or all of, the recesses 414
and/or the apertures and at least a majority of, or all of, the
projections 416. The land areas 412 may be positioned between a
plane of a perimeter of at least a majority of the apertures 422
and a plane of at least a majority of the top peaks 425 of the
projections 416.
[0165] The projections 416 may alternate with the recesses 414
and/or the apertures 422 in a direction generally parallel with a
lateral axis 424 of the liquid permeable substrate 400. The lateral
axis 424 is generally parallel with the lateral axis 410
illustrated in FIGS. 14-16. The projections 416 may also alternate
with the recesses 414 and/or apertures 422 in a direction generally
parallel with a longitudinal axis 426 of the liquid permeable
substrate 400. The longitudinal axis 426 is generally parallel with
the longitudinal axis 408 illustrated in FIGS. 14-16. In such a
configuration, in a direction generally parallel with the lateral
axis 424 or in a direction generally parallel with the longitudinal
axis 426, the projections 416 and the recesses 414 and/or apertures
422 alternate (i.e., projection, recess and/or apertures,
projection, recess and/or aperture). This feature provides better
softness to the substrate 400 in that there is a soft projection
peak 425 intermediate most of, or all of, adjacent recesses 414
and/or apertures 422. This feature also helps maintain the skin of
a wearer away from fluids in the land areas 412 and/or the recesses
414, since the projections 416 essentially create a spacer between
the skin and the fluids.
[0166] Two or more adjacent projections 416 may be separated from
each other by a recess 414 and/or an aperture 422 and one or more
land areas 412 in a direction generally parallel to the lateral
axis 424 or in a direction generally parallel to the longitudinal
axis 426. Two or more adjacent recesses 414 and/or apertures 422
may be separated by a projection 416 and one or more land areas 412
in a direction generally parallel to the lateral axis 424 or in a
direction generally parallel to the longitudinal axis 426. The land
areas 412 may fully surround the apertures 422 and the projections
416. The land areas 412 may together form a generally continuous
grid through the substrate 400, while the projections 416 and the
recesses 414 and/or the apertures 422 may be discrete elements
throughout the substrate.
[0167] In some instances, two or more, such as four projections 416
may be positioned around at least a majority of, substantially all
of, or all of, the recesses 414 and/or the apertures 422 (this does
not include the land areas 412 intermediate the projections 416 and
the recesses 414 and/or the apertures 422). Two or more recesses
414 and/or apertures 422, such as four, may be positioned around at
least a majority of, substantially all of, or all of, the
projections 416 (this does not include the land areas 412
intermediate the recesses 414 and/or the apertures 422 and the
projections 416). The projections 416, recesses 414, apertures 422,
and land areas 422 may all be formed of portions of the first and
second layers of the substrate. If more than two layers are
provided in a substrate, the projections 416, recesses 414,
apertures 422, and land areas 422 may all be formed of portions of
the first, second and third layers of the substrate. The same may
be true if more than three layers are provided in a particular
substrate. In other instances, the land areas 422 may only be
formed in the first layer.
[0168] The apertures 422 and/or the recesses 414 may comprise a
first set of apertures and/or recesses 414 together forming a first
line in the substrate 400 and a second set of apertures 422 and/or
recesses 414 together forming a second line in the substrate 400.
The first line may be generally parallel with or generally
perpendicular to the second line. The first line may also form an
acute or obtuse angle with the second line. The projections 416 may
comprise a first set of projections 416 together forming a first
line in the substrate 400 and a second set of projections 416
together forming a second line in the substrate 400. The first line
may be generally parallel with or generally perpendicular to the
second line. The first line may also form an acute or obtuse angle
with the second line.
[0169] The substrate 400 may be generally symmetrical about the
lateral axis 424 and/or generally symmetrical about the
longitudinal axis 426. In other instances, the substrate may not be
symmetrical about the lateral axis 424 and/or the longitudinal axis
426.
[0170] In one form, the substrate 400 may comprise a first line
comprising alternating apertures 422 and projections 416 extending
in a direction parallel to the lateral axis 424 and a second
adjacent line comprising alternating apertures 422 and projections
416 extending in the direction generally parallel to the lateral
axis 424. The lines will run through the center of the apertures
422 and the projections 416. See for, example, FIG. 17, lines A and
B. If a line, C, is drawn in a direction generally parallel to the
longitudinal axis 426 and that intersects lines A and B, an
aperture 422 will be located at the intersection of lines A and C
and a projection 416 will be located at the intersection of the
lines B and C. The same is true if lines A and B are drawn in a
direction parallel to the longitudinal axis 426 and line C is draw
in a direction generally parallel to the lateral axis 424, as
illustrated in FIG. 18. If the lines are drawn at different
locations, the intersection of lines A and C may have a projection
416 and the intersection of lines B and C may have an aperture 422.
The main point being that the rows of apertures and the rows of
projections are staggered. By staggering the apertures and
projections in this fashion, better softness is achieved in the
wearer-facing surface of the substrate 400 owing to a soft
projection or projection crest being intermediate two
apertures.
Parameters of the Three-Dimensional Substrates
[0171] All or a majority of the projections 416 may have a
z-directional height in the range of about 300 .mu.m to about 6000
.mu.m, about 500 .mu.m to about 5000 .mu.m, about 500 .mu.m to
about 4000 .mu.m, about 300 .mu.m to about 3000 .mu.m, about 500
.mu.m to about 3000 .mu.m, about 500 .mu.m to about 2000 .mu.m,
about 750 .mu.m to about 1500 .mu.m, about 800 .mu.m to about 1400
.mu.m, about 900 .mu.m to about 1300 .mu.m, about 1000 .mu.m to
about 1300 .mu.m, about 1100 .mu.m to about 1200 .mu.m, about 1165,
about 1166, about 1167, or about 1150 .mu.m to about 1200 .mu.m,
specifically reciting all 1 .mu.m increments within the
above-specified ranges and all ranges formed therein or thereby.
The z-directional height of the projections 416 are measured
according to the Projection Height Test described herein.
[0172] All or a majority of the recesses 414 may have a
z-directional height in the range of about 200 .mu.m to about 3000
.mu.m, about 300 .mu.m to about 2000 .mu.m, about 100 .mu.m to
about 2000 .mu.m, about 500 .mu.m to about 2000 .mu.m, about 500
.mu.m to about 1500 .mu.m, about 700 .mu.m to about 1300 .mu.m,
about 800 .mu.m to about 1200 .mu.m, about 900 .mu.m to about 1100
.mu.m, about 900 .mu.m to about 1000 .mu.m, about 970 .mu.m, or
about 950 .mu.m to about 1000 .mu.m, specifically reciting all 1
.mu.m increments within the above-specified ranges and all ranges
formed therein or thereby. The z-directional height of the recesses
416 are measured according to the Recess Height Test described
herein.
[0173] The substrate, 400, or portions thereof, may have an overall
z-directional height in the range of about 500 .mu.m to about 6000
.mu.m, about 750 .mu.m to about 4000 .mu.m, about 1000 .mu.m to
about 6000 .mu.m, about 1500 .mu.m to about 6000 .mu.m, about 1000
.mu.m to about 3000 .mu.m, about 1500 .mu.m to about 2500 .mu.m,
about 1750 .mu.m to about 2300 .mu.m, about 1900 .mu.m to about
2300 .mu.m, about 2000 .mu.m to about 2300 .mu.m, about 2100 .mu.m
to about 2250 .mu.m, about 2136 .mu.m, or about 2135 .mu.m,
specifically reciting all 1 .mu.m increments within the
above-specified ranges and all ranges formed therein or thereby.
The overall z-directional height of the substrate 400, or portions
thereof, is measured according to the Overall Substrate Height Test
described herein.
[0174] A majority of, or all of, the apertures 422 may have an
effective aperture area in the range of about 0.4 mm.sup.2 to about
10 mm.sup.2, about 0.5 mm.sup.2 to about 8 mm.sup.2, about 0.5
mm.sup.2 to about 3 mm.sup.2, about 0.5 mm.sup.2 to about 4
mm.sup.2, about 0.5 mm.sup.2 to about 5 mm.sup.2, about 0.7
mm.sup.2 to about 6 mm.sup.2, about 0.7 mm.sup.2 to about 3
mm.sup.2, about 0.8 mm.sup.2 to about 2 mm.sup.2, about 0.9
mm.sup.2 to about 1.4 mm.sup.2, about 1 mm.sup.2, about 1.1
mm.sup.2, about 1.2 mm.sup.2, about 1.23 mm.sup.2, about 1.3
mm.sup.2, or about 1.4 mm.sup.2, specifically reciting all 0.1
mm.sup.2 increments within the above-specified ranges and all
ranges formed therein or thereby. The effective aperture area of
the apertures is measured according to the Aperture Test described
herein.
[0175] A majority of, or all of, the apertures 422 may have a feret
(length of aperture) in the range of about 0.5 mm to about 4 mm,
about 0.8 mm to about 3 mm, about 1 mm to about 2 mm, about 1.2 mm
to about 1.8 mm, about 1.4 mm to about 1.6 mm, about 1.49, or about
1.5 mm specifically reciting all 0.1 mm increments within the
above-specified ranges and all ranges formed therein or thereby.
The aperture feret is measured according to the Aperture Test
described herein.
[0176] A majority of, or all of, the apertures 422 may have a
minimum feret (width of aperture) in the range of about 0.5 mm to
about 4 mm, about 0.7 mm to about 3 mm, about 0.8 mm to about 2 mm,
about 0.9 mm to about 1.3 mm, about 1 mm to about 1.2 mm, about 1
mm, about 1.1 mm, about 1.11 mm, about 1.2 mm, or about 1.3 mm,
specifically reciting all 0.1 mm increments within the
above-specified ranges and all ranges formed therein or thereby.
The aperture minimum feret is measured according to the Aperture
Test described herein.
[0177] A majority of, or all of, the apertures 422 may have a feret
to minimum feret ratio in the range of about 0.3 to about 2.5,
about 0.5 to about 2, about 0.8 to about 1.6, about 1 to about 1.5,
about 1.1 to about 1.5, about 1.2, about 1.3, about 1.35, about
1.4, or about 1.5, specifically reciting all 0.1 increments within
the above-specified ranges and all ranges formed therein or
thereby. The feret ratio is calculated by dividing the aperture
feret by the aperture minimum feret.
[0178] The average lateral axis center-to-center aperture spacing
of a majority of, or all of, adjacent apertures, measuring across a
projection, is in the range of about 2 mm to about 20 mm, about 2
mm to about 15 mm, about 3 mm to about 12 mm, about 3 mm to about
10 mm, about 3 mm to about 8 mm, about 3 mm to about 7 mm, about 4
mm to about 6 mm, about 5 mm to about 6 mm, about 4 mm, about 4.8
mm, about 4.9 mm, about 5.0 mm, about 5.1 mm, about 5.2 mm, about
5.3 mm, about 5.4 mm, about 5.5 mm, about 5.6 mm, about 5.7 mm,
about 5.8 mm, or about 5.9 mm, about 6 mm, about 7 mm, about 8 mm,
about 9 mm, or about 10 mm, specifically reciting all 0.1 mm
increments within the above-specified ranges and all ranges formed
therein or thereby. The average lateral axis center-to-center
spacing of adjacent apertures is measured according to the Average
Aperture Spacing Test (Lateral Axis Aperture Spacing) described
herein.
[0179] The average longitudinal axis center-to-center aperture
spacing of a majority of, or all of, adjacent apertures, measuring
across a projection, is in the range of about 2 mm to about 20 mm,
about 2 mm to about 15 mm, about 3 mm to about 12 mm, about 3 mm to
about 10 mm, about 3 mm to about 8 mm, about 3 mm to about 7 mm,
about 4 mm to about 6 mm, about 5 mm to about 6 mm, about 4 mm,
about 4.8 mm, about 4.9 mm, about 5.0 mm, about 5.1 mm, about 5.2
mm, about 5.3 mm, about 5.4 mm, about 5.5 mm, about 5.6 mm, about
5.7 mm, about 5.8 mm, or about 5.9 mm, about 6 mm, about 7 mm,
about 8 mm, about 9 mm, or about 10 mm, specifically reciting all
0.1 mm increments within the above-specified ranges and all ranges
formed therein or thereby. The average longitudinal axis
center-to-center spacing of adjacent apertures is measured
according to the Average Aperture Spacing Test (Longitudinal Axis
Aperture Spacing) described herein.
[0180] A majority of, or all of, the projections 416 may have a
widest cross-sectional diameter, taken in a direction parallel to
the lateral axis of the absorbent article, in the range of about 1,
to about 15 mm, about 1 mm to about 10 mm, about 1 mm to about 8
mm, about 1 mm to about 6 mm, about 1.5 mm to about 6 mm, about 2
mm to about 5 mm, specifically reciting all 0.1 mm increments
within the above-specified ranges and all ranges formed therein or
thereby.
[0181] A majority of, or all of, the projections 416 may have a
widest cross-sectional diameter, taken in a direction parallel to
the longitudinal axis of the absorbent article, in the range of
about 1 mm to about 15 mm, about 1 mm to about 10 mm, about 1 mm to
about 8 mm, about 1 mm to about 6 mm, about 1.5 mm to about 6 mm,
about 2 mm to about 5 mm, specifically reciting all 0.1 mm
increments within the above-specified ranges and all ranges formed
therein or thereby.
[0182] The substrates of the present disclosure may have a %
effective open area in the range of about 1% to about 50%, about 1%
to about 40%, about 3% to about 35%, about 5% to about 25%, about
5% to about 20%, about 6% to about 18%, about 5% to about 15%,
about 5%, about 8%, about 9%, about 9.5%, about 10%, about 10.5%,
about 11%, or about 12%, specifically reciting all 0.1% increments
within the above-specified ranges and all ranges formed therein or
thereby. The % effective open area of the substrates is measured
according to the Aperture Test described herein.
[0183] The substrates of the present disclosure may have apertures
having a perimeter in the range of about 1 mm to about 50 mm, about
1 mm to about 30 mm, about 2 mm to about 20 mm, about 2 mm to about
15 mm, about 2 mm to about 10 mm, about 3 mm to about 8 mm, about 4
mm, about 5 mm, about 5.42 mm, about 6 mm, or about 7 mm,
specifically reciting all 0.1 mm increments within the
above-specified ranges and all ranges formed therein or thereby.
The perimeter of the apertures is measured according to the
Aperture Test described herein.
[0184] The first side 418 of the substrates 400 of the present
disclosure may have geometric roughness value in the range of about
2 to about 4.5, about 2.5 to about 4, about 3 to about 4, about 3.1
to about 3.5, about 3.2, about 3.3, about 3.31, about 3.35, about
3.4, or about 3.5, specifically reciting all 0.1 increments within
the above-specified ranges and all ranges formed therein or
thereby. The geometric roughness values of the first side 418 of
the substrates 400 of the present disclosure are measured according
to the Descriptive Analysis Roughness Test described herein. The
first side 418 of the substrates 400 of the present disclosure may
have a coefficient of friction value in the range of about 0.2 to
about 0.4, about 0.25 to about 0.35, about 0.27 to about 0.31,
about 0.27, about 0.28, about 0.29, about 0.30, or about 0.31,
specifically reciting all 0.01 increments within the
above-specified ranges and all ranges formed therein or thereby.
The coefficient of friction values of the first side 418 of the
substrates 400 of the present disclosure are measured according to
the Descriptive Analysis Roughness Test described herein. The first
side 418 of the substrates 400 of the present disclosure may have a
slip stick value in the range of about 0.010 to about 0.025, about
0.015 to about 0.020, about 0.015, about 0.016, about 0.017, about
0.018, or about 0.019, specifically reciting all 0.001 increments
within the above-specified ranges and all ranges formed therein or
thereby. The coefficient of friction values of the first side 418
of the substrates 400 of the present disclosure are measured
according to the Descriptive Analysis Roughness Test described
herein.
[0185] The second side 420 of the substrates 400 of the present
disclosure may have geometric roughness value in the range of about
2 to about 4.0, about 2.3 to about 3.5, about 2.5 to about 3.3,
about 2.6 to about 3.1, about 2.6, about 2.7, about 2.8, about
2.83, about 2.9, or about 3.0, specifically reciting all 0.1
increments within the above-specified ranges and all ranges formed
therein or thereby. The geometric roughness values of the second
side 420 of the substrates 400 of the present disclosure are
measured according to the Descriptive Analysis Roughness Test
described herein. The second side 420 of the substrates 400 of the
present disclosure may have a coefficient of friction value in the
range of about 0.2 to about 0.4, about 0.25 to about 0.35, about
0.27 to about 0.31, about 0.27, about 0.28, about 0.29, about 0.30,
or about 0.31, specifically reciting all 0.01 increments within the
above-specified ranges and all ranges formed therein or thereby.
The coefficient of friction values of the second side 420 of the
substrates 400 of the present disclosure are measured according to
the Descriptive Analysis Roughness Test described herein. The
second side 420 of the substrates 400 of the present disclosure may
have a slip stick value in the range of about 0.010 to about 0.025,
about 0.011 to about 0.018, about 0.012, about 0.013, about 0.014,
about 0.015, or about 0.016, specifically reciting all 0.001
increments within the above-specified ranges and all ranges formed
therein or thereby. The coefficient of friction values of the
second side 420 of the substrates 400 of the present disclosure are
measured according to the Descriptive Analysis Roughness Test
described herein.
Ratios
[0186] The ratio of the height of the projections (.mu.m) to the %
effective open area may be in the range of about 70 to about 160,
about 80 to about 150, about 100 to about 145, about 95 to about
150, about 100 to about 140, about 110 to about 130, about 115 to
about 130, about 118 to about 125, about 120, about 121, about 122,
about 122.74, about 123, or about 124, specifically reciting all
0.1 increments within the specified ranges and all ranges formed
therein or thereby.
[0187] The ratio of the overall substrate height (.mu.m) to the %
effective open area may be in the range of about 125 to about 350,
about 150 to about 300, about 175 to about 275, about 200 to about
250, about 215 to about 235, about 220 to about 230, or about 225,
specifically reciting all 0.1 increments within the specified
ranges and all ranges formed therein or thereby.
[0188] The ratio of the height of the projections (.mu.m) to the
geometric roughness of a surface (e.g., first or second; 418 or
420) of the three-dimensional substrates may be in the range of
about 250 to about 600, about 300 to about 500, about 325 to about
450, about 325 to about 425, about 350, about 352, about 410, or
about 412, specifically reciting all 0.1 increments within the
specified ranges and all ranges formed therein or thereby.
[0189] The ratio of the overall substrate height (.mu.m) to the
geometric roughness of a surface (e.g., first or second; 418 or
420) of the three-dimensional substrates may be in the range of
about 500 to about 900, about 600 to about 800, about 645, about
650, about 700, about 750 m, or about 755, specifically reciting
all 0.1 increments within the specified ranges and all ranges
formed therein or thereby.
[0190] The substrates of the present disclosure may comprise one or
more colors, dyes, inks, indicias, patterns, embossments, and/or
graphics. The colors, dyes, inks, indicias, patterns, and/or
graphics may aid the aesthetic appearance of the substrates.
[0191] The substrates of the present disclosure may be used as a
portion of, or all of, any suitable products, such as dusters,
wipes (wet or dry), makeup removal substrates, paper towels, toilet
tissue, facial tissue, medical gowns, surgical substrates, wraps,
filtration substrates, or any other suitable products.
Method of Making the Three-Dimensional Substrates or Absorbent
Articles Comprising the Three-Dimensional Substrates
[0192] The three-dimensional substrates and absorbent articles
comprising three-dimensional substrates of the present disclosure
may be made by any suitable methods known in the art. In
particular, the articles may be hand-made or industrially produced
at high speed.
[0193] FIG. 26 is a schematic illustration of one example process
for forming the substrates of the present disclosure. FIG. 27 is a
view of intermeshing engagement of portions of first and second
rolls. FIG. 28 is a view of a portion of the first roll. FIG. 29 is
a view of a portion of the second roll.
[0194] Referring to FIGS. 26-29, the substrates of the present
disclosure may be formed by passing a one or more layer substrate
399 (non-three dimensional) through a nip 502 formed by two
intermeshing rolls 504 and 506 to form a three-dimensional
substrate 400. The rolls 504 and 506 may be heated. A first roll
504 may create the apertures 422 and the recesses 414 in the
substrate 400 (in combination with the second roll) and a second
roll 506 may create the projections 416 in the substrate 400 (in
combination with the first roll). The first roll 504 may comprise a
plurality of conically-shaped protrusions 508 extending radially
outwardly from the first roll 504. The first roll 504 may also
comprise a plurality of recesses 510 formed in a radial outer
surface of the first roll 504. The second roll 506 may comprise a
plurality of dome-shaped protrusions 512 extending radially
outwardly from the second roll 506. The second roll 506 may also
comprise a plurality of recesses 514 formed in the radial outer
surface of the second roll 506. The protrusions 508 on the first
roll 504 may have a different size, shape, height, area, width
and/or dimension than the protrusions 512 on the second roll 506.
The recesses 510 formed in the first roll 504 may have a different
size, shape, height, area, width, and/or dimension than the
recesses 514 formed in the second roll 506. The recesses 510 in the
first roll 504 may be configured to at least partially receive the
dome-shaped protrusions 512, thereby creating the projections 414
in the substrate 400. The recesses 510 may be deep enough so that
the portions of the substrate forming the projections 414 and
projection peaks 425 will not be compressed, or sufficiently
compressed. Specifically as the dome-shaped protrusions 512 engage
into the recesses 510, there is sufficient depth left in the space
between the metal surfaces in a radial direction so that the
thickness of the substrate in the projections is higher than the
thickness of the recesses. This feature provides projections 414
with a softer feel and a greater height compared to compressing the
portions of the substrate forming the projections. The recesses 514
in the second roll 506 may be configured to at least partially
receive the conically-shaped protrusions 508 thereby creating the
recesses 414 and the apertures 422 in the substrate 400.
[0195] The substrates of the present disclosure may also be formed
by any other suitable methods known to those of skill in the
art.
Multi-Component Topsheets Employing the Three-Dimensional
Substrates
[0196] The three-dimensional substrates detailed herein may be more
expensive than traditional topsheet materials. Accordingly, when
employing any variation of the three-dimensional substrates
detailed herein in an absorbent article, a multi-component topsheet
application, as described below, may be utilized. Such
multi-component topsheets may comprise one or more of the
variations of the three-dimensional substrates detailed herein, as
well as traditional topsheet materials.
[0197] FIGS. 30-37 depict top and cross-sectional schematic
illustrations of embodiments of a multi-component topsheet. The
multi-component topsheet 600 may include a first discrete substrate
610, a second discrete substrate 620, and a third discrete
substrate 630. The multi-component topsheet 600 has a longitudinal
axis 601 that runs the longer overall dimension of the topsheet (in
this case, the MD or machine direction), and a lateral axis 602
that runs perpendicular to the longitudinal axis. The
multi-component topsheet 600 may have an overall outer perimeter
defined by first longitudinal edge 603, second longitudinal edge
604, first lateral edge 605, and second lateral edge 606. The first
discrete substrate may have a perimeter defined by first
longitudinal edge 611, second longitudinal edge 612, first lateral
edge 613, and second lateral edge 614. The second discrete
substrate may have a perimeter defined by first longitudinal edge
621, second longitudinal edge 622, first lateral edge 623, and
second lateral edge 624. The third discrete substrate may have a
perimeter defined by first longitudinal edge 631, second
longitudinal edge 632, first lateral edge 633, and second lateral
edge 634.
[0198] As shown in the embodiments of FIGS. 30-37, the second
discrete substrate 620 may be disposed at least partially
intermediate the first discrete substrate 610 and the third
discrete substrate 630. FIGS. 30-33 depict the second discrete
substrate 620 disposed at least partially intermediate the first
discrete substrate 610 and the third discrete substrate 630 along a
longitudinal direction (running the same directional as the
longitudinal axis 601). FIGS. 34-37 depict the second discrete
substrate 620 disposed at least partially intermediate the first
discrete substrate 610 and the third discrete substrate 630 along a
lateral direction (running the same directional as the lateral axis
602).
[0199] In some embodiments, the first and/or second longitudinal
edges of the first discrete substrate 610, the second discrete
substrate 620, and/or the third discrete substrate 630 will be
common with the longitudinal edges 603, 604 of the multi-component
topsheet 600. In some embodiments, the first and/or second lateral
edge of the first discrete substrate 610, second discrete substrate
620, and/or the third discrete substrate 630 will be common with
the lateral edges 605, 606 of the multi-component topsheet 600. In
the non-limiting embodiments of FIGS. 30 and 32, the longitudinal
edge 603 of the multi-component topsheet 600 is common with the
longitudinal edges 611, 621, 631 of the first, second and third
discrete substrates. In FIGS. 30 and 32, the longitudinal edge 604
of the multi-component topsheet 600 is common with the longitudinal
edges 612, 622, 632 of the first, second and third discrete
substrates. In FIGS. 30 and 32, the lateral edge 605 of the
multi-component topsheet 600 is common with the first lateral edge
613 of the first discrete substrate 610. In FIGS. 30 and 32, the
lateral edge 606 of the multi-component topsheet 600 is common with
the second lateral edge 634 of the third discrete substrate 630. In
the non-limiting embodiments of FIGS. 34 and 36, the longitudinal
edge 603 of the multi-component topsheet 600 is common with the
first longitudinal edge 611 of the first discrete substrate 610. In
FIGS. 34 and 36, the longitudinal edge 604 of the multi-component
topsheet 600 is common with the second longitudinal edge 632 of the
third discrete substrate 630. In FIGS. 34 and 36, the lateral edge
605 of the multi-component topsheet 600 is common with the lateral
edges 613, 623, 633 of the first, second and third discrete
substrates. In FIGS. 34 and 36, the lateral edge 606 of the
multi-component topsheet 600 is common with the lateral edges 614,
624, 634 of the first, second and third discrete substrates.
[0200] FIGS. 30 and 32 schematically illustrate a top view of a
body facing side of one embodiment of the multi-component topsheets
600 detailed herein. FIGS. 31 and 33 depict cross sectional views
of FIGS. 30 and 32, respectively, taken about line 607. As shown in
FIGS. 30-33, the second substrate 620 is disposed at least
partially intermediate the first discrete substrate 610 and the
third discrete substrate 630 along a longitudinal direction. The
second substrate 620 is joined to the first discrete substrate 610
and the third discrete substrate 630, with overlapping substrate
between the first and second discrete substrates and between the
second and third discrete substrates. The joining of discrete
substrates may be made by any method known in the art, including,
but not limited to, mechanical bonding, hydroentangling, embossing,
adhesive bonding, pressure bonding, heat bonding, or by other
methods of joining multiple discrete substrates. The non-limiting
embodiments of FIGS. 30-33 show the substrates joined by mechanical
bonding 641, 651.
[0201] The overlap between the first discrete substrate 610 and the
second discrete substrate 620 is, from a top view, the area
contained by a perimeter consisting of the first lateral edge 623
of the second discrete substrate 620, the second lateral edge 614
of the first discrete substrate 610, the first longitudinal edge
621 of the second discrete substrate 620, and the second
longitudinal edge 622 of the second discrete substrate 620. Because
this area contains two layers of substrate (located between
adjacent single layers of substrate), it is referred to as the
first dual layer area 640. The overlap between the second discrete
substrate 620 and the third discrete substrate 630 is, from a top
view, the area contained by a perimeter consisting of the second
lateral edge 624 of the second discrete substrate 620, the first
lateral edge 633 of the third discrete substrate 630, the first
longitudinal edge 621 of the second discrete substrate 620, and the
second longitudinal edge 622 of the second discrete substrate 620.
Because this area also contains two layers of substrate (located
between adjacent single layers of substrate), it is referred to as
the second dual layer area 650. The first dual layer area 640 and
the second dual layer area 650 add up to form the dual layer of
substrate of the multi-component topsheet 600. As a non-limiting
example, utilizing the non-limiting embodiments shown in FIGS.
30-33, if the first dual layer area 640 is 10 cm.sup.2 and the
second dual layer area 650 is 10 cm.sup.2, the dual layer of
substrate for the multi-component topsheet 600 is 20 cm.sup.2.
[0202] Still referring to the embodiments depicted in FIGS. 30-33,
from a top view, the areas of the multi-component topsheet 600 that
are not the dual layer of substrate are defined as a single layer
of substrate. The single layer of substrate for this particular
embodiment of multi-component topsheet 600 consists of three single
layer areas added together. The first single layer area is the
area, from a top view, contained by a perimeter consisting of the
first lateral edge 613 of the first discrete substrate 610, the
first lateral edge 623 of the second discrete substrate 620, the
first longitudinal edge 611 of the first discrete substrate 610,
and the second longitudinal edge 612 of the first discrete
substrate 610. The second single layer area is the area, from a top
view, contained by a perimeter consisting of the second lateral
edge 614 of the first discrete substrate 610, the first lateral
edge 633 of the third discrete substrate 630, the first
longitudinal edge 621 of the second discrete substrate 620, and the
second longitudinal edge 622 of the second discrete substrate 620.
The third single layer area is the area, from a top view, contained
by a perimeter consisting of the second lateral edge 624 of the
second discrete substrate 620, the second lateral edge 634 of the
third discrete substrate 630, the first longitudinal edge 631 of
the third discrete substrate 630, and the second longitudinal edge
632 of the third discrete substrate 630. The first, second, and
third single areas add up to form the single layer of substrate of
the multi-component topsheet 600. As a non-limiting example,
utilizing the embodiment shown in FIGS. 30-33, if the first single
layer area is 50 cm.sup.2, the second single layer area is 100
cm.sup.2 and the third single layer area is 50 cm.sup.2, the single
layer of substrate for the multi-component topsheet 600 is 200
cm.sup.2.
[0203] Still referring to the non-limiting embodiments depicted in
FIGS. 30-33, the distance between the first lateral edge 613 of the
first discrete substrate 610 and the second lateral edge 614 of the
first discrete substrate 610 may be between about 20 mm and about
70 mm. The distance between the first lateral edge 633 of the third
discrete substrate 630 and the second lateral edge 634 of the third
discrete substrate 630 may be between about 20 mm and about 70 mm.
The distance between the first lateral edge 613 of the first
discrete substrate 610 and the first lateral edge 623 of the second
discrete substrate 620 may be between about 16 mm and about 66 mm.
The distance between the second lateral edge 624 of the second
discrete substrate 620 and the second lateral edge 634 of the third
discrete substrate 630 may be between about 16 mm and about 66 mm.
The distance between the first lateral edge 623 of the second
discrete substrate 620 and the second lateral edge 624 of the
second discrete substrate 620 may be between about 40 mm and about
120 mm. The distance between the first lateral edge 623 of the
second discrete substrate 620 and the second lateral edge 614 of
the first discrete substrate 610 may be between about 4 mm and
about 24 mm. The distance between the first lateral edge 633 of the
third discrete substrate 630 and the second lateral edge 624 of the
second discrete substrate 620 may be between about 4 mm and about
24 mm.
[0204] As shown in FIG. 30, looking down on a top view of the body
facing side of an embodiment of the multi-component topsheet 600
(and also detailed in the cross sectional view of FIG. 31), the
second discrete substrate 620 is disposed above the first discrete
substrate 610 and the third discrete substrate 630. Accordingly,
the overlap between the first discrete substrate 610 and the second
discrete substrate 620 includes the garment facing side of the
second discrete substrate contacting the body facing side of the
first discrete substrate. Likewise, the overlap between the third
discrete substrate 630 and the second discrete substrate 620
includes the garment facing side of the second discrete substrate
contacting the body facing side of the third discrete substrate.
Alternatively, as shown in FIG. 32, looking down on a top view of
the body facing side of an embodiment of the multi-component
topsheet 600 (and also detailed in the cross sectional view of FIG.
33), the second discrete substrate 620 is disposed below the first
discrete substrate 610 and the third discrete substrate 630.
Accordingly, the overlap between the first discrete substrate 610
and the second discrete substrate 620 includes the body facing side
of the second discrete substrate contacting the garment facing side
of the first discrete substrate. Likewise, the overlap between the
third discrete substrate 630 and the second discrete substrate 620
includes the body facing side of the second discrete substrate
contacting the garment facing side of the third discrete
substrate.
[0205] FIGS. 34 and 36 schematically illustrate a top view of a
body facing side of one embodiment of the multi-component topsheets
600 detailed herein. FIGS. 35 and 37 depict cross sectional views
of FIGS. 34 and 36, respectively, taken about line 608. As shown in
FIGS. 34-37, the second substrate 620 is disposed at least
partially intermediate the first discrete substrate 610 and the
third discrete substrate 630 along a lateral direction. The second
substrate 620 is joined to the first discrete substrate 610 and the
third discrete substrate 630, with overlapping substrate between
the first and second discrete substrates and between the second and
third discrete substrates. The joining of discrete substrates may
be made by any method known in the art, including, but not limited
to, mechanical bonding, hydroentangling, embossing, adhesive
bonding, pressure bonding, heat bonding, or by other methods of
joining multiple discrete substrates. The non-limiting embodiments
of FIGS. 34-37 show the substrates joined by mechanical bonding
641, 651.
[0206] The overlap between the first discrete substrate 610 and the
second discrete substrate 620 is, from a top view, the area
contained by a perimeter consisting of the first lateral edge 623
of the second discrete substrate 620, the second lateral edge 624
of the second discrete substrate 620, the first longitudinal edge
621 of the second discrete substrate 620, and the second
longitudinal edge 612 of the first discrete substrate 610. Because
this area contains two layers of substrate (located between
adjacent single layers of substrate), it is referred to as the
first dual layer area 640 of multi-component topsheet 600. The
overlap between the second discrete substrate 620 and the third
discrete substrate 630 is, from a top view, the area contained by a
perimeter consisting of the first lateral edge 623 of the second
discrete substrate 620, the second lateral edge 624 of the second
discrete substrate 620, the first longitudinal edge 631 of the
third discrete substrate 630, and the second longitudinal edge 622
of the second discrete substrate 620. Because this area also
contains two layers of substrate (located between adjacent single
layers of substrate), it is referred to as the second dual layer
area 650 of multi-component topsheet 600. The first dual layer area
640 and the second dual layer area 650 add up to form the dual
layer of substrate of multi-component topsheet 600. As a
non-limiting example, utilizing the embodiments shown in FIGS.
34-37, if the first dual layer area 640 is 10 cm.sup.2 and the
second dual layer area 650 is 10 cm.sup.2, the dual layer of
substrate for the multi-component topsheet 600 is 20 cm.sup.2.
[0207] Still referring to the embodiments depicted in FIGS. 34-37,
from a top view, the areas of the multi-component topsheet 600 that
are not the dual layer of substrate are defined as a single layer
of substrate. The single layer of substrate for this particular
embodiment of multi-component topsheet 600 consists of three single
layer areas added together. The first single layer area is the
area, from a top view, contained by a perimeter consisting of the
first lateral edge 613 of the first discrete substrate 610, the
second lateral edge 614 of the first discrete substrate 610, the
first longitudinal edge 611 of the first discrete substrate 610,
and the first longitudinal edge 621 of the second discrete
substrate 620. The second single layer area is the area, from a top
view, contained by a perimeter consisting of the first lateral edge
623 of the second discrete substrate 620, the second lateral edge
624 of the second discrete substrate 620, the second longitudinal
edge 612 of the first discrete substrate 610, and the first
longitudinal edge 631 of the third discrete substrate 630. The
third single layer area is the area, from a top view, contained by
a perimeter consisting of the first lateral edge 633 of the third
discrete substrate 630, the second lateral edge 634 of the third
discrete substrate 630, the second longitudinal edge 622 of the
second discrete substrate 620, and the second longitudinal edge 632
of the third discrete substrate 630. The first, second and third
single areas add up to form the single layer of substrate of
multi-component topsheet 600. As a non-limiting example, utilizing
the embodiment shown in FIGS. 47-50, if the first single layer area
is 50 cm.sup.2, the second single layer area is 100 cm.sup.2 and
the third single layer area is 50 cm.sup.2, the single layer of
substrate for the multi-component topsheet 600 is 200 cm.sup.2.
[0208] Still referring to the non-limiting embodiments depicted in
FIGS. 34-37, the distance between the first longitudinal edge 611
of the first discrete substrate 610 and the second longitudinal
edge 612 of the first discrete substrate 610 may be between about
20 mm and about 70 mm. The distance between the first longitudinal
edge 631 of the third discrete substrate 630 and the second
longitudinal edge 632 of the third discrete substrate 630 may be
between about 20 mm and about 70 mm. The distance between the first
longitudinal edge 611 of the first discrete substrate 610 and the
first longitudinal edge 621 of the second discrete substrate 620
may be between about 16 mm and about 66 mm. The distance between
the second longitudinal edge 622 of the second discrete substrate
620 and the second longitudinal edge 632 of the third discrete
substrate 630 may be between about 16 mm and about 66 mm. The
distance between the first longitudinal edge 621 of the second
discrete substrate 620 and the second longitudinal edge 622 of the
second discrete substrate 620 may be between about 40 mm and about
120 mm. The distance between the first longitudinal edge 621 of the
second discrete substrate 620 and the second longitudinal edge 612
of the first discrete substrate 610 may be between about 4 mm and
about 24 mm. The distance between the first longitudinal edge 631
of the third discrete substrate 630 and the second longitudinal
edge 622 of the second discrete substrate 620 may be between about
4 mm and about 24 mm.
[0209] As shown in FIG. 34, looking down on a top view of the body
facing side of an embodiment of the multi-component topsheet 600
(and also detailed in the cross sectional view of FIG. 35), the
second discrete substrate 620 is disposed above the first discrete
substrate 610 and the third discrete substrate 630. Accordingly,
the overlap between the first discrete substrate 610 and the second
discrete substrate 620 includes the garment facing side of the
second discrete substrate contacting the body facing side of the
first discrete substrate. Likewise, the overlap between the third
discrete substrate 630 and the second discrete substrate 620
includes the garment facing side of the second discrete substrate
contacting the body facing side of the third discrete substrate.
Alternatively, as shown in FIG. 36, looking down on a top view of
the body facing side of an embodiment of the multi-component
topsheet 600 (and also detailed in the cross sectional view of FIG.
37), the second discrete substrate 620 is disposed below the first
discrete substrate 610 and the third discrete substrate 630.
Accordingly, the overlap between the first discrete substrate 610
and the second discrete substrate 620 includes the body facing side
of the second discrete substrate contacting the garment facing side
of the first discrete substrate. Likewise, the overlap between the
third discrete substrate 630 and the second discrete substrate 620
includes the body facing side of the second discrete substrate
contacting the garment facing side of the third discrete
substrate.
[0210] In some embodiments, the single layer of substrate may
comprise about 80% or more of the total area of the multi-component
topsheet 600, and the dual layer of substrate may comprise about
20% or less of the total area of the multi-component topsheet 600.
In other embodiments, the single layer of substrate may comprise
about 70% or more, about 75% or more, about 85% or more, about 90%
or more, or about 95% or more of the total area of the
multi-component topsheet 600, and the dual layer of substrate may
comprise about 30% or less, about 25% or less, about 15% or less,
about 10% or less, or about 5% or less of the total area of the
multi-component topsheet 600.
[0211] The first discrete substrate 610, the second discrete
substrate 620, and/or the third discrete substrate 630 may be
composed of any one or more of the three-dimensional substrates
detailed herein. In some embodiments, the second discrete substrate
620 is composed of an embodiment of the three-dimensional
substrates detailed herein, and both the first discrete substrate
610 and the third discrete substrate 630 are made of traditional
topsheet materials, such as P10. P10 is a 12 gsm or 15 gsm basis
weight poly-propylene nonwoven substrate (as further detailed
herein), available from Polymer Group, Inc of Charlotte, N.C.
According to the Descriptive Analysis Roughness Test, P10 has a
geometric roughness of between about 2.2 and about 2.8, and in some
embodiments, geometric roughness of about 2.6. In some embodiments,
both the first discrete substrate 610 and the third discrete
substrate 630 are composed of the same material, but in other
embodiments, the first and second discrete substrates may be
composed of different materials.
[0212] When viewed from the top, the multi-component topsheets 600
may have one or more shapes, patterns or other distinct visible
interfaces between the first discrete substrate 610 and the second
discrete substrate 620, and between the second discrete substrate
and the third discrete substrate 630. Depending on whether the
second discrete substrate 620 is located above (as depicted in
FIGS. 30, 31, 34 and 35) or below (as depicted in FIGS. 32, 33, 36
and 37) the first discrete substrate 610 and third discrete
substrate 630, the longitudinal or lateral edges of the first,
second or third discrete substrates may determine the shape of the
visible interface. For example, in the embodiment depicted in FIGS.
43 and 44, the shape or pattern of the first lateral edge 623 of
the second discrete substrate 620 will determine the visible
interface adjacent the first dual layer area 640 and the shape or
pattern of the second lateral edge 624 of the second discrete
substrate 620 will determine the visible interface adjacent the
second dual layer area 650. In the embodiment depicted in FIGS. 32
and 33, the shape or pattern of the second lateral edge 614 of the
first discrete substrate 610 will determine the visible interface
adjacent the first dual layer area 640 and the shape or pattern of
the first lateral edge 633 of the third discrete substrate 630 will
determine the visible interface adjacent the second dual layer area
650. In the embodiment depicted in FIGS. 34 and 35, the shape or
pattern of the first longitudinal edge 621 of the second discrete
substrate 620 will determine the visible interface adjacent the
first dual layer area 640 and the shape or pattern of the second
longitudinal edge 622 of the second discrete substrate 620 will
determine the visible interface adjacent the second dual layer area
650. In the embodiment depicted in FIGS. 36 and 37, the shape or
pattern of the second longitudinal edge 612 of the first discrete
substrate 610 will determine the visible interface adjacent the
first dual layer area 640 and the shape or pattern of the first
longitudinal edge 631 of the third discrete substrate 630 will
determine the visible interface adjacent the second dual layer area
650.
[0213] In any of the non-limiting embodiments of FIGS. 30-37, the
lateral edges or longitudinal edges that create the visible
interface between the second discrete layer 620 and the first
discrete layer 610, and between the second discrete layer 620 and
the third discrete layer 630 may be linear (i.e., straight line) or
non-linear (i.e., not a straight line), and symmetrical or
asymmetrical about either the lateral or longitudinal axes 601,
602. FIGS. 30-37 are examples of linear, symmetrical visible
interfaces. For non-limiting examples of additional visible
interfaces (dependent on any combination of longitudinal and/or
lateral edges of the first, second, and/or third discrete
substrates), please refer to FIGS. 38-45. FIG. 38 depicts a
multi-component topsheet 600 with a visible interface that is
non-linear and asymmetrical about the longitudinal axis. One way to
achieve such a visible interface is to have a multi-component
topsheet 600 with the second discrete substrate 620 disposed above
the first and third discrete substrates 610, 630, and the first
lateral edge 623 and the second lateral edge 624 of the second
discrete substrate are non-linear and asymmetrical about the
longitudinal axis 601 of the topsheet. In this particular example,
repeating waves form the visible interface. However, in other
embodiments, all kinds of waves may be used, such as sine waves,
saw tooth waves, square waves, etc. FIG. 39 depicts a
multi-component topsheet 600 with a visible interface that is
non-linear and symmetrical about the longitudinal axis. One way to
achieve such a visible interface is to have a multi-component
topsheet 600 with the second discrete substrate 620 disposed above
the first and third discrete substrates 610, 630, and the first
lateral edge 623 and the second lateral edge 624 of the second
discrete substrate are non-linear and symmetrical about the
longitudinal axis 601 of the topsheet. FIGS. 40 and 41 are further
examples of multi-component topsheet 600 with non-linear and
symmetrical visible interfaces along the longitudinal axis 601.
[0214] FIG. 42 depicts a multi-component topsheet 600 with a
visible interface that is non-linear and asymmetrical about the
lateral axis 602. One way to achieve such a visible interface is to
have a multi-component topsheet 600 with the second discrete
substrate 620 disposed above the first and third discrete
substrates 610, 630, and the first longitudinal edge 621 and the
second longitudinal edge 622 of the second discrete substrate are
non-linear and asymmetrical about the lateral axis 602 of the
topsheet. In this particular example, repeating waves form the
visible interface. However, in other embodiments, all kinds of
waves may be used, such as sine waves, saw tooth waves, square
waves, etc. FIG. 43 depicts a multi-component topsheet 600 with a
visible interface that is non-linear and symmetrical about the
lateral axis. One way to achieve such a visible interface is to
have a multi-component topsheet 600 with the second discrete
substrate 620 disposed above the first and third discrete
substrates 610, 630, and the first longitudinal edge 621 and the
second longitudinal edge 622 of the second discrete substrate are
non-linear and symmetrical about the lateral axis 602 of the
topsheet. FIGS. 44 and 45 are further examples of a multi-component
topsheet 600 with a non-linear and symmetrical visible interface
about a lateral axis 602. In addition to these specific
embodiments, it is contemplated that any combination of linear
and/or non-linear, symmetrical and/or asymmetrical visible
interfaces may be employed with the multi-component topsheets 600
detailed herein.
[0215] In some embodiments of multi-component topsheet 600, there
may be a color difference between the first discrete substrate 610,
the second discrete substrate 620, and/or the third discrete
substrate 630. For example the first discrete substrate 610 and the
third discrete substrate 630 may be a first color (e.g., purple,
green, teal, blue), and the second discrete substrate 620 may be a
second, different color, such as white. Alternatively, the first
discrete substrate 610 and the third discrete substrate 630 may be
white and the second discrete substrate 620 may be a different
color.
[0216] FIGS. 46-57 depict top and cross-sectional schematic
illustrations of embodiments of a multi-component topsheet 700. The
multi-component topsheet 700 may include a first discrete substrate
710 and a second discrete substrate 720, and optionally in some
embodiments (e.g., FIGS. 50-52 and 55-57), a third discrete
substrate 730. The multi-component topsheet 700 has a longitudinal
axis 701 that runs the longer overall dimension of the topsheet (in
this case, the MD or machine direction), and a lateral axis 702
that runs perpendicular to the longitudinal axis. The
multi-component topsheet 700 may have an overall outer perimeter
defined by first longitudinal edge 703, second longitudinal edge
704, first lateral edge 705, and second lateral edge 706. The first
discrete substrate may have an outer perimeter defined by first
longitudinal edge 711, second longitudinal edge 712, first lateral
edge 713, and second lateral edge 714. The first discrete substrate
may have an inner perimeter defined by first longitudinal edge 715,
second longitudinal edge 716, first lateral edge 717, and second
lateral edge 718. The second discrete substrate may have an outer
perimeter defined by first longitudinal edge 721, second
longitudinal edge 722, first lateral edge 723, and second lateral
edge 724. The second discrete substrate may have an inner perimeter
defined by first longitudinal edge 725, second longitudinal edge
726, first lateral edge 727, and second lateral edge 728. In
embodiments that include a third discrete substrate 730, the third
discrete substrate may have a perimeter defined by first
longitudinal edge 731, second longitudinal edge 732, first lateral
edge 733, and second lateral edge 734.
[0217] The outer perimeter of the first discrete substrate 710 may
form about 80% or more of the overall outer perimeter of the
multi-component topsheet 700, and about 80% or more of the outer
perimeter of the second discrete substrate 720 may be joined with a
portion of the first discrete substrate. In some embodiments, the
outer perimeter of the first discrete substrate 710 may comprise
about 70% or more, about 75% or more, about 85% or more, about 90%
or more, about 95% or more, or 100% of the overall outer perimeter
of the multi-component topsheet 700. In some embodiments, about 70%
or more, about 75% or more, about 85% or more, about 90% or more,
about 95% or more, or 100% of the outer perimeter of the second
discrete substrate 720 may be joined with a portion of the first
discrete substrate 710. In some embodiments, about 70% or more,
about 75% or more, about 85% or more, about 90% or more, about 95%
or more, or 100% of the perimeter of the third discrete substrate
730 may be in contact with a portion of the second discrete
substrate 720.
[0218] In some embodiments, the first and/or second longitudinal
edges of the first discrete substrate 710, the second discrete
substrate 720, and/or the third discrete substrate 730 will be
common with the longitudinal edges 703, 704 of the multi-component
topsheet 700. In some embodiments, the first and/or second lateral
edges of the first discrete substrate 710, second discrete
substrate 720, and/or the third discrete substrate 730 will be
common with the lateral edges 705, 706 of the multi-component
topsheet 700. In the non-limiting embodiments of FIGS. 46-52 the
longitudinal edge 703 of the multi-component topsheet 700 is common
with the longitudinal edge 711 of the first discrete substrate 710.
In FIGS. 46-52, the longitudinal edge 704 of the multi-component
topsheet 700 is common with the longitudinal edge 712 of the first
discrete substrate 710. In FIGS. 46-52, the lateral edge 705 of the
multi-component topsheet 700 is common with the lateral edge 713 of
the first discrete substrate 610. In FIGS. 46-52, the lateral edge
706 of the multi-component topsheet 700 is common with the lateral
edge 714 of the first discrete substrate 710. In the non-limiting
embodiment of FIGS. 53 and 54 the longitudinal edge 703 of the
multi-component topsheet 700 is common with the longitudinal edge
711 of the first discrete substrate 710. In FIGS. 53 and 54, the
longitudinal edge 704 of the multi-component topsheet 700 is common
with the longitudinal edges 712 and 722 of the first and second
discrete substrates. In FIGS. 53 and 54, the lateral edge 705 of
the multi-component topsheet 700 is common with the lateral edge
713 of the first discrete substrate 710. In FIGS. 53 and 54, the
lateral edge 706 of the multi-component topsheet 700 is common with
the lateral edge 714 of the first discrete substrate 710. In the
non-limiting embodiment of FIGS. 55-57 the longitudinal edge 703 of
the multi-component topsheet 700 is common with the longitudinal
edge 711 of the first discrete substrate 710. In FIGS. 55-57, the
longitudinal edge 704 of the multi-component topsheet 700 is common
with the longitudinal edges 712, 722 and 732 of the first, second,
and third discrete substrates. In FIGS. 55-57, the lateral edge 705
of the multi-component topsheet 700 is common with the lateral edge
713 of the first discrete substrate 710. In FIGS. 55-57, the
lateral edge 706 of the multi-component topsheet 700 is common with
the lateral edge 714 of the first discrete substrate 710.
[0219] FIGS. 46, 48, 50, 53, and 55 schematically illustrate a top
view of a body facing side of one embodiment of the multi-component
topsheets 700 detailed herein. FIGS. 47, 49, 51, 52, 54, 56, and 57
depict cross sectional views of FIGS. 46, 48, 50, 53, and 55,
respectively, taken about line 707. As shown in FIGS. 46-57, the
second discrete substrate 720 may be surrounded by (i.e., either
fully surrounded on all four sides or partially surrounded on three
sides) and joined to the first discrete substrate 710, with
overlapping substrate between the first and second discrete
substrates. The joining of the discrete substrates may be made by
any method known in the art, including, but not limited to,
mechanical bonding, hydroentangling, embossing, adhesive bonding,
pressure bonding, heat bonding, or by other methods of joining
multiple discrete substrates. The non-limiting embodiments of FIGS.
46-57 show the substrates joined by mechanical bonding 761. In
certain embodiments, the second discrete substrate 720 can be
joined to the third discrete substrate 730 by any method known in
the art (mechanical bonding, hydroentangling, embossing, adhesive
bonding, pressure bonding, heat bonding, or by other methods of
joining multiple discrete substrates), and in some particular
embodiments, by mechanical bonding 762.
[0220] The overlap between the first discrete substrate 710 and the
second discrete substrate 720 is, from a top view, the area
contained by perimeter consisting of the first longitudinal edge
721 of the second discrete substrate 720, the second longitudinal
edge 722 of the second discrete substrate 720, the first lateral
edge 723 of the second discrete substrate 720, and the second
lateral edge 724 of the second discrete substrate 720, minus the
area contained by a perimeter consisting of the inner perimeter
first longitudinal edge 715 of the first discrete substrate 710,
the inner perimeter second longitudinal edge 716 of the first
discrete substrate 710, the inner perimeter first lateral edge 717
of the first discrete substrate 710, and the inner perimeter second
lateral edge 718 of the first discrete substrate 710. As a
non-limiting example, utilizing the embodiments shown in FIGS.
46-49, if the area contained by the outer perimeter of the second
discrete substrate 720 is 240 cm.sup.2 and the area contained by
the inner perimeter of the first discrete substrate 710 is 220
cm.sup.2, the dual layer of substrate for the multi-component
topsheet 700 is 20 cm.sup.2.
[0221] Still referring to the embodiments depicted in FIGS. 46-49
and 53-54, from a top view, the areas of the multi-component
topsheet 700 that are not the dual layer of substrate are defined
as a single layer of substrate. The single layer of substrate for
this particular embodiment of multi-component topsheet 700 consists
of two single layer areas added together. The first single layer
area is the area, from a top view, contained by a perimeter
consisting of the first lateral edge 713 of the first discrete
substrate 710, the second lateral edge 714 of the first discrete
substrate 710, the first longitudinal edge 711 of the first
discrete substrate 710, and the second longitudinal edge 712 of the
first discrete substrate 710, minus the area contained by a
perimeter consisting of the first lateral edge 723 of the second
discrete substrate 720, the second lateral edge 724 of the second
discrete substrate 720, the first longitudinal edge 721 of the
second discrete substrate 720, and the second longitudinal edge 722
of the second discrete substrate 720. The second single layer area
is the area, from a top view, contained by a perimeter consisting
of the inner perimeter first lateral edge 717 of the first discrete
substrate 710, the inner perimeter second lateral edge 718 of the
first discrete substrate 710, the inner perimeter first
longitudinal edge 715 of the first discrete substrate 710, and the
inner perimeter second longitudinal edge 716 of the first discrete
substrate 710. The first and second single areas add up to form the
single layer of substrate. As a non-limiting example, utilizing the
embodiment shown in FIGS. 46 and 47, if the first single layer area
is 120 cm.sup.2 and the second single layer area is 80 cm.sup.2,
the single layer of substrate for the multi-component topsheet 700
is 200 cm.sup.2.
[0222] Referring now to the embodiments of multi-component topsheet
700 with a third discrete substrate 730 (as depicted in FIGS. 50-52
and 55-57) the overlap between the first discrete substrate 710 and
the second discrete substrate 720 is, from a top view, the area
contained by a perimeter consisting of the first longitudinal edge
721 of the second discrete substrate 720, the second longitudinal
edge 722 of the second discrete substrate 720, the first lateral
edge 723 of the second discrete substrate 720, and the second
lateral edge 724 of the second discrete substrate 720, minus the
area contained by a perimeter consisting of the inner perimeter
first longitudinal edge 715 of the first discrete substrate 710,
the inner perimeter second longitudinal edge 716 of the first
discrete substrate 710, the inner perimeter first lateral edge 717
of the first discrete substrate 710, and the inner perimeter second
lateral edge 718 of the first discrete substrate 710. Because this
area contains two layers of substrate (located between adjacent
single layers of substrate), it is referred to as the first dual
layer area 740. The overlap between the second discrete substrate
720 and the third discrete substrate 730 is, from a top view, the
area contained by a perimeter consisting of the first longitudinal
edge 731 of the third discrete substrate 730, the second
longitudinal edge 732 of the third discrete substrate 730, the
first lateral edge 733 of the third discrete substrate 730, and the
second lateral edge 734 of the third discrete substrate 730, minus
the area contained by a perimeter consisting of the inner perimeter
first longitudinal edge 725 of the second discrete substrate 720,
the inner perimeter second longitudinal edge 726 of the second
discrete substrate 720, the inner perimeter first lateral edge 727
of the second discrete substrate 720, and the inner perimeter
second lateral edge 728 of the second discrete substrate 720.
Because this area also contains two layers of substrate (located
between adjacent single layers of substrate), it is referred to as
the second dual layer area 750. The first dual layer area 740 and
the second dual layer area 750 add up to form the dual layer of
substrate. As a non-limiting example, utilizing the embodiment
shown in FIGS. 50-52, if the first dual layer area 740 is 20
cm.sup.2 and the second dual layer area 750 is 10 cm.sup.2, the
dual layer of substrate for the multi-component topsheet 700 is 30
cm.sup.2.
[0223] Still referring to FIGS. 50-52 and 55-57, from a top view,
the areas of the multi-component topsheet 700 that are not the dual
layer of substrate are defined as a single layer of substrate. The
single layer of substrate for this particular embodiment of
multi-component topsheet 700 consists of three single layer areas
added together. The first single layer area is the area, from a top
view, contained by a perimeter consisting of the first lateral edge
713 of the first discrete substrate 710, the second lateral edge
714 of the first discrete substrate 710, the first longitudinal
edge 711 of the first discrete substrate 710, and the second
longitudinal edge 712 of the first discrete substrate 710, minus
the area contained by a perimeter consisting of the first lateral
edge 723 of the second discrete substrate 720, the second lateral
edge 724 of the second discrete substrate 720, the first
longitudinal edge 721 of the second discrete substrate 720, and the
second longitudinal edge 722 of the second discrete substrate 720.
The second single layer area is the area, from a top view,
contained by a perimeter consisting of the inner perimeter first
lateral edge 717 of the first discrete substrate 710, the inner
perimeter second lateral edge 718 of the first discrete substrate
710, the inner perimeter first longitudinal edge 715 of the first
discrete substrate 710, and the inner perimeter second longitudinal
edge 716 of the first discrete substrate 710, minus the area
contained by a perimeter consisting of the first lateral edge 733
of the third discrete substrate 730, the second lateral edge 734 of
the third discrete substrate 730, the first longitudinal edge 731
of the third discrete substrate 730, and the second longitudinal
edge 732 of the third discrete substrate 730. The third single
layer area is the area, from a top view, contained by a perimeter
consisting of the inner perimeter first lateral edge 727 of the
second discrete substrate 720, the inner perimeter second lateral
edge 728 of the second discrete substrate 720, the inner perimeter
first longitudinal edge 725 of the second discrete substrate 720,
and the inner perimeter second longitudinal edge 726 of the second
discrete substrate 720. The first, second, and third single areas
add up to form the single layer of substrate. As a non-limiting
example, utilizing the embodiment shown in FIGS. 50-52, if the
first single layer area is 120 cm.sup.2 and the second single layer
area is 20 cm.sup.2, and the third single layer area is 50
cm.sup.2, the single layer of substrate for the multi-component
topsheet 700 is 190 cm.sup.2.
[0224] Referring to the non-limiting embodiments depicted in FIGS.
46-57, the distance between the first lateral edge 705 of the first
discrete substrate 710 and the inner perimeter first lateral edge
717 of the first discrete substrate 710 may be between about 20 mm
and about 70 mm. The distance between the inner perimeter second
lateral edge 718 of the first discrete substrate 710 and the second
lateral edge 714 of the first discrete substrate 710 may be between
about 20 mm and about 70 mm. The distance between the first lateral
edge 713 of the first discrete substrate 710 and the first lateral
edge 723 of the second discrete substrate 720 may be between about
16 mm and about 66 mm. The distance between the second lateral edge
724 of the second discrete substrate 720 and the second lateral
edge 714 of the first discrete substrate 710 may be between about
16 mm and about 66 mm. The distance between the first lateral edge
723 of the second discrete substrate 720 and the second lateral
edge 724 of the second discrete substrate 720 may be between about
40 mm and about 120 mm. The distance between the first lateral edge
723 of the second discrete substrate 720 and the inner perimeter
first lateral edge 717 of the first discrete substrate 710 may be
between about 4 mm and about 24 mm. The distance between the inner
perimeter second lateral edge 718 of the first discrete substrate
710 and the second lateral edge 724 of the second discrete
substrate 720 may be between about 4 mm and about 24 mm.
[0225] As shown in FIG. 46, looking down on a top view of the body
facing side of an embodiment of the multi-component topsheet 700
(and also detailed in the cross sectional view of FIG. 47), the
second discrete substrate 720 is disposed above the first discrete
substrate 710. Accordingly, the overlap between the first discrete
substrate 710 and the second discrete substrate 720 includes the
garment facing side of the second discrete substrate contacting the
body facing side of the first discrete substrate. Alternatively, as
shown in FIG. 48, looking down on a top view of the body facing
side of an embodiment of the multi-component topsheet 700 (and also
detailed in the cross sectional view of FIG. 49), the second
discrete substrate 720 is disposed below the first discrete
substrate 710. Accordingly, the overlap between the first discrete
substrate 710 and the second discrete substrate 720 includes the
body facing side of the second discrete substrate contacting the
garment facing side of the first discrete substrate. In the
embodiment of multi-component topsheet 700 that includes a third
discrete substrate 730, the overlap between the second discrete
substrate 720 and the third discrete substrate may have the third
discrete substrate located above (FIGS. 50-52 and 55-57) or below
the second discrete substrate.
[0226] In some embodiments, the single layer of substrate may
comprise about 75% or more of the total area of the multi-component
topsheet 700, and the dual layer of substrate may comprise about
25% or less of the total area of the multi-component topsheet 700.
In other embodiments, the single layer of substrate may comprise
about 65% or more, about 70% or more, about 80% or more, about 85%
or more, about 90% or more, or about 95% or more of the total area
of the multi-component topsheet 700, and the dual layer of
substrate may comprise about 35% or less, about 30% or less, about
25% or less, about 15% or less, about 10% or less, or about 5% or
less of the total area of the multi-component topsheet 700.
[0227] The first discrete substrate 710, the second discrete
substrate 720, and/or the optional third discrete substrate 730 may
be composed of any one or more of the three-dimensional substrates
detailed herein. In some embodiments, the second discrete substrate
720 is composed of an embodiment of the three-dimensional
substrates detailed herein, and the first discrete substrate 710 is
made of traditional topsheet materials, such as P10.
[0228] When viewed from the top, the multi-component topsheets 700
may have one or more shapes, patterns or other distinct visible
interfaces between the first discrete substrate 710 and the second
discrete substrate 720 (and in certain embodiments, between the
second discrete substrate and the third discrete substrate 730).
Depending on whether the second discrete substrate 720 is located
above (as depicted in FIGS. 46-47, 50-52 and 55-57) or below (as
depicted in FIGS. 48-49 and 53-54) the first discrete substrate
710, the longitudinal or lateral edges of the first or second
discrete substrates may determine the shape of the visible
interface. For example, in the embodiment depicted in FIG. 46, the
shape or pattern of the first lateral edge 723 of the second
discrete substrate 720 will determine the visible interface
adjacent the inner perimeter first lateral edge 717 of the first
discrete substrate 710, and the shape or pattern of the second
lateral edge 724 of the second discrete substrate 720 will
determine the visible interface adjacent the inner perimeter second
lateral edge 718 of the first discrete substrate 710. In the
embodiment depicted in FIG. 48, the shape or pattern of the inner
perimeter first lateral edge 717 of the first discrete substrate
710 will determine the visible interface adjacent the first lateral
edge 723 of the second discrete substrate 720 and the shape or
pattern of the inner perimeter second lateral edge 718 of the first
discrete substrate 710 will determine the visible interface
adjacent the second lateral edge 724 of the second discrete
substrate 720.
[0229] In any of the non-limiting embodiments of FIGS. 46-57, the
lateral edges or longitudinal edges that create the visible
interface between the second discrete layer 720 and the first
discrete layer 710 (and in certain embodiments, between the second
discrete substrate and the third discrete substrate 730) may be
linear (i.e., straight line) or non-linear (i.e., not a straight
line) and symmetrical or asymmetrical, about either the lateral or
longitudinal axes 701, 702. FIGS. 46-52 are examples of linear,
symmetrical visible interfaces. For non-limiting examples of
additional visible interfaces (dependent on any combination of
longitudinal and/or lateral edges of the first, second, and/or
third discrete substrates), please refer to FIGS. 58-61. FIG. 58
depicts a multi-component topsheet 700 with a visible interface
that is non-linear and asymmetrical about the longitudinal axis
701. One way to achieve such a visible interface is to have a
multi-component topsheet 700 with the second discrete substrate 720
disposed above the first discrete substrate 710, and the first
lateral edge 723 and the second lateral edge 724 of the second
discrete substrate are non-linear and asymmetrical about the
longitudinal axis 701 of the topsheet. In this particular example,
repeating waves form the visible interface. However, in other
embodiments, all kinds of waves may be used, such as sine waves,
saw tooth waves, square waves, etc. FIG. 59 is another example of a
multi-component topsheet 700 with a non-linear and asymmetrical
visible interface. FIG. 60 depicts a multi-component topsheet 700
with a visible interface that is non-linear and symmetrical about
the lateral axis 702. One way to achieve such a visible interface
is to have a multi-component topsheet 700 with the second discrete
substrate 720 disposed above the first discrete substrate 710 and
the first longitudinal edge 721 and the second longitudinal edge
722 of the second discrete substrate are non-linear and symmetrical
about the lateral axis 702 of the topsheet. FIG. 61 is an example
of a multi-component topsheet 700 with a non-linear and
asymmetrical visible interface about the lateral axis 702.
[0230] In some embodiments of multi-component topsheet 700, there
may be a color difference between first discrete substrate 710 and
the second discrete substrate 720 and/or, if present, the third
discrete substrate 730. For example the first discrete substrate
710 may be a first color (e.g., purple, green, teal, blue), and the
second discrete substrate 720 may be a second, different color,
such as white. Alternatively, the first discrete substrate 710 may
be white and the second discrete substrate 720 may be a different
color. Alternatively, the first discrete substrate 710 and the
second discrete substrate 720 can be a first and/or a second color,
and the third discrete substrate 730 can be a different, third
color.
[0231] In some embodiments of multi-component topsheets 600, 700,
one or more elastics may be disposed in the overlap between first
discrete substrate and second discrete substrate and/or the overlap
between second discrete substrate and third discrete substrate. As
depicted in FIGS. 62-65, the multi-component topsheet 600 may have
one or more elastics 660 disposed in the first dual layer area 640
and/or the second dual layer area 650. As depicted in FIG. 62, the
second discrete substrate 620 may be disposed on top of the first
discrete substrate 610 and the third discrete substrate 630, with
the elastics 660 located within the overlaps between the
substrates. As depicted in FIG. 64, the second discrete substrate
620 may be disposed below the first discrete substrate 610 and the
third discrete substrate 630, with the elastics 660 located within
the overlaps between the substrates. As depicted in FIGS. 63 and
65, a portion of the second discrete substrate 620 may wrap around
the elastics 660, thereby creating a triple layer of substrate in
the overlap regions 640, 650.
[0232] In some embodiments of absorbent articles 800, as depicted
in FIGS. 66-68, the multi-component topsheets 600, 700 may be
combined with additional absorbent article elements such as
acquisition layers, distributions layers, absorbent layers, etc. As
one non-limiting example shown in FIG. 66, the absorbent article
includes a multi-component topsheet 800 that comprises first
discrete substrate 810, second discrete substrate 820, third
discrete substrate 830, wherein the multi-component topsheet is
joined (e.g., mechanical bonding and/or adhesive) to acquisition
layer 840, which sits above a distribution layer 850. The
acquisition layer 840 and the distribution layer 850 can be the
same lateral width as the second discrete substrate 820 of the
multi-component topsheet, or wider or narrower than the second
discrete substrate.
[0233] As another non-limiting example shown in FIG. 67, the
absorbent article includes a multi-component topsheet 800 that
comprises first discrete substrate 810, second discrete substrate
820, third discrete substrate 830, wherein the multi-component
topsheet is joined (e.g., mechanical bonding and/or adhesive) to
acquisition layer 840, which is joined (e.g., mechanical bonding
and/or adhesive) to a distribution layer 850. The acquisition layer
840 and the distribution layer 850 can be the same lateral width as
the second discrete substrate 820 of the multi-component topsheet,
or wider or narrower than the second discrete substrate.
[0234] As another non-limiting example shown in FIG. 68, the
absorbent article includes a multi-component topsheet 800 that
comprises first discrete substrate 810, second discrete substrate
820, third discrete substrate 830, wherein the multi-component
topsheet is joined (e.g., mechanical bonding and/or adhesive) to
acquisition layer 840, which is joined (e.g., mechanical bonding
and/or adhesive) to a distribution layer 850. The acquisition layer
840 and the distribution layer 850 can be the same lateral width as
the second discrete substrate 820 of the multi-component topsheet
800, or wider or narrower than the second discrete substrate. In
such embodiment, the second discrete substrate 820 sits above the
first discrete substrate 810 and the third discrete substrate 830,
but the second discrete substrate is joined (e.g., mechanical
bonding 860 and/or adhesive) in the lateral open space between
first and third discrete substrates to the acquisition layer
840.
Test Methods
[0235] Condition all samples at about 23.degree. C..+-.2 C.
.degree. and about 50%.+-.2% relative humidity for 2 hours prior to
testing.
Aperture Test
[0236] Aperture dimensions, effective aperture area, and %
effective open area measurements are performed on images generated
using a flat bed scanner capable of scanning in reflectance mode at
a resolution of 6400 dpi and 8 bit grayscale (a suitable scanner is
the Epson Perfection V750 Pro, Epson, USA). Analyses are performed
using ImageJ software (v.s 1.46, National Institute of Health, USA)
and calibrated against a ruler certified by NIST. A steel frame
(100 mm square, 1.5 mm thick with an opening 60 mm square) is used
to mount the specimen and a black glass tile (P/N 11-0050-30,
available from HunterLab, Reston, Va.) is used as the background
for the scanned images.
[0237] Take the steel frame and place double-sided adhesive tape on
the bottom surface surrounding the interior opening. To obtain a
specimen, lay the absorbent article flat on a lab bench with the
wearer-facing surface directed upward. Remove the release paper of
the tape, and adhere the steel frame to the topsheet (substrates
described herein may only form a portion of the topsheet, e.g., by
being positioned on the topsheet--the three-dimensional material is
what is sampled) of the absorbent article. Using a razor blade,
excise the top sheet from the underling layers of the absorbent
article around the outer perimeter of the frame. Carefully remove
the specimen such that its longitudinal and lateral extension is
maintained. A cryogenic spray (such as Cyto-Freeze, Control
Company, Houston Tex.) can be used to remove the topsheet specimen
from the underling layers, if necessary. Five replicates obtained
from five substantially similar absorbent articles are prepared for
analysis.
[0238] Place the ruler on the scanner bed, close the lid and
acquire a 50 mm by 50 mm calibration image of the ruler in
reflectance mode at a resolution of 6400 dpi and 8 bit grayscale.
Save the 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 with the wearer-facing surface of the
specimen facing the scanner's glass surface. Place the black glass
tile on top of the frame covering the specimen, close the lid and
acquire a scanned image. In like fashion scan the remaining four
replicates.
[0239] Open the calibration file in ImageJ and perform a linear
calibration using the imaged ruler, with the scale set to Global so
that the calibration will be applied to subsequent specimens. Open
a specimen image in ImageJ. View the histogram and identify the
gray level value for the minimum population located between the
dark pixel peak of the holes and the lighter pixel peak of the
nonwoven. Threshold the image at the minimum gray level value to
generate a binary image. In the processed image, the apertures
appear as black and nonwoven as white.
[0240] Select the analyze particles function. Set the minimum
aperture area exclusion limit to 0.3 mm.sup.2 and for the analysis
to exclude the edge apertures. Set the software to calculate:
effective aperture area, perimeter, feret (length of the aperture)
and minimum feret (width of the aperture).
[0241] Record the average effective aperture area to the nearest
0.01 mm.sup.2, and the average perimeter to the nearest 0.01 mm.
Again select the analyze particles function, but his time set the
analysis to include the edge holes as it calculates the effective
aperture areas. Sum the effective aperture areas (includes whole
and partial apertures) and divide by the total area included in the
image (2500 mm.sup.2). Record as the % effective open area to the
nearest 0.01%.
[0242] In like fashion analyze the remaining four specimen images.
Calculate and report the average effective aperture area to the
nearest 0.01 mm.sup.2, the average aperture perimeter to the
nearest 0.01 mm, feret and minimum feret to the nearest 0.01 mm,
and the % effective open area to the nearest 0.01% for the five
replicates.
Height Tests
[0243] Substrate projection heights and overall substrate heights
are measured using a GFM MikroCAD Premium instrument commercially
available from GFMesstechnik GmbH, Teltow/Berlin, Germany. The GFM
MikroCAD Premium instrument includes the following main components:
a) a DLP projector with direct digital controlled micro-mirrors; b)
a CCD camera with at least a 1600.times.1200 pixel resolution; c)
projection optics adapted to a measuring area of at least 60
mm.times.45 mm; d) recording optics adapted to a measuring area of
at least 60 mm.times.45 mm; e) a table tripod based on a small hard
stone plate; f) a blue LED light source; g) a measuring, control,
and evaluation computer running ODSCAD software (version 6.2, or
equivalent); and h) calibration plates for lateral (x-y) and
vertical (z) calibration available from the vendor.
[0244] The GFM MikroCAD Premium system measures the surface height
of a sample using the digital micro-mirror pattern fringe
projection technique. The result of the analysis is a map of
surface height (z-directional or z-axis) versus displacement in the
x-y plane. The system has a field of view of 60.times.45 mm with an
x-y pixel resolution of approximately 40 microns. The height
resolution is set at 0.5 micron/count, with a height range of +/-15
mm. All testing is performed in a conditioned room maintained at
about 23.+-.2.degree. C. and about 50.+-.2% relative humidity.
[0245] A steel frame (100 mm square, 1.5 mm thick with an opening
70 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. To obtain a specimen, lay the
absorbent article flat on a bench with the wearer-facing surface
directed upward. Remove the release paper of the tape, and adhere
the steel frame to the topsheet (substrates described herein may
only form a portion of the topsheet, e.g., by being positioned on
the topsheet--the three-dimensional material is what is sampled) of
the absorbent article. Using a razor blade, excise the topsheet
from the underling layers of the absorbent article around the outer
perimeter of the frame. Carefully remove the specimen such that its
longitudinal and lateral extension is maintained. A cryogenic spray
(such as Cyto-Freeze, Control Company, Houston Tex.) can be used to
remove the topsheet specimen from the underling layers, if
necessary. Five replicates obtained from five substantially similar
absorbent articles are prepared for analysis.
[0246] Calibrate the instrument according to manufacturer's
specifications using the calibration plates for lateral (x-y axis)
and vertical (z axis) available from the vendor.
[0247] Place the steel plate and specimen on the table beneath the
camera, with the wearer-facing surface oriented toward the camera.
Center the specimen within the camera field of view, so that only
the specimen surface is visible in the image. Allow the specimen to
lay flat with minimal wrinkles.
[0248] Collect a height image (z-direction) of the specimen by
following the instrument manufacturer's recommended measurement
procedures. Select the Technical Surface/Standard measurement
program with the following operating parameters: Utilization of
fast picture recording with a 3 frame delay. Dual phaseshifts are
used with 1) 16 pixel stripe width with a picture count of 12 and
2) 32 pixel stripe width with a picture count of 8. A full Graycode
starting with pixel 2 and ending with pixel 512. After selection of
the measurement program, continue to follow the instrument
manufacturer's recommended procedures for focusing the measurement
system and performing the brightness adjustment. Perform the 3D
measurement then save the height image and camera image files.
[0249] Load the height image into the analysis portion of the
software via the clipboard. The following filtering procedure is
then performed on each image: 1) removal of invalid points; 2)
removal of peaks (small localized elevations); 3) polynomial
filtering of the material part with a rank of n=5, with exclusion
of 30% of the peaks and 30% of the valleys from the material part,
and 5 cycles.
Projection Height Test
[0250] Draw a line connecting the peaks of a series of projections,
with the line crossing a non-apertured land area located between
each of the projections. Generate a sectional image of the height
image along the drawn line. Along the sectional line, measure the
vertical height (z-direction) difference between the peak of the
projection and the adjacent valley of the land area. Record the
height to the nearest 0.1 .mu.m. Average together 10 different
projection peak to land area height measures and report this value
to the nearest 0.1 .mu.m. This is the projection height.
Recess Height Test
[0251] Subtract the projection height from the overall substrate
height to obtain the recess height. This should be done with each
of the ten measurements from the Projection Height Test and the
Overall Substrate Height Test. Average together the ten recess
heights and report this value to the nearest 0.1 .mu.m. This is the
recess height.
Overall Substrate Height Test
[0252] Draw a line connecting the peaks of a series of projections,
with the line crossing the center of an aperture located between
each of the projections and within a recess. Generate a sectional
image of the height image along the drawn line. Along the sectional
line, measure the vertical height difference between the peak of
the projection and the adjacent base of the recess. Record the
height to the nearest 0.1 .mu.m. Average together 10 different
projection peak to base of recess height measures and report this
value to the nearest 0.1 .mu.m. This is the overall substrate
height.
Average Aperture Spacing Test
[0253] Lateral Axis Aperture Spacing and Longitudinal Axis Aperture
Spacing are performed on images generated using a flat bed scanner
capable of scanning in reflectance mode at a resolution of 6400 dpi
and 8 bit grayscale (a suitable scanner is the Epson Perfection
V750 Pro, Epson, USA). Analyses are performed using ImageJ software
(v.s 1.46, National Institute of Health, USA) and calibrated
against a ruler certified by NIST. A steel frame (100 mm square,
1.5 mm thick with an opening 60 mm square) is used to mount the
specimen and a black glass tile (P/N 11-0050-30, available from
HunterLab, Reston, Va.) is used as the background for the scanned
images. Testing is performed at about 23.degree. C..+-.2 C.
.degree. and about 50%.+-.2% relative humidity.
[0254] Take the steel frame and place double-sided adhesive tape on
the bottom surface surrounding the interior opening. To obtain a
specimen, lay the absorbent article flat on a lab bench with the
wearer-facing surface directed upward. Remove the release paper of
the tape, and adhere the steel frame to the topsheet of the
absorbent article. Using a razor blade excise the topsheet (i.e.,
the three dimensional substrate that forms all of or part of the
wearer-facing surface) from the underling layers of the absorbent
article around the outer perimeter of the frame. Carefully remove
the specimen such that its longitudinal and lateral extension is
maintained. A cryogenic spray (such as Cyto-Freeze, Control
Company, Houston Tex.) can be used to remove the topsheet specimen
from the underling layers, if necessary. Five replicates obtained
from five substantially similar absorbent articles are prepared for
analysis. Condition the samples at about 23.degree. C..+-.2 C.
.degree. and about 50%.+-.2% relative humidity for 2 hours prior to
testing.
[0255] Place the ruler on the scanner bed, close the lid and
acquire a 50 mm by 50 mm calibration image of the ruler in
reflectance mode at a resolution of 6400 dpi and 8 bit grayscale.
Save the 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 with the wearer-facing surface of the
specimen facing the scanner's glass surface. Place the black glass
tile on top of the frame covering the specimen, close the lid and
acquire a scanned image. In a like fashion, scan the remaining four
replicates.
[0256] Open the calibration file in ImageJ and perform a linear
calibration using the imaged ruler, with the scale set to Global so
that the calibration will be applied to subsequent specimens. Open
a specimen image in ImageJ and perform the following measures:
Lateral Axis Aperture Spacing
[0257] Measure from a center point of one aperture to a center
point of an adjacent aperture on the other side of a projection,
wherein the projection is positioned between the two apertures. The
measurement will be taken in a direction parallel to a lateral axis
of the specimen across the projection. Report each distance to the
nearest 0.1 mm. Take 5 random measurements in the specimen. Average
the five values to and report the average lateral axis center to
center spacing to the nearest 0.1 mm. Repeat this procedure for the
additional four samples.
Longitudinal Axis Aperture Spacing
[0258] Measure from a center point of one aperture to a center
point of an adjacent aperture on the other side of a projection,
wherein the projection is positioned between the two apertures. The
measurement will be taken in a direction parallel to a longitudinal
axis of the specimen across the projection. Report each distance to
the nearest 0.1 mm. Take 5 random measurements in the specimen.
Average the five values to and report the average longitudinal axis
center to center spacing to the nearest 0.1 mm. Repeat this
procedure for the additional four samples.
Basis Weight Test
[0259] Basis weight of the three-dimensional substrates may be
determined by several available techniques but a simple
representative technique involves taking an absorbent article,
removing any elastic which may be present and stretching the
absorbent article 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 substrate forming
a topsheet, positioned on the topsheet, or forming a portion of the
topsheet (the "topsheet" in this method), from the approximate
center of the diaper or absorbent product in a location which
avoids to the greatest extent possible any adhesive which may be
used to fasten the topsheet to any other layers which may be
present and removing the topsheet layer 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 topsheet.
Results are reported as a mean of 5 samples to the nearest 0.1 gram
per square meter.
Descriptive Analysis Roughness Method
[0260] Surface Geometrical Roughness is measured using a Kawabata
Evaluation System KES FB4 Friction tester with Roughness Sensor
(available from Kato Tech Co., Japan). The instrument measures both
surface friction and geometric roughness simultaneously, but herein
only the geometric roughness (SMD value) is reported. All testing
is performed at about 23.degree. C..+-.2 C. .degree. and about
50%.+-.2% relative humidity. Samples are preconditioned at about
23.degree. C..+-.2 C. .degree. and about 50%.+-.2% relative
humidity for 2 hours prior to testing. The instrument is calibrated
as per the manufacturer's instructions.
[0261] The absorbent article is placed, wearer-facing surface
upward, onto a lab bench. The absorbent article's cuffs are clipped
with scissors to facilitate the article lying flat. With scissors
or a scalpel excise a specimen of the topsheet 20 cm long in the
longitudinal direction of the absorbent article and 10 cm wide in
the lateral direction of the absorbent article. Care should be
taken in removing the specimen as to not distort the dimensions in
either the longitudinal or lateral direction. Specimens are
collected from a total of five substantially identical absorbent
articles.
[0262] Turn on the KES FB4. The instrument should be allowed to
warm up for at least 10 minutes before use. Set the instrument to a
SMD sensitivity of 2.times.5, a testing velocity of 0.1, and a
compression area of 2 cm. The roughness contractor compression
(contact force) is adjusted to 10 gf. Place the topsheet specimen
on the tester with the wearer-facing surface facing upward and the
longitudinal dimension aligned with the test direction of the
instrument. Clamp the specimen with an initial tension of 20 gf/cm.
Initiate the test. The instrument will automatically take 3
measurements on the specimen. Record the MIU (Coefficient of
Friction), MMD (Slip Stick), and SMD (Geometrical Roughness) value
from each of the three measurements to the nearest 0.001 micron.
Repeat in like fashion for the remaining four specimens.
[0263] Report Coefficient of Friction as an average of the 15
recorded values to the nearest 0.01. Report Slip Stick as an
average of the 15 recorded values to the nearest 0.001. Report the
Geometrical Roughness as an average of the 15 recorded values to
the nearest 0.01 micron.
[0264] 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."
[0265] Every document cited herein, including any cross referenced
or related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any embodiment disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
embodiment. 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.
[0266] While particular embodiments of the present disclosure have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications may
be made without departing from the spirit and scope of the present
disclosure. It is therefore intended to cover in the appended
claims all such changes and modifications that are within the scope
of this disclosure.
* * * * *