U.S. patent application number 16/391421 was filed with the patent office on 2019-08-15 for method of producing a multi-layered printed absorbent article.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to David Christopher Oetjen.
Application Number | 20190247239 16/391421 |
Document ID | / |
Family ID | 44903411 |
Filed Date | 2019-08-15 |
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United States Patent
Application |
20190247239 |
Kind Code |
A1 |
Oetjen; David Christopher |
August 15, 2019 |
METHOD OF PRODUCING A MULTI-LAYERED PRINTED ABSORBENT ARTICLE
Abstract
A method for producing a multi-layered absorbent articles is
disclosed. At least two of the layers include a colored region.
Inventors: |
Oetjen; David Christopher;
(West Chester, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
44903411 |
Appl. No.: |
16/391421 |
Filed: |
April 23, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15943816 |
Apr 3, 2018 |
10307299 |
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16391421 |
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15722397 |
Oct 2, 2017 |
9962299 |
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15943816 |
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15220420 |
Jul 27, 2016 |
9801762 |
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15722397 |
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14568156 |
Dec 12, 2014 |
9414971 |
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15220420 |
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12908558 |
Oct 20, 2010 |
8945334 |
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14568156 |
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12548603 |
Aug 27, 2009 |
8262633 |
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12908558 |
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12548604 |
Aug 27, 2009 |
8292864 |
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12548603 |
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12188543 |
Aug 8, 2008 |
7967801 |
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12548604 |
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12188598 |
Aug 8, 2008 |
8058501 |
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12188543 |
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Aug 8, 2008 |
8058501 |
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Aug 8, 2008 |
7967801 |
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12188598 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 5/00 20130101; B32B
5/024 20130101; B32B 2307/75 20130101; B32B 2262/06 20130101; B41J
11/70 20130101; D04H 1/4382 20130101; Y10T 156/1052 20150115; B32B
27/12 20130101; A61F 13/84 20130101; B32B 2307/726 20130101; A61F
13/15739 20130101; A61F 2013/8497 20130101; B32B 5/022 20130101;
B32B 2307/4023 20130101; A61F 13/15699 20130101; Y10T 156/1074
20150115; B32B 5/26 20130101; B32B 2307/402 20130101; A61F 13/51394
20130101; B32B 2555/02 20130101; B32B 5/08 20130101; B32B 2555/00
20130101; A61F 13/472 20130101; Y10T 156/1084 20150115; B32B
2262/02 20130101; D04H 1/4374 20130101; A61F 13/15764 20130101;
B32B 5/22 20130101; A61F 13/51496 20130101; B41M 3/008 20130101;
B32B 38/145 20130101; B32B 38/0004 20130101; B32B 2307/58 20130101;
B32B 2262/14 20130101 |
International
Class: |
A61F 13/15 20060101
A61F013/15; A61F 13/513 20060101 A61F013/513; B32B 5/26 20060101
B32B005/26; B32B 5/00 20060101 B32B005/00; D04H 1/4374 20060101
D04H001/4374; D04H 1/4382 20060101 D04H001/4382; B32B 27/12
20060101 B32B027/12; B32B 38/00 20060101 B32B038/00; B32B 5/02
20060101 B32B005/02; B32B 5/08 20060101 B32B005/08; B32B 5/22
20060101 B32B005/22; A61F 13/84 20060101 A61F013/84; B41J 11/70
20060101 B41J011/70; A61F 13/472 20060101 A61F013/472; A61F 13/514
20060101 A61F013/514 |
Claims
1. A method of producing a multi-layered absorbent articles having
two or more colored regions, the absorbent articles each comprising
a lateral centerline and a longitudinal centerline, the method
comprising the steps of: providing an absorbent article converting
line; supplying a first material web to the converting line;
supplying a second material web to the converting line; printing a
first colored region on at least one of the first material web or
the second material web using contact printing at a contact
printing station; printing a second colored region on at least one
of the first material web or the second material web using
non-contact printing at a non-contact printing station; wherein the
first colored region and the second colored region have a .DELTA.E*
of at least about 1.0.
2. The method of claim 1, further comprising the steps of:
combining the first material web and the second material web and
cutting the first material web and the second material web into
individual sheets.
3. The method of claim 1, wherein the first colored region and the
second colored region do not overlap one another.
4. The method of claim 1, wherein the first colored region is
printed on the first material web and the second colored region is
printed on the second material web.
5. The method of claim 1, further comprising the step of combining
an individual sheet of the first material web and the second
material web thereby forming a laminate sheet.
6. The method of claim 5, further comprising the step of providing
an absorbent core; combining the absorbent core with the laminate
sheet; and combining a backsheet with the absorbent core.
7. The method of claim 22, wherein the laminate sheet has a first
surface and an opposing second surface, wherein the first color
signal is disposed on the first surface or more proximal to the
first surface than the second color signal.
8. The method of claim 5, wherein the laminate sheet has a first
surface and an opposing second surface, wherein the second color
signal is disposed on the second surface or more proximal to the
second surface than the first color signal.
9. The method of claim 1, wherein the second material web comprises
a nonwoven material.
10. The method of claim 1, wherein the second material web
comprises a film.
11. The method of claim 10, wherein the first material web
comprises a nonwoven material.
12. The method of claim 1, wherein the first material web comprises
a combination of nonwoven material and film.
Description
FIELD OF THE INVENTION
[0001] Disclosed is a method for producing an absorbent article
having multiple layers.
BACKGROUND OF THE INVENTION
[0002] Absorbent articles having colored regions are preferred by
consumers for the benefits they provide. One benefit is that
colored regions can help mask bodily fluid, for instance menses or
urine, collected by the absorbent article. The ability to mask the
absorbed bodily fluids provides a user with an increased feeling of
cleanliness and protection from soiled undergarments. Another
benefit is that colored regions in secondary layers, especially in
the central region of the absorbent article where bodily fluid is
primarily absorbed, provide a desired visual impression of depth to
a user. This perception of absorbent article depth increases a
user's confidence in the absorption capacity of the absorbent
article, resulting in increased confidence that bodily fluids will
be successfully absorbed and stored; thereby reducing the chance of
soiled undergarments.
[0003] However it has been difficult to produce absorbent articles
having the desired colored regions. One of the difficulties has
been providing the central region of an absorbent article with a
colored region that will provide the desired coverage; as some
users associate stain patterns that extend outside the central
colored region as indicating that the absorbent capacity of the
absorbent article is exhausted. In some absorbent articles, the
central colored region could account for less than 25% of the
absorbent capacity of the absorbent article. Most digital printers
lack the width-wise spray area to provide the desired colored
region width to the central region, especially if products are
produced multi-lane or broad front, where two or more products are
simultaneously on the production line. One attempted fix has been
to try and arrange multiple digital printers in a side-by-side
arrangement to provide increased spray area in the widthwise
direction of the absorbent article. The rearrangement of the
digital printers has not provided the desired results. The
side-by-side arrangement increases the cost of the digital printers
and further decreases the reliability of the printing process. If
one of the coupled printheads in the width direction fails, the
production line stops. Image quality is also at risk as the
multiple digital printers must be coordinated to produce a colored
region that is not noticeably offset in the machine direction. As
the colored region is on or close to the absorbent article surface
any errors are quickly noticed by a user, reducing or eliminating
the benefits provided by colored regions.
[0004] Another attempt to provide colored regions having the
desired coverage area has been to use a contact method of printing,
such as flexographic printing. Contact printing has traditionally
been an economical way to print large or wide patterns on an
absorbent article with reproducible results. However, contact
printing may result in higher initial expense because the specific
pattern rolls, plates, or screens must be manufactured. Because of
the custom manufacturing, subsequent changes to the print pattern
may require the manufacture of new equipment and may limit the
economic feasibility of quickly changing the print pattern for
specific needs or limited production situations. A further issue is
that contact printing does not work equally well with all
substrates. For example, to create the visual perception of depth
the central portion will be printed on to create a central colored
region. However to create the visual perception of depth, a layer
below the surface layer (top layer) is printed to produce the
central colored region. In general the layers below the surface
layer include "dusty" or "loose" non-woven or cellulose containing
web materials that cannot be printed on using a contact method, as
the loose fiber sticks to the print plate resulting in light or
missing print.
[0005] In a further effort to provide the desired colored regions
to an absorbent article, multiple printing processes have been used
during the production of an absorbent article. These multiple
printing processes have several shortcomings. In one method a
single layer is printed on multiple times. However, printing on a
single layer of an absorbent article multiple times does not
provide a perception of depth that printing on multiple layers
does. Another method involves printing on multiple layers of an
absorbent article after they have been brought in contact with one
another. This reduces the surfaces which can be printed,
restricting printed webs to being in contact with one another, thus
the perception of depth is lost. An additional method uses
preprinted rolls of materials to produce absorbent articles.
However the use of preprinted rolls increases the cost of the
absorbent articles due to supply chain complexity and increased
product scrap linked to registration of the image(s) in the
preprinted roll.
[0006] Therefore there is a need for a method of producing
absorbent articles having colored regions on multiple layers, such
that the colored regions provide a visual perception of depth and
sufficient coverage to at least partially mask absorbed bodily
fluids.
SUMMARY OF THE INVENTION
[0007] A method of producing a multi-layered absorbent articles
having two or more colored regions is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic representation of one embodiment of
the present invention.
[0009] FIG. 2 is a schematic representation of a flexographic
printing process of the present invention.
[0010] FIG. 3 is a schematic representation of a gravure printing
process of the present invention.
[0011] FIG. 4 is a schematic of an absorbent article.
[0012] FIG. 5 is a cross-section of the absorbent article
illustrated in FIG. 4.
[0013] FIG. 6 is a schematic of the second substrate of the
absorbent article of FIG. 4.
[0014] FIG. 7 is a schematic of the first substrate of the
absorbent article of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention relates to a method of producing a
printed multi-layered absorbent article on a converting line. A
first substrate, such as a topsheet, is supplied to a converting
line and printed with a first colored region using a contact method
of printing, for instance, flexographic printing, rotogravure
printing, offset printing, lithographic printing, screen printing,
or the like. A second substrate, such as a non-woven or cellulose
based secondary topsheet is also supplied to the converting line
and printed with a second colored region using a non-contact method
of printing, such as, for example, wax jet printing, ink jet
printing, bubble jet printing, laser jet printing, or the like.
Following the printing steps the first substrate and second
substrate are combined in the process of producing an absorbent
article, such as a feminine sanitary napkin.
[0016] As used herein the term "converting line" means a
manufacturing line used to make absorbent articles. The purpose of
a converting line is to take raw materials, process and combine
them to produce absorbent articles. A converting line comprises
various unit-operations used in the production of absorbent
articles. A unit-operation can range from simple actions such as
raw material transport (unwind, meter, reposition, and the like) to
complex material transformations (melting, cutting, stretching,
fluid application (ink, lotion, adhesive), and the like). In the
converting line many unit-operations are occurring in parallel as
well as in sequence to produce an absorbent article.
[0017] As used herein, the term "print" or "printing" means to
produce a colored region on a substrate. Frequently, printing
involves formation of a colored region by the transfer of pigment,
colorant, or brightener in the form of ink, wax, paint, or the like
to a substrate. The printed colored region is visible to the human
eye and can include, for example, shapes, patterns, designs,
objects, likenesses of real or fictitious characters, or the like,
or combinations thereof. Examples of printing methods include
contact printing and non-contact printing. Contact printing
includes the direct transfer of pigment from a print roll, plate,
or screen to a substrate. In non-contact printing methods, the
printing apparatus does not directly contact the substrate, for
example when printing from ink jet printers, wax jet printers,
bubble jet printers, laser jet printers, or the like, or
combinations thereof.
[0018] As used herein, the term "substrate" means a web of material
capable of moving through a converting line. A substrate can
include contiguous material wherein individual units of material
are connected or directly joined to the immediately preceding and
trailing units of material. For example, a substrate may include a
continuous web of woven material, nonwoven material, film, or the
like, or combinations thereof. A substrate may also include
interconnected absorbent articles in various stages of manufacture.
A substrate may also include a web of discrete units of material
separated by space or by other materials. For example, a substrate
may include discreet absorbent articles moving through a converting
line via one or more conveyor belts or other means of conveyance
known in the art.
[0019] As used herein, the phrase "absorbent article" refers to
devices which absorb and contain fluids, which includes bodily
fluids, and more specifically refers to devices which may be placed
against or near the skin to absorb and contain the various fluids
discharged from the body. In typical use absorbent articles are not
intended to be laundered or otherwise restored or reused after a
single use. Examples of absorbent articles include, but are not
limited to sanitary tissue products, for example facial tissue,
toilet tissue, paper towels, wipes; home care products, for example
cleaning wipes, such as Swiffer.RTM. (The Procter & Gamble
Company, Cinc., Ohio); beauty care products such as wipes and
cleaning pads; feminine hygiene products, for example sanitary
napkins, pantiliners, tampons, interlabial devices and the like;
infant diapers; children's training pants; adult incontinence
products. Non-limiting examples of pantiliners and sanitary napkins
which may be provided with a first colored region on a laminate
substrate and second colored region on a lower substrate include
those manufactured by The Procter & Gamble Company of
Cincinnati, Ohio, such as ALWAYS ULTRA, ALWAYS INFINITY, and ALWAYS
pantiliners. Absorbent articles such as those disclosed in U.S.
Pat. Nos. 4,324,246, 4,463,045, 6,004,893, 4,342,314, 4,463,045,
4,556,146, 4,589,876, 4,687,478, 4,950,264, 5,009,653, 5,267,992,
and Re. 32,649 are also contemplated as being absorbent articles
that might benefit from a first and second colored region.
[0020] Absorbent articles, and their individual components, such as
a liquid pervious topsheet, a secondary topsheet, an absorbent
core, and a substantially liquid impervious backsheet, have a body
facing surface and a garment facing surface. As used herein,
"body-facing surface" means that surface of the article or
component which is intended to be disposed toward or placed
adjacent to the body of the wearer during ordinary use, while the
"garment facing surface" is on the opposite side, and is intended
to be disposed to face away from the wearer's body during ordinary
use. The garment facing surface may be arranged to face toward or
placed adjacent to the wearer's undergarments when the absorbent
article is worn. In general the topsheet is operatively permeable
to the liquids that are intended to be held or stored by the
absorbent article, and the backsheet may be substantially
impermeable or otherwise operatively impermeable to the intended
liquids. The absorbent article may also include components such as
liquid wicking layers, liquid distribution layers, barrier layers,
and the like, as well as combinations thereof.
[0021] The term `color` as referred to herein includes any primary
color, for example, white, black, red, blue, violet, orange,
yellow, green, and indigo as well as any declination thereof or
mixture thereof. The term `non-color` or `non-colored` refers to
the color white which is further defined as those colors having an
L* value of at least 80, an a* value equal to 0.+-.2, and a b*
value equal to 0.+-.2.
[0022] One embodiment of the method is illustrated in FIG. 1. FIG.
1 shows a schematic representation of a converting line 100
according to the method of the present invention, wherein a first
substrate 101 is supplied to a contact printing station 103 within
the converting line 100. The contact printing station 103 prints at
least one first colored region on the first substrate 101. A second
substrate 141 is also supplied to a non-contact printing station
143 within the converting line 100. The non-contact printing
station 143 prints at least one second colored region on the second
substrate 141.
[0023] The first substrate 101 and second substrate 141 may be
supplied to the converting line 100 concurrently.
[0024] With reference to FIG. 1 the method of the present invention
can have a machine-direction (MD) which extends longitudinally, and
a lateral cross-direction (CD) which extends transversely. The
machine-direction is the direction along which a particular
substrate is transported along and through a particular position of
the converting line. The cross-direction lies generally within the
plane of the substrate being transported through the converting
line, and is aligned perpendicular to the machine-direction.
[0025] In one embodiment, the contact printing station 103 for
printing a first colored region on a first substrate can comprise a
flexographic printing process 105, as shown in FIG. 2. A
flexographic printing process 105 can use any known flexographic
printing apparatus and equipment, including processing means known
in the art. As shown, ink 107 is supplied in a chamber 109
comprising a doctor blade, and which is in operative relationship
with an anilox roller 111 to which ink 107 from the chamber 109 is
transferred in a uniform manner as the anilox roller 111 rotates in
the direction indicated. The anilox roller 111 is in operative
relationship with a plate roller 113 such that at a transfer nip
115, ink 107 is transferred from the anilox roller 111 to the plate
roller 113. The plate roller 113 picks up ink 107 from the anilox
roller 111 in a pattern corresponding to the first colored region
printed on a first substrate 101. The first substrate 101 on which
the first colored region will be printed, such as a web for a
topsheet of an absorbent article, such as a feminine sanitary
napkin, is fed onto the central impression drum 117 (in any
conventional manner), which is rotating in the direction shown in
FIG. 2.
[0026] As the first substrate 101 enters the printing nip 119
formed by the operational relationship of the surfaces of the plate
roller 113 and the central impression roller 117, the ink 107 on
the surface of the plate roller 113 makes contact with, and is
transferred to, the first substrate 101.
[0027] Alternatives to the described flexographic printing process
can also be used in the contact printing station of the present
invention. For example, in certain embodiments, the contact
printing station may comprise a gravure printing process 131 as
illustrated in FIG. 3. In the gravure process 131, a first
substrate 101 is passed between a rubber impression roller 132 and
a gravure cylinder 133. The surface of the gravure cylinder 133
contains a large number of cells 134, which are designed to
receive, hold, and transfer ink to the first substrate 101. Ink 135
is applied to the surface of the gravure cylinder 133 downstream of
a nip 137 and is removed from the land areas of the gravure
cylinder 133 with a doctor blade 138. As the first substrate 101
enters the nip 137, it is pressed against the gravure cylinder 133
by the rubber impression roller 132, thereby permitting the Ink 135
to transfer from the gravure cylinder cells 134 and be deposited on
the surface of the first substrate 101 in small colored or
brightened areas 139 corresponding to the individual gravure
cylinder cells 134.
[0028] As shown in FIG. 1, in the method of the present invention
the converting line 100 also comprises a non-contact printing
station 143. The non-contact printing station 143 may use a
non-contact process to print at least one second colored region on
a second substrate. In one embodiment the non-contact printing
station 143 may include an inkjet process. In this embodiment the
non-contact printing station 143 includes an inkjet printing
station capable of printing a colored region on a second substrate
141, such as a nonwoven or cellulose based web for use as a
secondary topsheet. The second substrate 141 can be provided to the
non-contact printing station 143 by any suitable means; for example
as shown in FIG. 1, through the use of a first metering device 145
(for example an omega roll or an s-wrap device), a series of idle
rollers 147 and 149, and a second metering device 151 (for example
a vacuum conveyor). Both the metering devices 145 and 151 create a
desired tension in the second substrate 141 and move the second
substrate 141 in a machine direction MD at a desired linear
velocity V, which can be as high as about 6 meters/second or even
greater. However, the present invention is applicable at any other
linear velocity V of the second substrate, for example, at least 5
meters/second, at least 4 meters/second, at least 3 meters/second,
at least 2 meters/second, and lower (which occurs during a startup
of the converting line when the converting line speed, including
the linear velocity V of the second substrate 141, is gradually
increasing from a zero to a desired production speed).
[0029] As shown in FIG. 1, the inkjet printing station 143 in
certain embodiments may include a dual-head arrangement comprising
a first inkjet print head 153 and a second inkjet print head 155,
disposed at a spatial distance 157 extending in the machine
direction MD. However, it should be noted that the first and the
second print heads 153, 155 could be disposed from each other at
any desired spatial distance. In certain embodiments the first
inkjet print head 153 and second inkjet print head 155 can be
oriented in a side-by-side manner in a cross-direction across the
second substrate. This side-by-side orientation increases the
widthwise coverage of the inkjet print heads 153, 155.
[0030] The first and the second print heads 153 and 155 can be any
type that is suitable to print a colored region, and may be
disposed at a certain suitable distance from the second substrate
141. In certain embodiments the distance may be form about 0.5 mm
to about 3 mm, and in certain other embodiments from about 1 mm to
about 2 mm. In certain embodiments, the inkjet printing station may
comprise one or more digital printers, such as a continuous binary
array allowing for a greater ink drop velocity than other inkjet
printers, allowing for a wider gap between the print head and web
to provide a quality image.
[0031] The print heads 153 and 155 can be supplied with ink from a
common ink source; although in certain embodiments, separate ink
sources can be also utilized.
[0032] Each of the print heads 153 and 155 includes a multiplicity
of jets dispensing a multiplicity of substantially uniform ink
dots. In one embodiment of the present invention, each of the print
heads 153 and 155 can include 256 jets, forming a linear
configuration in the cross-direction of about 2 inches long (about
50.8 mm). Therefore, each of the print heads 153 and 155 can print
an ink image containing 256 ink dots extending linearly about 50.8
mm across the second substrate 141. This arrangement is sufficient
for printing any image of up to about 50.8 mm wide, as measured in
the cross-direction of the second substrate 141. However, any
number of jets per a print head can be provided to print a desired
width W of a colored region, which in certain embodiments, for
absorbent articles produced in the process of the present invention
can vary from about 5 mm to about 185 mm, in certain other
embodiments from about 20 mm to about 105 mm.
[0033] With respect to the print heads having 256 jets, such print
heads are available from Videojet Technologies, Inc., (Wood Dale,
Ill.). The printing station 143 can be a part of an inkjet printing
system that is also available from Videojet Technologies, Inc., as
the BX6000 series inkjet print system including an ink source and a
controller for providing ink and controlling jets forming
individual ink droplets.
[0034] In the BX6000 series inkjet print system a continuous binary
array can be used, wherein the ink droplets are dispensed from all
of the jets of the print heads 153 and 155 continuously, but only
certain ink droplets are allowed to reach the second substrate 141
at desired locations to form a printed image. The other ink
droplets can be prevented from reaching the second substrate 141 by
deflecting the ink droplets into a recycling flow for a continuous
re-use. The operation of the individual ink jets of each print head
can be controlled by a controller included in the BX6000 series
system.
[0035] In certain embodiments, in place of a continuous type of the
inkjet printing system the inkjet printing system can be an
on-demand type inkjet printing system (such as thermal ink jet or
Peizo Drop on Demand), wherein ink typically is not recycled and
ink droplets are formed on a demand basis and in a desired order to
print a colored region.
[0036] Referring again to FIG. 1, each of the first and the second
print heads 153 and 155 is capable of printing colored regions
separately from each other. For example, in certain embodiments
when the first print head 153 is in a print mode, the second print
head 155 can be in a standby or idle mode (is not printing an image
on the second substrate 141). Conversely, when the first print head
153 is in a standby mode, the second print head 155 can be in a
print mode, printing an image. As described above, in both modes of
operation, the print mode and the standby mode, the droplet
formation by each of the 256 jets of each of the print heads 153
and 155 occurs continuously; however, in the standby mode, all of
the dispensed droplets are deflected and recycled into a recycled
ink flow, but in the print mode the un-deflected droplets are
deposited on the second substrate 141 and the deflected droplets
are recycled into the recycle ink flow. In certain other
embodiments, the first print head 153 and second print head 155 can
print colored regions at the same time to print two colors. In
another embodiment, the first print head 153 and second print head
155 can be offset in the CD to increase the CD resolution, for
example from 128 dpi to 256 dpi. A still further embodiment the
first print head 153 and second print head 155 can be used to print
the same colored region twice to increase color intensity.
[0037] Referring again to FIG. 1, after the inkjet printing, the
second substrate 141 travels to a cut and placement device 159,
capable of severing the second substrate 141 into individual sheets
comprising, in this embodiment the secondary topsheet 41, and then
placing the secondary topsheets 41 at a desired pitch interval P
onto a topsheet web 101 produced from the first substrate moving in
a machine direction MD at a desired velocity. The topsheet web 101
can be provided and metered at a desired velocity by any suitable
means known to one skilled in the art. Then, an absorbent core web
160 (which can be also provided and metered by any suitable means)
is cut into individual absorbent cores 60, which are then placed
onto a secondary topsheet 41, previously disposed on the topsheet
web 101. The cutting and placing operations of the absorbent core
60 can be provided by a cut-and-slip or cut-and-lay device 161 or
any suitable web cutting and placing device known in the art.
Further, a backsheet web 170 (which can be also provided and
metered by any suitable means) is deposited onto the absorbent
cores 60 to provide a sandwiched-type web 175, which is
subsequently bonded together and cut into individual absorbent
articles 200. The bonding, cutting, and placing operations of the
sandwiched-type web 175 can also be provided by any suitable means
known in the art, for example, by a final knife 176. A variety of
suitable securing mechanisms or systems known to one of skill in
the art may be utilized to achieve any bonding. Examples of such
securing mechanisms can include, but are not limited to, the
application of adhesives in a variety of patterns between the two
adjoining surfaces, entangling at least some portions of one
absorbent body component with portions of the adjacent surface of
another component, or fusing at least portions of the adjacent
surface of one component to portions of another component of the
absorbent. The individual absorbent articles, which in this
instance are feminine sanitary napkins 200, can then be transported
by any suitable means, such as a conveyor 178, to other downstream
operations, such as folding, wrapping, and packing.
[0038] Referring now to FIG. 4, a top view of an absorbent article
produced from the method of the present invention is shown, which
in this illustrated embodiment is a feminine sanitary napkin 200.
The feminine sanitary napkin 200 can have a substantially planar
configuration and a central region 202. The central region 202 is
the in-plane center of mass of the feminine sanitary napkin 200.
The central region 202 is at the intersection between the
longitudinal centerline L and transverse centerline T. The
transverse centerline T is perpendicular to the longitudinal
centerline L. The feminine sanitary napkin 200 can be symmetrical
or asymmetrical about the transverse centerline T. The feminine
sanitary napkin 200 has a body facing surface 204 comprising a
topsheet 208 produced from a first substrate, an absorbent core 60,
a secondary topsheet 41 produced from a second substrate positioned
between the topsheet 208 and absorbent core 60, and a garment
facing surface 206 comprising a liquid impervious backsheet
209.
[0039] In certain embodiments the topsheet, secondary topsheet, or
both may be compliant, soft feeling, and non-irritating to the
wearers skin and hair. Further, the topsheet or secondary topsheet
is liquid pervious, permitting liquids, such as menses or urine, to
readily penetrate through its thickness. A suitable topsheet or
secondary topsheet may be manufactured from a wide range of
materials such as woven and nonwoven materials, for example a
nonwoven web of fibers; polymeric materials such as apertured
formed thermoplastic films, apertured plastic films, and
hydroformed thermoplastic films; porous foams; reticulated foams;
reticulated thermoplastic films; and thermoplastic scrims. Suitable
woven and nonwoven materials can be comprised of: natural fibers,
such as wood or cotton fibers; synthetic fibers, such as polymeric
fibers--for example polyester, polypropylene, or polyethylene
fibers; or from a combination of natural and synthetic fibers. When
the topsheet or secondary topsheet comprises a nonwoven web, the
web may be manufactured by a wide number of known techniques. For
example, the web may be spunbonded, carded, wet-laid, melt-blown,
hydroentangled, combinations of the above, or the like.
[0040] The backsheet is substantially impervious to liquids, such
as menses or urine and may be manufactured from a thin plastic
film, although other flexible liquid impervious materials may also
be used. The backsheet prevents the exudates absorbed by the
absorbent core from wetting a user's bedding or clothes, for
example bedsheets, pants, pajamas and undergarments. In certain
embodiments, the backsheet can operatively permit a sufficient
passage of air and moisture vapor out of an absorbent article,
particularly out of the absorbent core, while blocking the passage
of bodily liquids. The backsheet may thus comprise: a woven or
nonwoven material; polymeric films, such as thermoplastic films of
polyethylene or polypropylene; or composite materials such as a
film-coated nonwoven material. In one embodiment, the backsheet can
be a breathable backsheet such as that described in U.S. Pat. No.
6,623,464 (Bewick-Sonntag et al.) issued 23 Sep. 2003.
[0041] As shown in FIG. 4 the backsheet 209 and the topsheet 208
are positioned adjacent the garment facing surface 206 and the body
facing surface 204, respectively, of the absorbent core 60. In
certain embodiments the absorbent core can be joined with the
topsheet, the backsheet, or both by known bonding means, such as
those described above or those well known in the art. However, in
certain embodiments of the present invention the absorbent core is
unattached to the topsheet, the backsheet, or both.
[0042] The absorbent core 60 in FIG. 1 is generally disposed
between the topsheet 208 and the backsheet 209. The absorbent core
60 may comprise any absorbent material that is generally
compressible, conformable, non-irritating to the wearer's skin, and
capable of absorbing and retaining liquids such as urine and other
certain body exudates, such as menses. The absorbent core 60 may
comprise a wide variety of liquid-absorbent materials commonly used
in feminine care articles and other absorbent articles, such as
comminuted wood pulp, which is generally referred to as air felt.
Examples of other suitable absorbent materials include creped
cellulose wadding; melt blown polymers, including co-form;
chemically stiffened, modified or cross-linked cellulosic fibers;
tissue, including tissue wraps and tissue laminates; absorbent
foams such as foams formed from High Internal Phase Emulsions
(HIPEs); absorbent sponges; superabsorbent polymers; absorbent
gelling materials; or any other known absorbent material or
combinations of materials. The absorbent core may further comprise
minor amounts (typically less than 10%) of non-liquid absorbent
materials, such as adhesives, waxes, oils and the like. Examples of
absorbent structures that may be used in the present invention are
found in U.S. Pat. No. 4,834,735 (Alemany et al.) issued 30 May
1989; U.S. Pat. No. 5,625,222 (DesMarais et al.) 22 Jul. 1997.
[0043] The absorbent core may also include one or more
superabsorbent materials. Superabsorbent materials suitable for use
in the present invention are known to those skilled in the art, and
may be in any operative form, such as particulate form. The
superabsorbent material can be a water-swellable, generally
water-insoluble, hydrogel-forming polymeric absorbent material,
which is capable of absorbing at least about 20, in certain
embodiments about 30, and in additional embodiments about 60 times
or more its weight in physiological saline (for example 0.9 wt %
NaCl). The hydrogel-forming polymeric absorbent material may be
formed from organic hydrogel-forming polymeric material, which may
include natural material such as agar, pectin, and guar gum;
modified natural materials such as carboxymethyl cellulose,
carboxyethyl cellulose, and hydroxypropyl cellulose; and synthetic
hydrogel-forming polymers. Synthetic hydrogel-forming polymers
include, for example, alkali metal salts of polyacrylic acid,
polyacrylamides, polyvinyl alcohol, ethylene maleic anhydride
copolymers, polyvinyl ethers, polyvinyl morpholinone, polymers and
copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides,
polyvinyl pyridine, and the like. Other suitable hydrogel-forming
polymers include hydrolyzed acrylonitrile grafted starch, acrylic
acid grafted starch, and isobutylene maleic anhydride copolymers
and mixtures thereof. The hydrogel-forming polymers are preferably
lightly crosslinked to render the material substantially water
insoluble. Crosslinking may, for example, be by irradiation or
covalent, ionic, Van der Waals, or hydrogen bonding. Suitable
materials are available from various commercial vendors, such as
the Dow Chemical Company and Stockhausen, Inc. The superabsorbent
material may be included in an appointed storage or retention
portion of the absorbent article, and may optionally be employed in
other components or portions of the absorbent article.
[0044] As shown in FIG. 4, the feminine sanitary napkin 200 can be
considered to have a viewing surface that is the body facing
surface 204. The topsheet 208 and secondary topsheet 41 are visible
(can be visually perceived by the observer) when the body facing
surface 204 is presented towards an observer even though the
topsheet is between the observer and the secondary topsheet 41.
[0045] When the body facing surface 204 of the feminine sanitary
napkin 200 is viewed, the feminine sanitary napkin 200 can have a
background region 214. The background region 214 is a region that
is visually distinguishable from the first colored region 216 and
second colored region 218. The background region 214 can be white
or any other color visually distinguishable from the first colored
region 216 and second colored region 218. Colors are believed to be
visually distinguishable if there is a E between the two colors of
at least about 1.
[0046] The topsheet 208 comprises the first colored region 216. The
first colored region 216 can be the constituent color of the
topsheet 208 with the background region 214 rendered to have a
color that differs from the constituent color of the topsheet 208.
The first colored region 216 can be provided on, for instance, the
body facing side of the topsheet 208 or the garment facing side of
the topsheet 208. Similarly, the secondary topsheet 41 comprises
the second colored region 218. The second colored region 218 can be
the constituent color of the secondary topsheet 41 with the
background region 214 rendered to have a color that differs from
the constituent color of the secondary topsheet 41. The second
colored region 218 can be provided on, for instance, the body
facing side of the secondary topsheet 41 or the garment facing side
of the secondary topsheet 41. The second colored region 218 can be
coincident with the longitudinal centerline L. That is, a portion
of the second colored region 218 can intersect with the
longitudinal centerline L.
[0047] When the body facing surface 204 is viewed, the background
region 214, first colored region 216, and second colored region 218
are viewable by an observer. The first colored region 216 and
second colored region 218 are visibly distinct from the background
region 214 in that first colored region 216 and second colored
region 218 each differ in color as compared to the background
region 214. The first colored region 216 and the background region
214 can differ in color by a .quadrature.E, which is discussed in
more detail below, of at least about 1. The first colored region
216 and the background region 214 can differ in color by a
.quadrature.E, which is discussed in more detail below, of at least
about 3, if more visual distinctiveness is desired.
[0048] Similarly, the second colored region 218 and the background
region 214 can differ in color by a .DELTA.E of at least about 1.
The first colored region 216 and the second colored region 218 can
both differ in color as compared to the background region 214 by a
.DELTA.E of at least about 1. The first colored region 216 and the
second colored region 218 can be more visually distinguishable if
there is a .DELTA.E between the two colors of at least about 3.
[0049] As shown in FIG. 4, in certain embodiments, the first
colored region 216 can be laterally more extensive in a direction
perpendicular to the longitudinal centerline L than the second
colored region 218.
[0050] The first colored region 216 can be designed so as to be
visually complementary to the second colored region 218 and be
presented to the viewer over a wider/more extensive portion of the
body facing surface 204. It is thought that by having the first
colored region 216 on a different layer of material than the second
colored region 218 that a richer visual impression can be created
on the feminine sanitary napkin 200. For instance, since the first
colored region 216 and second colored region 218 are on different
layers of materials, when viewed, at least one of the colored
regions will be viewed through the layer comprising the other
colored region. A colored region viewed through another layer
material can have a significantly different visual impression in
terms of softness/diffuseness of the image, somewhat like the
difference between a matte finished photograph versus a gloss
finished photograph.
[0051] Further, if the second colored region 218 is provided by
inkjet printing, the design of the second colored region 218 can be
easily changed so that feminine sanitary napkins 200 within a
single package or different packages can have different designs for
the second colored region 218. The first colored region 216 might
be provided by a contact printing apparatus that cannot be easily
altered. Thus, the first colored region 216 can be a constant
design recognizable by consumers as being a product from a
particular brand or of a particular quality.
[0052] A first colored region 216 that is laterally more extensive
than the second colored region 218 can also provide the impression
to the wearer that such laterally more extensive portions of the
feminine sanitary napkin 200 are capable of acquiring and retaining
fluid. For instance, if the first colored region extends across a
substantial portion of the feminine sanitary napkin 200 in the
cross-direction CD, viewers of the feminine sanitary napkin 200 may
interpret the first colored region 216 as providing a barrier to
fluid flow beyond the first colored region 216 or a boundary beyond
which the user should not expect fluid to pass as the fluid travels
in the machine-direction MD of the feminine sanitary napkin
200.
[0053] The second colored region 218 can be coincident with the
central region 202. The central region 202, being the in-plane
center of mass of the feminine sanitary napkin 200, might be
associated by the user as being the location of the feminine
sanitary napkin 200 that should be proximal her vaginal opening or
urethra. Designs in which the second colored region 218 is
symmetric about the longitudinal centerline may provide for a more
pleasing impression of the feminine sanitary napkin 200 than
designs in which the second colored region 218 is not symmetric
with respect to the longitudinal centerline L.
[0054] As shown in FIG. 4, the second colored region 218 and first
colored region 216 can be spaced apart from one another along the
longitudinal centerline. By spacing apart the first colored region
216 and second colored region 218, it is believed that improper
phasing of the topsheet 208 and secondary topsheet 41 that might
occur when the two substrates are brought together during
manufacture might not be so apparent to the user because it might
be difficult to perceive relatively small differences from one pad
to another pad of a gap between the first colored region 216 and
second colored region 218. The first colored region 216 and second
colored region 218 can be separated from one another by the
background region 214.
[0055] As shown in FIG. 4, the feminine sanitary napkin 200 has a
periphery 220. The background region 214 can be between the first
colored region 218 and the periphery 220. Such an arrangement is
thought to provide for an improved visual impression in that the
periphery 220 has a clean line that is not interrupted by colored
regions of the feminine sanitary napkin 200. For the same reason,
the first colored region 216 and second colored region 218 can be
substantially surrounded by the background region 214. For
instance, less than 25% of the periphery 220 can be interrupted by
the second colored region 218 or first colored region 216 or the
combination of the first colored region 216 and second colored
region 218. The second colored region 218 can be surrounded by the
background region 214.
[0056] The second colored region 218, as shown in FIG. 4, can be a
substantially elongated shape. Without being bound by theory, it is
believed that substantially elongated shapes that are aligned with
or on the longitudinal centerline L may make the feminine sanitary
napkin 200 look as if the feminine sanitary napkin 200 is slim as
compared to a feminine sanitary napkin devoid of such an elongated
shape. A user might associate such an impression with a belief that
the apparently narrow feminine sanitary napkin 200 will fit
comfortably in the crotch of their panty. The second colored region
218, in certain embodiments can have a width less than about 50% of
the maximum distance between portions of the periphery 220
coincident with the transverse centerline T. Ovals and generally
rectangular shaped shapes are examples of substantially elongated
shapes. To provide for more visually coherent designs, the first
colored region 216 and second colored region 218 can be within a
CIELab color space volume of less than about 200. CIELab color
space volume is discussed in more detail below. With such an
approach, the colors of the first colored region 216 and second
colored region 218 do not differ substantially to the eye of most
viewers and viewers might perceive the colors to be the same or
shades or subtle variations of the same color. Subtle variations in
color are thought to be pleasing to the eye, much like sample paint
chips having slightly varying colors found in home decoration
stores that can be pleasurable and interesting to view. If less
distinctiveness between the first colored region 216 and second
colored region 218 is desired, the first colored region 216 and
second colored region 218 can be within a CIELab color space volume
of less than about 50.
[0057] The first colored region 216 can be substantially arcuate
shaped. Arcuate shaped first colored regions 216 are thought to be
perceived by users as barriers to flow of liquid in the absorbent
article or as providing an indication to a user that they may not
want fluid to pass beyond such a colored region or that once such
fluid flow has occurred they may want to be prepared to wear a
fresh product in the near future.
[0058] Arcuate shapes include, but are not limited to, shapes
generally corresponding to those found on common keyboards
including the greater than symbol, parenthesis, circumflex (also
referred to as the caret symbol), and bracket as well as generally
c-shaped shapes, and slight modifications of any of these
previously mentioned shapes. Arcuate shapes, as defined herein, can
be generally curved like a letter C or can be more angular such as
the symbol <. Thus, arcuate shapes do not necessarily have any
particular curvature.
[0059] A cross section of the feminine sanitary napkin 200
illustrated in FIG. 4 is shown in FIG. 5. Each component of the
feminine sanitary napkin 200 can be considered to have a body
facing side 215 and a garment facing side 217. The body facing side
215 being oriented towards the user's body when the absorbent
article is in-use and the garment facing side 217 opposing the body
facing side 215.
[0060] FIG. 6 is a schematic of a secondary topsheet 41 of a
feminine sanitary napkin having a second colored region 218. FIG. 7
is a schematic of a topsheet 208 of a feminine sanitary napkin
having a first colored region 216. The secondary topsheet 41
illustrated in FIG. 6 can be registered with the topsheet 208
illustrated in FIG. 7 to create a feminine sanitary napkin 200
having a visual impression similar to that illustrated in FIG.
4.
[0061] The color of the first colored region 216 and second colored
region 218 and background region 214 are measured by the
reflectance spectrophotometer according to the colors L*, a*, and
b* values. The L*, a*, and b* values are measured from the body
facing surface 204 of the feminine sanitary napkin 200 inboard of
the periphery 220 of the feminine sanitary napkin 200. The
difference in color is calculated using the L*, a*, and b* values
by the formula
.DELTA.E=[(L*.sub.X.-L*.sub.Y).sup.2+(a*.sub.X.-a*.sub.Y).sup.2+(b*.sub.X-
-b*.sub.Y).sup.2].sup.1/2. Herein, the `X` in the equation may
represent the first colored region 216, the second colored region
218, or the background region 214 and `Y` may represent the color
of another region against which the color of such region is
compared. X and Y should not be the same two points of measurement
at the same time. In other words, for any particular comparison of
the difference in color, the location of X the location of Y.
[0062] Where more than two colors are used, the `X` and `Y` values
alternately include points of measurement in them also. The key to
the .DELTA.E calculation herein is that the `X` and `Y` values
should not stem from the same measured point on the viewing
surface. In those instances where there is effectively no
background region 214 within the confines of the measurement area,
the `X` values should flow from a point different in spatial
relationship to the `Y` values, but within the confines of the
absorbent core periphery.
[0063] Reflectance color is measured using the Hunter Lab LabScan
XE reflectance spectrophotometer obtained from Hunter Associates
Laboratory of Reston, Va. A feminine sanitary napkin 200 is tested
at an ambient temperature between 65.degree. F. and 75.degree. F.
and a relative humidity between 50% and 80%.
[0064] The spectrophotometer is set to the CIELab color scale and
with a D65 illumination. The Observer is set at 100 and the Mode is
set at 45/0.degree.. Area View is set to 0.125'' and Port Size is
set to 0.20'' for films. The spectrophotometer is calibrated prior
to sample analysis utilizing the black glass and white reference
tiles supplied from the vendor with the instrument. Calibration is
done according to the manufacturer's instructions as set forth in
LabScan XE User's Manual, Manual Version 1.1, August 2001,
A60-1010-862. If cleaning is required of the reference tiles or
samples, only tissues that do not contain embossing, lotion, or
brighteners should be used (e.g., PUFFS tissue). Any sample point
on the absorbent article containing the imparted color to be
analyzed can be selected.
[0065] The feminine sanitary napkin 200 is placed over the sample
port of the spectrophotometer with a white clamp disk placed behind
the feminine sanitary napkin 200. The feminine sanitary napkin 200
is to be in a substantially flat condition and free of
wrinkles.
[0066] The feminine sanitary napkin 200 is removed and repositioned
so that a minimum of six readings of color of the body facing
surface 204 are conducted. If possible (e.g., the size of the
imparted color on the element in question does not limit the
ability to have six discretely different, non-overlapping sample
points), each of the readings is to be performed at a substantially
different region on the externally visible surface so that no two
sample points overlap. If the size of the imparted colored region
requires overlapping of sample points, only six samples should be
taken with the sample points selected to minimize overlap between
any two sample points. The readings are averaged to yield the
reported L*, a*, and b* values for a specified color on an
externally visible surface of an element.
[0067] In calculating the CIELab color space volume, V, maximum and
minimum L*, a*, and b* values reported are determined for a
particular set of regions to be measured. The maximum and minimum
L*, a*, and b* values reported are used to calculate the CIELab
color space volume, V, according to the following formula:
V = 4 3 .DELTA. L * 2 .DELTA. a * 2 .DELTA. b * 2 ##EQU00001##
[0068] Within the above formula, .DELTA.L* is the difference in L*
values between the two colored regions being compared and is
calculated by: .DELTA.L*=L*.sub.X-L*.sub.Y. The .DELTA.a* is the
difference in a* values between the two colored regions being
compared and is calculated by: .DELTA.a*=a*.sub.X-a*.sub.Y. The
.DELTA.b* is the difference in b* values between the two colored
regions being compared and is calculated by:
.DELTA.b*=b*.sub.X-b*.sub.Y. The CIELab color space volume can
result in a solid substantially ellipsoidal in shape. If .DELTA.L*,
.DELTA.a*, and .DELTA.b* are equal, the solid will be spherical. As
used herein, a "solid" refers to the mathematical concept of a
three-dimensional figure having length, breadth, and height (or
depth). An ellipsoidal volume is preferred to calculate volume
because an ellipsoid generally requires the dimensional differences
of .DELTA.L*, .DELTA.a*, and .DELTA.b* to be relatively more
uniform than other solids. Furthermore, it is believed that
ellipsoidal volumes are more visually acceptable (less detectable
color mismatch by human perception) than spherical volumes.
[0069] In some embodiments, the imparted colors of at least two
externally visible surfaces of discrete elements will occupy a
CIELab color space volume of less than about 200. The externally
visible surfaces are analyzed according to the Test Method
described below. Upon analysis, the inherent color of an element
comprising an externally visible surface will yield L*, a*, and b*
coordinates. The CIELab color space volume is then calculated using
the formula presented above. The resulting volume can be less than
about 200. The resulting volume can be less than about 50.
[0070] It should be recognized that the imparted colors of more
than two discrete colored regions having a visible surface may
occupy the aforementioned CIELab color space volumes. In
calculating the CIELab color space volume for more than two
elements, the CIELab color space volume is calculated using the
maximum and minimum L*, a*, and b* from a set of elements. The
maximum color values and minimum color values are used to calculate
V according to the formula presented above.
[0071] 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."
[0072] 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 invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0073] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *