阅读说明：本技术 吸收性物品和制造吸收性物品的方法 (Absorbent article and method of manufacturing absorbent article ) 是由 M·斯韦德贝里 A·西尔弗斯特兰德 于 2017-12-22 设计创作，主要内容包括：吸收性物品,其包括分层结构和至少一个细长突片,该分层结构具有夹在诸如例如尿布的所述分层结构的至少两层之间的吸收性材料。每个细长突片包括附接部和紧固部,突片通过该附接部被附接到分层结构的至少一层,紧固部被提供用于可释放地接合吸收性物品上的着陆区。每个突片的至少附接部由借助于能量源可变形的预定材料制成。附接部包括由所述材料一体形成的多个表面突起,所述表面突起中的每个包括基部和基部上方的头部。附接部借助于所述表面突起中的至少一些的变形头部而被附接到所述层。用于制造这种物品的方法,其中附接是通过使表面突起的头部变形。(An absorbent article comprising a layered structure having an absorbent material sandwiched between at least two layers of said layered structure, such as for example a diaper, and at least one elongate tab. Each elongate tab comprises an attachment portion by which the tab is attached to at least one layer of the layered structure, and a fastening portion provided for releasably engaging a landing zone on the absorbent article. At least the attachment portion of each tab is made of a predetermined material that is deformable by means of an energy source. The attachment portion includes a plurality of surface protrusions integrally formed from the material, each of the surface protrusions including a base and a head above the base. The attachment portion is attached to the layer by means of a deformed head of at least some of the surface protrusions. A method for manufacturing such an article, wherein the attachment is by deforming the head of the surface protrusion.)

1. An absorbent article comprising a layered structure having absorbent material sandwiched between at least two layers of the layered structure and at least one elongate tab, each elongate tab comprising an attachment portion by which the tab is attached to at least one layer of the layered structure and a fastening portion provided for releasably engaging a landing zone on the absorbent article, wherein at least the attachment portion of each tab is made of a predetermined material that is deformable by means of an energy source, wherein the attachment portion comprises a plurality of surface protrusions integrally formed from the material, each of the surface protrusions comprising a base and a head above the base, and wherein the attachment portion is attached to the layer by means of a deformed head of at least some of the surface protrusions.

2. The absorbent article of claim 1, wherein the deformed head is wider than the base such that the fibers of the at least one layer are engaged by surface protrusions of the attachment portion.

3. The absorbent article of claim 1 or 2, wherein the deformed head is bonded to or fused with the material of the at least one layer.

4. The absorbent article according to any one of claims 1 to 3, wherein the fastening portion includes hooks integrally formed of the same material as the surface projections of the attachment portion.

5. The absorbent article of any one of claims 1-4, wherein the at least one elongate tab comprises a complete layer of the predetermined material or is made entirely of the material.

6. The absorbent article according to any one of claims 1 to 5, wherein the material is a thermoplastic material deformable by means of an energy source selected from the group consisting of: heat, ultrasonic vibration, microwave, infrared radiation.

7. The absorbent article according to claim 6, wherein said layer is made of a different thermoplastic material having a different melting temperature than said predetermined material, preferably a higher melting temperature than the melting temperature of said predetermined material.

8. The absorbent article according to any one of claims 1 to 7, wherein the predetermined material of the attachment portion and the material of the layer to which the tab is attached are incompatible polymer blends.

9. The absorbent article of any one of claims 1-8, wherein the tab is permanently attached to at least one layer of the layered structure.

10. The absorbent article of any one of claims 1 to 9, wherein the at least one elongate tab is a disposal tab attached to an outer layer of the layered structure and provided for wrapping around the article.

11. The absorbent article of claim 10, wherein the disposal tab is a Z-folded tab, a bottom layer of the Z-folded tab including the attachment portion and a top layer of the Z-folded tab including the fastening portion.

12. The absorbent article of claim 11, wherein the layers of the Z-folded tab are adhered to one another.

13. The absorbent article of any of claims 10-12, wherein the disposal tab is stretchable or elastic to be wrapped around the article.

14. The absorbent article of any one of claims 1-9, wherein the at least one elongate tab is a fastening tab attached to a first side of the layered structure and provided for being fastened to one or more landing zones on a surface of the layered structure.

15. A method of manufacturing an absorbent article having an absorbent material sandwiched between at least two layers of the layered structure and at least one elongate tab, the method comprising the steps of:

a) providing layers of the layered structure and at least one elongate tab, wherein at least a first portion of each tab is made of a predetermined material that is deformable by means of an energy source;

b) forming a surface protrusion on at least the first portion of each tab by deforming the predetermined material by means of the energy source;

c) positioning each of the at least one elongated tab relative to the layer such that the first portion of the tab overlaps the respective layer and the surface protrusions are directed toward the respective layer; and

d) attaching the first portion of each of the at least one elongated tabs to the layer by further deforming heads of at least some of the surface protrusions of the first portion by means of the energy source, thereby creating an attachment, wherein the tabs are attached to the layer by means of the deformed heads.

16. The method of claim 15, wherein the deformed head is wider than the base such that the fibers of the layer are engaged by surface protrusions of the attachment portion.

17. The method of claim 15 or 16, wherein the deformed head is bonded to or fused with the material of the layer.

18. The method according to any one of claims 15 to 17, wherein the second portion of each tab is also made of the predetermined material, and a surface protrusion is also formed on the second portion in step b, thereby creating a fastening portion in the second portion that provides a landing zone for releasably engaging on the absorbent article.

19. The method of any of claims 15-18, wherein the at least one elongate tab comprises a complete layer of the predetermined material or is made entirely of the material.

20. The method of any one of claims 15 to 19, wherein the material is a thermoplastic material and wherein the energy source is selected from the group consisting of: heat, ultrasonic vibration, microwave, infrared radiation.

21. The method according to claim 20, wherein the layer is made of a different thermoplastic material having a different melting temperature than the predetermined material, preferably a higher melting temperature than the predetermined material.

22. The method of any of claims 15-21, wherein the predetermined material of the attachment portion and the material of the layer to which the tab is attached are incompatible polymer blends.

23. The method of claim 22, wherein the thermoplastic material of the layer is also deformed by the energy source.

24. The method of any of claims 15-23, further comprising the step of folding the at least one elongate tab.

Technical Field

The present disclosure relates to an absorbent article and a method of manufacturing the absorbent article.

Background

Known absorbent articles, such as diapers, comprise a layered structure enclosing an absorbent material and at least one elongate tab, such as for example a lateral fastening tab for fastening side panels of the article laterally to each other or a disposal tab wrapped around the article when the article is thrown away. Such tabs are typically attached to the layered structure by means of an adhesive and have a fastening portion with hooks provided for releasably engaging a landing zone (landingzone) on another part of the absorbent article.

From US6746434B2 an absorbent article is known which comprises a garment material, a portion of the surface of which is mechanically modified to integrally form a plurality of surface protrusions from the garment material. The absorbent article further includes a landing zone having a plurality of fibrous loops adapted to engage with the surface protrusions to provide a fastening mechanism. US6746434B2 further describes a method of mechanically forming surface protrusions on a garment material.

A method for forming such surface protrusions on a substrate is further known from WO2010/085492a 1.

Disclosure of Invention

It is a first object of the present disclosure to provide an absorbent article of this type: comprising a layered structure with an absorbent material sandwiched between at least two layers, and at least one elongated tab attached to at least one layer of the layered structure, wherein the tab is attached to the layer more firmly, preferably without the use of an adhesive.

A second object of the present disclosure is to provide a method of manufacturing such an absorbent article, whereby a more robust attachment of the tab to the layer can be achieved, preferably without the use of adhesives.

According to a first aspect, the present disclosure provides an absorbent article comprising a layered structure having an absorbent material sandwiched between at least two layers of the layered structure (such as, for example, a diaper), and at least one elongate tab. Each elongate tab comprises an attachment portion by which the tab is attached to at least one layer of the layered structure, and a fastening portion provided for releasably engaging a landing zone on the absorbent article. At least the attachment portion of each tab is made of a predetermined material that is deformable by means of an energy source. The attachment portion includes a plurality of surface protrusions integrally formed from the material, each of the surface protrusions including a base and a head above the base. The attachment portion is attached to the layer by means of a deformed head of at least some of the surface protrusions.

It has been found that in this way a strong attachment with a mechanical bond, for example a strong releasable attachment, can be achieved which can be stronger than typical hook and loop fasteners, or alternatively a permanent attachment (which cannot be released without damaging the article), and the use of adhesive for attaching the elongate tab to the layer can be avoided. The use of adhesive is undesirable because it can be difficult to control the amount of adhesive exiting the adhesive applicator, and the adhesive can contaminate the production line. The use of adhesives is further undesirable because it may be transferred to the wearer's clothing.

In embodiments according to the present disclosure, the tab may be permanently attached to at least one layer of the layered structure. Permanent attachment means that it cannot be released without damaging the item. Depending on the materials and structure of the at least one layer of the layered structure and the head, some of the head may be thermally bonded to or fused with the layered structure.

The present disclosure is particularly advantageous for attaching disposal tabs to the backsheet of a baby diaper: in this field it is common today to treat the fibres of the backsheet with a substance, for example by adding a low molecular weight wax to soften the material, which may reduce the adhesion of the adhesive typically used for attaching the handling tabs. The present disclosure provides a solution that may no longer require the use of adhesives.

In embodiments according to the present disclosure, the deformed head may take the form of a rivet or be generally wider than the base so that the fibers of the layer may be engaged by the surface protrusions of the attachment portion. Depending on the material and structure, in particular the melting temperature, of at least one layer of the layered structure, some of the heads may be bonded to or fused with the material(s) of the at least one layer. Depending on manufacturing process parameters, such as time and heat exposure, at least some of the base of the surface protrusions of the attachment portion may also be at least partially deformed.

In embodiments according to the present disclosure, the predetermined material of the attachment portion and the thermoplastic material of the layer to which the tab is attached may have different melting temperatures, the predetermined material preferably having a lower melting temperature.

In embodiments according to the present disclosure, the predetermined material of the attachment portion and the material of the layer to which the tab is attached may be incompatible polymer blends, also referred to as immiscible or heterogeneous.

In embodiments according to the present disclosure, the predetermined material of the attachment portion and the material of the layer to which the tab is attached may be compatible polymer blends.

In embodiments according to the present disclosure, the absorbent material sandwiched between at least two layers of the layered structure may be an absorbent core. The layered structure may comprise a liquid permeable topsheet and a liquid impermeable backsheet. The absorbent core may be arranged along a longitudinal axis of the layered structure and a transverse axis extending in a perpendicular direction with respect to the longitudinal axis, and the article may define a front portion, a back portion and a crotch portion.

In an embodiment according to the present disclosure, the fastening part may include a hook integrally formed of the same material as the surface protrusion of the attachment part. These hooks may be attached to a portion of the layered structure, such as a predetermined landing zone, similar to a common hook and loop structure. A construction in the same material has the advantage of allowing an economical manufacturing process in which e.g. hooks and surface protrusions can be formed in the same step. In embodiments, the surface protrusions initially formed for the attachment portions may also take the form of hooks, the heads of which are further deformed for attachment. This has the advantage that the hooks can already engage the layer before the further deformation step and thereby ensure that the position of the tab on the layer is maintained until the further deformation step.

In embodiments according to the present disclosure, the at least one elongate tab may comprise an integral layer of the material or may be made entirely of the material. The material is preferably a thermoplastic material. The at least one elongated tab is preferably a film, a (nonwoven) web, a sheet or a laminate, such as a film and a nonwoven laminated together.

In embodiments according to the present disclosure, the material may be a thermoplastic material deformable by means of an energy source selected from the group consisting of: heat, ultrasonic vibration, microwave, infrared radiation.

In embodiments according to the present disclosure, the at least one elongate tab may comprise a disposal tab attached to an outer layer of the layered structure and provided for being wrapped around the absorbent article. After use, the absorbent article is typically folded or rolled such that the soiled portion is wrapped inside for disposal. In order to prevent the soiled article from unrolling and to keep the soiled portion inside, it is desirable that so-called disposal tabs are arranged to keep the article in a folded or rolled-up state under disposal.

In embodiments according to the present disclosure, the disposal tab may be a Z-folded tab, a bottom layer of the Z-folded tab comprising an attachment portion attached to the outer layer of the layered structure and a top layer of the Z-folded tab comprising a fastening portion, preferably with integrally formed hooks, for releasably engaging a first region on the outer layer of the layered structure when the tab is folded and a second region on the outer layer of the layered structure when the tab is wrapped around the article. The layers of the Z-folded tab may be adhered to each other, for example by means of an adhesive between the bottom layer and the middle layer and between the middle layer and the top layer, or as a result of the self-adhering material of the layers.

In embodiments according to the present disclosure, the at least one elongate tab may be stretchable or elastic. For example, the disposal tab may be stretchable or elastic to the extent that it can be wrapped around the absorbent article.

In embodiments according to the present disclosure, the at least one elongate tab may be a fastening tab attached to a first side of the layered structure and provided for fastening to one or more landing zones on a surface of the layered structure (e.g., on a second side of the layered structure), for example to fasten the absorbent article around the waist of a wearer.

In embodiments according to the present disclosure, the first side portion may be a side panel of the layered structure at the rear body portion of the article. The first side panel may be made of a nonwoven material. The fastening tabs can each be attached to a first surface of a respective side panel and folded such that the fastening portion releasably engages a region on the first surface of the side panel or a region on a second surface of the side panel opposite the first surface.

In embodiments according to the present disclosure, the second side portion may be a side panel of the layered structure at the front body portion of the article. The second side panel may be made of a nonwoven material to provide a landing zone for the fastening portion of the fastening tab.

In a second aspect which may be combined with other aspects and embodiments described herein, the present disclosure provides a method of manufacturing an absorbent article having an absorbent material sandwiched between at least two layers of a layered structure, the method comprising the steps of: (a) providing layers of the layered structure and at least one elongate tab, wherein at least a first portion of each tab is made of a predetermined material that is deformable by means of an energy source; (b) forming a surface protrusion on at least the first portion of each tab by deforming the predetermined material by means of the energy source; (c) positioning each of the at least one elongate tab relative to the layers such that the first portion of the tab overlaps the respective layer; and (d) attaching the first portion of each of the at least one elongate tabs to the layer by further deforming the head portions of at least some of the surface protrusions of the first portion by means of the energy source, thereby creating an attachment, wherein the tabs are attached to the layer by means of the deformed head portions.

It has been found that a strong mechanical bond of the tab to the layer of the layered structure can be obtained by: in a first step (step b) surface protrusions are formed on the first portion of the tab by deformation of the material by means of said energy source and in a second step (step d) the tab is attached to the layer by further deforming the head portions of at least some of the surface protrusions of the first portion by means of said energy source.

In an embodiment according to the present disclosure, the second portion of each tab may also be made of said material and may further be formed with a surface protrusion on said second portion in step b, thereby creating a fastening portion in said second portion providing a landing zone for releasably engaging on an absorbent article. In this way, the fastening portion can be obtained in the same step as the first deformation of the material of the first portion (hereinafter referred to as the attachment portion of the tab). Possibly also further portions of the tab may be made of said material and deformed simultaneously with the first and/or second portion, for example to form further fastening portions on the tab.

In embodiments according to the present disclosure, the at least one elongate tab may comprise an integral layer of the predetermined material or may be made entirely of the material.

In embodiments according to the present disclosure, the material may be a thermoplastic material and the energy source may be selected from: heat, ultrasonic vibration, microwave, infrared radiation.

In an embodiment according to the present disclosure, the method may further comprise the step of folding the at least one elongate tab.

Drawings

The present disclosure will be discussed in more detail below with reference to the accompanying drawings.

Fig. 1-3 schematically illustrate an embodiment of a series of process steps for attaching an elongated tab to a layer according to the present disclosure.

Fig. 4-7 illustrate a first embodiment of an elongated tab and layers of a layered structure and how they are attached to one another according to the present disclosure.

Fig. 8-10 show a second embodiment of an elongated tab and layers of a layered structure and how they are attached to each other according to the present disclosure.

Fig. 11 shows a top view of an absorbent article according to the present disclosure.

Fig. 12 and 13 illustrate an embodiment of a manufacturing step according to the present disclosure.

Fig. 14 shows a top view of a portion of another embodiment of an absorbent article according to the present disclosure.

Detailed Description

The present disclosure will be described with respect to particular embodiments and with reference to certain drawings but the disclosure is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and relative dimensions do not necessarily correspond to actual reductions to practice of the present disclosure.

Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. The terms are interchangeable under appropriate circumstances and the embodiments of the disclosure can operate in other sequences than described or illustrated herein.

Furthermore, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. The terms so used are interchangeable under appropriate circumstances and the embodiments of the disclosure described herein can be operated in other orientations than described or illustrated herein.

Furthermore, although referred to as "preferred," the various embodiments are to be construed as exemplary ways in which the disclosure may be practiced and not as limiting the scope of the disclosure.

The term "comprising" as used in the claims should not be interpreted as being limited to the elements or steps listed thereafter; it does not exclude other elements or steps. It should be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression "a device comprising a and B" should not be limited to devices consisting of only components a and B, but rather with respect to the present disclosure, only the enumerated components of the device are a and B, and further, the claims should be interpreted to include equivalents of those components.

As used herein, by "hook" is intended to mean the hook portion or surface projection of a hook and loop type fastener that is adapted to be fastened to a zone comprising fibrous loops, known as a landing zone. The hook may have any shape. Preferred examples of hooks include pins (e.g., straight pins, angled pins, curved pins, tapered pins, branched or multi-branched pins), hooks, branched or multi-branched hooks, mushroom-shaped protrusions, palm tree-shaped protrusions. The hooks may have any type of cross-section, e.g. rounded, oval, square, rectangular, polygonal. The hook preferably has a solid core. In one fastening portion, all the hooks may have the same shape. Alternatively, one fastening portion may comprise several different shapes of hooks.

Any type of land area that is engageable, and preferably releasably engageable, with the surface protrusions may be considered for the landing area. The landing zone may be a zone attached to the absorbent article, for example one or more landing zones attached to one or more side panels of the absorbent article, or a larger patch (patch) in the front of the absorbent article. Examples include patches of loops or nonwoven, woven or knitted patches attached to the absorbent article, for example by gluing, melting or stitching. Alternatively, the material of the portion of the absorbent article may serve as a landing zone, e.g. the material of a portion or the entire outer cover or one or more side panels of the absorbent article. For example, if the outer covering or portions thereof or the side panels comprise a nonwoven.

The fastening portions described herein may include any number of hooks, possibly arranged in an array or zone within the fastening portion. Further, the fastening portion may have various densities. By "density" is meant herein the number of hooks per unit area (square inch or square millimeter). The density of the fastening portion may affect the flexibility and softness of the hook-and-loop type fastener. For example, the lower density regions generally provide higher material flexibility and softness. However, in order to provide a certain retention force between the engaged hooks and loops, a certain number of hooks must be available for engagement.

An "absorbent article" according to the present disclosure may refer to consumer products of the type that absorb and contain body exudates, and more particularly, to products that are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. Absorbent articles include, for example, diapers and incontinence devices. Diapers include, for example, all-in-one diapers, pant diapers, and belt diapers. The diaper may be a diaper for infants, toddlers, or adults. An absorbent article includes a layered structure having an absorbent material sandwiched between at least two layers of the layered structure. For example, the absorbent material may be part of an absorbent core sandwiched between layered structures, which may be, for example, a liquid permeable topsheet and a liquid impermeable backsheet. The absorbent article may comprise a front portion, a back portion and a crotch portion extending between the front portion and the back portion. Preferably, the front and/or back comprise a waist. The waist is preferably stretchable or elastic.

So-called all-in-one diapers are characterized in that they comprise fastening tabs with which the front and back parts of the diaper are joined when the diaper is applied around the waist of the user. The fastening tab may be attached to a layered structure having an absorbent material sandwiched between at least two layers of the layered structure.

So-called pant diapers are characterized in that the front and back portions of the diaper are joined at the waist. This type of diaper is intended to be worn as accurately as a pair of underpants on a user, i.e., pulled over the legs and hips of the user. The joint at the waist of the pant diaper may typically be broken open to remove the pant diaper from the user, so that the pant need not be pulled down over the legs and feet of the user to remove the pant diaper. Pant diapers typically comprise elastic regions both in the waist section and around the leg openings. There are also pant diapers which can be opened and reclosed by means of a refastening device. Such pant diapers may be opened, for example, to inspect the contents of the article or to adjust the width of the article and then later reclosed.

So-called belt diapers are characterized in that they comprise a belt which is oriented transversely with respect to the absorbent part of the diaper and which is attached integrally with the chassis, i.e. to a layered structure with absorbent material or absorbent part sandwiched between at least two layers of said layered structure. The belt may have two belt portions extending on either side of the rear or front end of the chassis or absorbent portion. When the belt diaper is worn, the two belt portions are intended to be fastened around the waist of the wearer in a first stage. The front or rear end of the absorbent part of the belt diaper hangs loosely from the belt between the legs of the wearer. Once the belt portions have been joined together, the absorbent part is guided between the legs of the user and fastened to the belt, wherein the belt comprises a fixing surface intended to be affixed by its free transverse edge to a fixing element arranged on the absorbent part of the diaper. Another type of belt diaper is in two pieces and comprises a separate belt and a separate absorbent structure. When in use, the belt is fastened around the waist of the user, after which the absorbent structure is joined to the outside of the belt by means of hook and loop elements or adhesive tape elements in the corners of the absorbent structure.

Absorbent articles according to the present disclosure may be disposable articles or non-disposable articles. The term "disposable" is used to describe absorbent articles that are generally not intended to be laundered or otherwise restored or reused as an absorbent article, e.g., they are intended to be discarded after a single use and may also be configured to be recycled, composted or otherwise disposed of in an environmentally compatible manner.

The disposal tab may be provided on the outside of the disposable article and is intended to be wrapped around the article to enable the article to be disposed of in a compact form with the absorbed fluid safely contained. The disposal tab generally has a portion attached to the article and a portion that is releasable and possibly stretchable or elastic for being wrapped around the article.

In embodiments according to the present disclosure, the absorbent portion of the absorbent article is generally formed by a layered structure comprising a core of absorbent material. The core may be sandwiched by the top sheet and the back sheet. The topsheet is permeable to the fluid to be absorbed(s); the backsheet is impermeable to these fluids. Additional layers may be provided between the topsheet or backsheet and the core to improve fluid absorption and/or retention. A core wrap, such as a nonwoven, may surround the core.

Examples of thermoplastic materials include polyamides, polyolefins such as polypropylene and polyethylene, polystyrene such as styrene-isoprene-styrene (SIS), styrene-butadiene-styrene (SBS), styrene-ethylene-butylene-styrene (SEBS), acrylonitrile-butadiene-styrene (ABS), polystyrene, polyesters, polycarbonates, polyvinyl chloride (PVC), polyether esters, polyetheramines, P L a, polylactic acid (polyester), thermoplastic starch, cellulose esters, similar poly 3-hydroxybutyrate (PHB), Polyhydroxyvalerate (PHV), Polyhydroxyhexanoate (PHH) and blends thereof, which may be modified with, for example, fillers, flame retardants, or the like.

In this context, embodiments of absorbent articles are described that comprise portions made of predetermined materials that are deformable by means of an energy source, the energy source being used to at least partially deform these portions to form a weld for attachment of the layers and to form hooks of a hook-and-loop type fastener, preferred materials are thermoplastic materials that are deformable by means of energy sources such as, for example, heat, ultrasonic vibration, microwaves, infrared radiation or other energy sources.

An embodiment of a series of process steps for attaching an elongated tab to a layer according to the present disclosure is described with reference to fig. 1-3.

Fig. 1 schematically shows a detail of a portion of layer 101 of elongated tab 100. The portion of the layer 101 is made of a predetermined material and has surface protrusions 150 formed thereon. Surface projection 150 includes a base 151 and a head 152. In the embodiment shown, the surface protrusions have a cylindrical shape, but a variety of other shapes are also possible, such as for example rectangular parallelepipeds, strips, etc. The surface protrusions 150 may also have an engagement shape resembling the "hooks" of a hook-and-loop type fastener.

Fig. 2 schematically shows that the layer 101 is brought into contact with the fibres 161 of the layers of the layered structure. The layers are preferably pushed onto each other so that the surface protrusions 150 of the tab layer 101 enter the spaces between the fibers 161. In case the surface protrusions 150 are hooks, they may already (preliminarily) engage the fibres 161 of the layered structure.

Fig. 3 schematically shows the head 152 widened in this way after the deformation step: such that the surface protrusions 150 engage the fibers 161 and form (at least) a mechanical bond. The deformed head 152 may take the form of a rivet or be generally wider than the base 151 so that the fibers 161 of the layer are engaged by the surface protrusions 150 of the attachment portion. Depending on the material and structure, particularly the melting temperature, of at least one layer of the layered structure of which the fibers 161 form a part, some of the heads 152 may be thermally bonded to or fused with the fibers and create a permanent bond. Depending on manufacturing process parameters, such as time and heat exposure, at least some of the bases 151 of the surface protrusions 150 of the attachment portion may also be at least partially deformed.

The predetermined material of the attachment portion 101 having the surface protrusions 150 and the material of the layer comprising the fibers 161 may both be thermoplastic materials. In embodiments where the materials may be different thermoplastic materials having different melting temperatures, the predetermined material of the surface protrusions 150 preferably has a lower melting temperature.

The predetermined material of the attachment portion 101 having the surface protrusions 150 and the material of the layer comprising the fibers 161 may be incompatible polymer blends, also referred to as immiscible or heterogeneous.

The predetermined material of the attachment portion 101 having the surface protrusions 150 and the material of the layer comprising the fibers 161 may be compatible polymer blends.

A first embodiment of the present disclosure is described with reference to fig. 4-7.

The elongated tab 200 may for example be a disposal tab, here a stretchable or elastic tab, which is attached to the outer layer 210 of the layered structure and provided for being wrapped around the absorbent article. The disposal tab is typically attached to the backsheet of the diaper, for example in the middle of the rear body portion and oriented in the longitudinal direction of the diaper, but it will be apparent that the disposal tab may be attached elsewhere on the article.

Fig. 4 shows the elongate tab 200 in an initial step of the manufacturing process. The tabs may be formed from a single layer 204 of nonwoven. Three zones are defined on the tab: the tab 200 is stretchable or elastic by a first zone or portion 201 at one end for first forming a surface protrusion and then further deforming the surface protrusion to attach to the layer 210, a second zone or portion 202 for forming the hooks of the fastening portion 206, and a third zone 203 therebetween forming a stretch zone in the final product. If more material is needed to create the surface protrusions, the single layer 204 may be folded in the regions 201, 202 to create a multi-layer material.

Fig. 5 shows the elongate tab 200 after surface protrusions are formed in regions 201 and 202 by deforming the material of layer 204 using an energy source (e.g., ultrasonic vibration). In the embodiment shown, the same kind of surface protrusions, in particular hooks 205 and 206, are formed in both zones 201, 202, now called "hooks", although this is not essential. The formation of the hooks 205 in the region 201 has the advantage that a preliminary attachment has been obtained in a subsequent step, but non-engaging surface protrusions are also possible as described elsewhere herein. Hook 201 is shown as being larger than hook 202, but this is not required. The advantage of a larger hook 201 is a larger area for attachment of the tab 200 to the layer 210, while the hook 202 is used for releasable attachment, i.e. a releasable fastening portion of a hook-and-loop type fastener. The hooks 205 and 206 may be economically formed simultaneously in the same process step, as will be explained further below.

Fig. 6 shows an elongated tab 200 positioned on top of a layer 210 of the layered structure, such as the back sheet of a diaper. Both hooks 201, 202 engage the annulus fibrosus of layer 210.

Fig. 7 shows the elongate tab 200 attached to the layer 210 by further deformation of at least some of the hooks 205 in the first region 201 indicated by deformation 207. This further deformation may be performed using the same energy source as used for forming the hooks 205, 206, however another energy source may also be used, preferably selected from: heat, ultrasonic vibration, microwave, infrared radiation. In an embodiment, the energy source or parameters thereof may be adapted to also deform portions of the material of the layer 210 in order to obtain a bonding or fusion of the materials.

The steps described with reference to fig. 4-7 may be performed on layer 210 before, during, or after assembly of the layered structure. Layer 210 may be a layer of the layered structure or in turn be attached to a layer of the layered structure. Layer 210 may be, for example, a back sheet of the layered structure, a side panel attached to the layered structure, or a tape attached to the layered structure.

A second embodiment of the present disclosure is described with reference to fig. 8-10, in which the elongate tab 300 is a Z-folded disposal tab attached to an outer layer 310 of the layered structure and provided for being wrapped around an absorbent article. The disposal tab is typically between 60 and 72mm long in the Z-folded configuration. When deployed, the total length of the treatment tab may be about 100 to 200 mm. The width of the disposal tape is typically between 10 and 20 mm. The disposal tab is typically attached to the backsheet of the diaper, for example in the middle of the rear body portion and oriented in the longitudinal direction of the diaper, but it is obvious that the disposal tab may be attached elsewhere on the article.

Fig. 8 shows the tab 300 in an initial state. The tabs may be formed from a single layer 304 of nonwoven. Three zones are defined on the tab: a first zone or first portion 301 at one end for first forming the surface protrusions 305 and then further deforming the surface protrusions to attach to the layer 310, a second zone or second portion 302 for forming the hooks of the fastening portion 306 and a third zone 303 on the opposite side of the tab for forming further hooks 307.

Fig. 9 shows elongated tab 300 after surface protrusions are formed in regions 301, 302, and 302 by deforming the material of layer 304 using an energy source (e.g., ultrasonic vibration). In the embodiment shown, the same kind of surface protrusions, in particular hooks 305, 306 and 207 (now called "hooks"), are formed in all zones 301, 302, 303, however this is not essential. The formation of the hooks 305 in the region 301 has the advantage that a preliminary attachment has been obtained in a subsequent step, but non-engaging surface protrusions are possible as described elsewhere herein. The hook 301 is shown as being larger than the hooks 302, 303, but this is not essential. The advantage of a larger hook 301 is a larger area for attachment of tab 300 to layer 310, whereas hooks 302, 303 are used for releasable attachment. As will be explained further below, the hooks 305, 306, 307 can be economically formed simultaneously in the same process step.

Fig. 10 shows the tab 300 after attachment to the layer 310 and after being Z-folded. The bottom layer 311 of the Z-folded tab 300 includes an attachment portion that is attached to the outer layer 310 by means of a further deformed surface protrusion indicated by deformation 308. The middle layer 312 is located on top of the chassis layer and includes hooks 307, the hooks 307 extending beyond the chassis layer and being releasably secured to the outer layer 310 of the absorbent article. The top layer 313 is located on top of the middle layer and comprises hooks 306, which hooks 306 extend beyond the bottom layer and the middle layer and are releasably fastened to the outer layer 310 of the absorbent article.

In use, when the user wants to handle the article, the user pulls the tab 300 at the end with the hook portion 306 to release the hook of the hook portion 306 from the outer layer 310 and unrolls the tab, thereby also releasing the hook 307 from the outer layer 310. The unfolded tab may then be wrapped around the article and the hook 306 as a fastening portion for subsequent fastening to a different area or landing zone on the article.

In alternative embodiments, the layers of the Z-folded disposal tab may be adhered to each other, for example by means of an adhesive between the bottom layer and the middle layer and between the middle layer and the top layer, or as a result of the self-adhering material of the layers.

The steps described with reference to fig. 8-10 may be performed on layer 310 before, during, or after assembly of the layered structure. Layer 310 may be one layer of the layered structure or in turn be attached to a layer of the layered structure. Layer 310 may be, for example, a back sheet of the layered structure, a side panel attached to the layered structure, or a tape attached to the layered structure.

Fig. 11 schematically illustrates a top view of an embodiment of an absorbent article, such as a diaper, according to the present disclosure. The diaper 140 is unfolded and in a flat state. The diaper comprises a layered structure 130, which layered structure 130 is constituted by a central portion having a (permeable) topsheet 120 and a (impermeable) backsheet 122 on opposite sides of a core 118 of absorbent material. In other words, the diaper 140 includes an absorbent core 118 sandwiched between a liquid pervious topsheet 120 and a liquid impervious backsheet 122. The diaper 140 may comprise one or more elongate tabs attached to the layered structure 130, such as, for example, a fastening tab 100 for fastening the diaper around the waist of a wearer and/or a disposal tab 200 to be used in disposing of an article. Both of these types of tabs 100, 200 are shown in fig. 11, but the present disclosure also extends to absorbent articles that include only one such type of tab or another type of elongated tab attached to its layered structure.

The diaper is arranged along a longitudinal axis "L A" and a transverse axis "TA" extending in a perpendicular direction relative to the longitudinal axis, the article comprising a front portion "FP", a back portion or portion "RP", and a crotch portion "CP" extending between the front and back portions.

Preferably, the absorbent core 118 is disposed at least in the crotch portion "CP". The absorbent core may extend in the front portion "EP" as well as in the rear portion "RP". The topsheet 120 is arranged at the surface of the diaper, i.e. at the wearer-facing side, while the backsheet 122 is arranged at the bottom side of the article. The absorbent structure (i.e., core 118) serves to absorb body exudates from the wearer and provide a dry and comfortable fit to the wearer.

Various types of materials may be used for the absorbent article. The topsheet is arranged to face a wearer of the absorbent article when worn. The topsheet may be formed from a fluid-permeable nonwoven fabric or a film made from thermoplastic synthetic fibers. The topsheet may be sufficiently liquid permeable to allow discharged body fluids to penetrate through the thickness of the topsheet. Also, the topsheet may suitably be manufactured from a material that is compliant and soft feeling against the wearer's skin. The topsheet may consist of a single layer or have a laminate structure comprising a plurality of layers (e.g., two or more layers). The layers may be made of the same material, or some or all of the layers may be made of different materials.

The layers of the topsheet 120, or one, some or all of the layers of the topsheet in the case of a laminate structure, may be made of a single material or have portions made of different materials (e.g., in different portions of the wearer-facing surface of the topsheet).

The layers of the topsheet or, in case of a laminate structure, one, some or all of the layers of the topsheet may be nonwoven, perforated plastic film, plastic or textile grid or a liquid permeable foam layer.

One, some or all of the layers of the topsheet or, in the case of a laminate structure, the layers of the topsheet may be, for example, webs of hydrophilic, non-perforated nonwoven fibers, such as natural fibers (e.g., cotton or pulp fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or combinations of these fibers.

The topsheet may have a thickness in the range of 8-40g/m²Basis weight in the range of (a). However, the present disclosure is not limited to topsheets having only this basis weight.

The backsheet 122 may be composed of a liquid impermeable and breathable layer, such as a polymeric film, for example, a film of polyethylene or polypropylene. According to various embodiments, materials that may be used for the backsheet include thin and flexible fluid impermeable plastic films or fluid impermeable nonwovens, fluid impermeable foams, and fluid impermeable laminates.

The backsheet may be formed from a single layer, but may alternatively be formed from a multi-layer structure (i.e., a laminate) in which at least one layer is fluid impermeable. Further, the back sheet 122 may be elastic in any direction.

Furthermore, the backsheet may have a laminate structure comprising a liquid barrier sheet and a nonwoven layer (not shown in detail in the figures) arranged on top of each other, wherein the nonwoven layer is arranged at the outer side, which is remote from the wearer of the absorbent article when worn.

The nonwoven layer may be made of fibers or filaments of a thermoplastic polymer material. The nonwoven layer may be formed by a number of different processes such as spunbond, airlaid, meltblown, or bonded carded web forming processes. The nonwoven layer may be made of SMS (spunbond/meltblown/spunbond) or SS (spunbond/spunbond) nonwoven material of polypropylene or bicomponent fibers of polypropylene and polyethylene or a combination of such materials.

The liquid barrier sheet may be made of a plastic material (e.g. a thermoplastic film material) and/or a nonwoven material. For example, the liquid barrier sheet may be formed as a plastic layer (e.g., a thermoplastic layer) or a plastic film (e.g., a thermoplastic film). Forming the liquid barrier sheet of a plastic material, such as a thermoplastic film material, allows particularly good printability of the liquid barrier sheet. The liquid barrier sheet may further comprise paper fibers.

The liquid barrier sheet may be a liquid impermeable, gas permeable or gas impermeable layer. The liquid barrier sheet may be composed of a single layer or have a laminated structure with a plurality of layers (for example, two or more layers, three or more layers, or four or more layers). The layers of the liquid barrier sheet may be laminated, bonded or attached to each other, for example by thermal and/or mechanical bonding (such as heat sealing), ultrasonic bonding (such as ultrasonic welding), adhesive or adhesives, stitching or the like.

The liquid barrier sheet may be a breathable microporous film. The microporous membrane may be made from a material that includes at least two essential components, namely a thermoplastic elastomeric polyolefin polymer and a filler. These components, and in certain embodiments additional other components, may be mixed together, heated and then extruded into monolayer or multilayer films using any of a variety of film production processes, such as cast embossing (cast embossed), cold flat casting (chill and flat cast), and blown film processes.

In addition, an absorbent core 118 is provided between the topsheet and the backsheet to absorb liquids, such as urine or other body fluids, that have passed through the topsheet. The absorbent core may be made of only one layer, of any suitable absorbent or liquid-absorbent material, such as one or more layers of cellulosic fluff pulp, foam, wadding or the like.

The absorbent core may include a suitable amount of superabsorbent particles. Such superabsorbent materials are well known in the art of absorbent articles and are comprised of water-swellable and water-insoluble materials capable of absorbing large amounts of fluid when forming hydrogels. The absorbent core may comprise superabsorbent material in the form of fibres or particles of absorbent polymer material. For example, the superabsorbent material can be a surface crosslinked, partially neutralized polyacrylate. Further, the core covering may surround the core and may be made of a material having a weight of 5-20g/m²Of the basis weight of (a).

The superabsorbent material (e.g., superabsorbent fibers or particles) can be mixed with other absorbent or liquid-absorbing materials or materials (such as cellulosic fluff pulp) and/or disposed in pockets or layers in the absorbent core.

The absorbent core may further comprise means for improving the properties of the absorbent core. For example, the absorbent core may include a binder or binders, such as binder fibers.

Furthermore, as known by the person skilled in the art, the various layers of the absorbent article may be attached by means of adhesive materials.

One or more additional layers may be provided in the absorbent article. For example, the acquisition layer may be arranged between the absorbent core and the topsheet. Such additional layers may be, for example, in the form of airlaid layers, hydroentangled layers, high loft, foam, or any other type of material layer that may be used in an absorbent article to act as a liquid acquisition and absorbent layer. The acquisition layer is adapted to quickly receive and temporarily store discharged liquid before it is absorbed by the absorbent core. Such acquisition layers may be comprised of, for example, airlaid nonwovens, spunlace nonwovens, high loft nonwovens, or foam materials. Airlaid nonwovens can be produced from fluff, wood pulp, and here the fluff fibers are dispersed into a rapidly moving air stream and consolidated onto a moving screen (screen) with the aid of pressure and vacuum.

In the embodiment of fig. 11, the first and second side panels 110, 112 are attached to the longitudinal edges of the central portion by means of welds 114 and in this way form part of the layered structure 130. The first side panel 110 is positioned at the rear body portion RP of the diaper and is provided with a fastening tab 100, which fastening tab 100 may be attached to the back side of the panel 110 (i.e. the outside of the diaper 140), but the fastening tab 100 may also be attached to the front side or a different layer. The second side panel 112 is positioned at the front body portion FP of the diaper. The back side of the second side panel 112 (i.e., the outside facing away from the user during use) provides a landing zone 116 for the fastening portion 106 of the fastening tab 100. In fig. 11, the tab 100 is shown in a released position, i.e. released and deployed by the user prior to use. In the packaged condition, i.e., when the article is sold, the tab 100 is typically in a folded position. Instead of separate side panels, both the topsheet and the backsheet may extend laterally along the periphery of the absorbent article outside the absorbent core and form the side panels.

The fastening tabs 100 typically have a length L of between 40 and 75mm and a width W of between 20 and 50mm each tab 100 comprises a layer of a predetermined material described herein that is deformable by means of an energy source, in particular ultrasonic vibrations, a first portion 107 is used for attachment to a layer of the layered structure 130, in particular the side panel 110, and is a portion having surface protrusions that deform as described elsewhere herein, a second portion 106 comprises hooks and together with the landing zone 116 can be used as a fastening portion 106 of a hook and loop type fastener.

The disposal tab 200 shown in fig. 11 is a disposal tab according to fig. 4-7, which is attached to the backsheet 122 of the diaper 140. Alternatively, the diaper may also have a disposal tab 300 according to fig. 8-10 or another type of disposal according to the present disclosure.

In an alternative embodiment, the elongate tab may be a tape attached to the absorbent article, for example to the backsheet, and the tape is provided for holding the article around the waist of the wearer, i.e. the article is then for example a belt diaper. A belt diaper with belts may have two belt portions, i.e. two belts extending on either side of the rear or front end of the chassis or absorbent part. When putting on the belt diaper, the two belt portions (i.e. the two belts) are intended to be fastened around the waist of the wearer in a first stage. The front or rear end of the absorbent part of the belt diaper hangs loosely from the belt between the legs of the wearer. Once the belt portions have been joined together, the absorbent part is guided between the legs of the user and fastened to the belt, wherein the belt comprises a fixing surface intended to be glued by its free transverse edge to a fixing element arranged on the absorbent part of the diaper. For such an absorbent article comprising two belt portions, only one of the belt portions may comprise a fastening portion to fasten the belts together when the belts overlap during use. Alternatively, each strap has fastening portions in opposite directions, such that when two straps overlap each other during use the fastening portion on the first strap attaches the second strap and the fastening portion of the second strap attaches the first strap.

In embodiments according to the present disclosure, the at least one elongate tab (e.g., the securing tab 100 or the disposal tabs 200, 300 described above) may be stretchable or elastic. For example, the disposal tab 200 may be elastic or stretchable to the extent that it can be wrapped around the absorbent article, e.g., stretchable from 50% to 300%.

Fig. 12 and 13 show an embodiment of successive steps of a method of manufacturing an absorbent article described herein, in particular the steps of forming surface protrusions in the first and second portions 201, 202 of the elongated tab 200 and subsequently positioning the elongated tab 200 on the layer 210 of the layered structure and attaching the elongated tab 200 to the layer 210 of the layered structure by deforming the surface protrusions of the first portion 201 of the elongated tab. These steps may be performed by deforming the predetermined material by means of the same energy source. In fig. 12 and 13, the tab according to fig. 4-7 is shown, but these steps can also be applied to other elongated tabs described herein.

In the embodiment of fig. 12 and 13, ultrasonic vibration is used as the energy source. Processes for forming surface protrusions using ultrasonic energy are known from WO2010/085492a1 and US6746434B 2. Here, the process is used to form surface protrusions in both regions 201, 202 at the same time. To this end, the tab 200 is located between an anvil (anvil)500 and an ultrasonic horn (ultrasonic horn) 400. Anvil 500 (at)

Shown in cross-section in fig. 12) may be a rotary anvil having annular projections 510, 520.

In the step of fig. 12, the annular projections 510, 520 have recesses in their top sides, which are shaped for forming the hooks 205, 206. Tab layer 204 is positioned between annular protrusion 510 of the anvil and ultrasonic horn 400 such that first portion 201 and second portion 202 are deformed by ultrasonic energy into a hook portion with hooks 205, 206. If more material is needed to create the surface protrusions, a single layer 204 may be folded in regions 201, 202 to create a multi-layer material.

In the step of fig. 13, the tab 200 is positioned on the layer 210. The correct position can be verified, for example, by means of a vision system. The tabs 200 and 210, and in particular the zone 201 with the surface protrusions 205, are brought between the second anvil 600 and the ultrasonic horn 450. The second anvil 600 may have an annular protrusion 610 and the horn 450 may be sized to apply energy only above this protrusion 610. By ultrasonic vibration, at least some of the surface protrusions 205, particularly the heads thereof (see fig. 1-3), are further deformed, possibly together with the material of the layer 210, to mechanically bond the tab 200 to the layer 210, as indicated by the deformed zone 207.

As an alternative to fig. 12, the ultrasonic horn 400 may have a recess, for example to form a hook in the other direction (i.e., on the top side of the tab in the orientation shown in fig. 12) or in two different directions (i.e., on each side of the tab).

Fig. 14 shows a top view of a portion of another embodiment of an absorbent article according to the present disclosure. The figure shows a portion of the back sheet 122 of the layered structure article and an elongated tab 700 attached to the portion. The elongated tab (e.g., treatment tab) includes at least portions 701, 702 of a predetermined material that is deformable by an energy source as described herein. The tab may further have any other feature as described herein. The back sheet 122 is, for example, a nonwoven. The first part 701 comprises a surface protrusion 705 integrally formed from the material. The surface protrusions 705 may have any form as described elsewhere herein. In a number of sub-areas of the first portion 701, at least the head of the surface protrusion 705 has been further deformed, for example to form an ultrasonic weld 707 by which ultrasonic weld 707 the first portion 701 of the tab is attached to the back sheet 702. The second portion 702 includes a hook 706 and is a fastening portion that is releasably fastened to the back sheet 122 and may be pulled loose by a user, for example, to wrap a tab around an article and fasten the portion 702 to a different portion of the back sheet to dispose of the article. In the embodiment of fig. 14, the materials of the tab (portion) and backsheet may be incompatible polymers.