阅读说明：本技术 用于在基底中形成性能区的方法和工具 (Method and kit for for forming properties area in the substrate ) 是由 U.施耐德 J.M.特林豪斯 H.A.杰克尔斯 G.艾尔德姆 于 2018-02-12 设计创作，主要内容包括：本发明提供了用于在基底中形成性能区的方法和工具。用于在基底中形成性能区的方法和工具可用于吸收制品生产线上。(The present invention provides the Method and kit fors for forming properties area in the substrate.Method and kit for for forming properties area in the substrate can be used for absorbent article production line.)

1. a kind of method for forming substrate on absorbent article production line, which comprises

Precursor substrate is transmitted in a machine direction on the absorbent article production line；

The first roller for having first rotation is provided；

Second roller with the second rotation axis is provided, wherein the first rotation and second rotation axis are big each other Cause positions in parallel, to form roll gap between first roller and second roller；

The precursor substrate is transported through into the roll gap to form two different performance areas, each in the machine direction Performance area has at least the two in following:

A. three-D elements, wherein before the precursor substrate is transmitted through the roll gap, at least most of three-dimensional element The thickness of part at least twice bigger than the thickness of the precursor substrate, and wherein the three-D elements have at least 2mm²X-Y The area of plane；

B. there is at least 0.5mm²To about 20mm²Average cell size hole；And

C. constricted zone；

The substrate is cut into the required spacing of absorbent article；And

The substrate cut is applied to the absorbent article；

Wherein each performance area has at least 1000mm²X-Y plane area.

2. according to the method described in claim 1, wherein first roller includes:

First radially-outer surface；

Multiple first protrusions, the multiple first protrusion extend outwardly from first radially-outer surface；And

Multiple first recessed portions, the multiple first recessed portion are limited in first radially-outer surface；And

Wherein second roller includes:

Second radially-outer surface；

Multiple second protrusions, the multiple second protrusion extend outwardly from second radially-outer surface；And

Multiple second recessed portions, the multiple second recessed portion are limited in second radially-outer surface.

3. according to the method described in claim 2, the described method includes:

The part of the multiple first protrusion is engaged with intermeshing with the part of the multiple second recessed portion；And

The part of the multiple second protrusion is engaged with intermeshing with the part of the multiple first recessed portion.

4. according to the method described in claim 3, wherein at least some of the multiple first protrusion includes forming elongated open First distal part of pore structure, wherein the first distal end of first distal part forms tip, wherein the multiple First protrusion has the first central longitudinal axis, wherein the elongate aperture structure includes side wall, and the wherein side wall Part has the first angle relative to the central longitudinal axis within the scope of about 5 degree to about 40 degree.

5. according to the method described in claim 4, wherein at least some of the multiple second protrusion includes the second distal portion Point, wherein at least some of the multiple second protrusion includes shoulder, wherein the multiple second protrusion includes the second center Longitudinal axis, and wherein the shoulder have in the range of about 3 degree to about 25 degree relative to second center longitudinal direction The second angle of axis.

6. described second is remote according to the method described in claim 5, wherein second distal part includes the second distal end Side end includes flat or substantially flat surface.

7. method according to claim 5 or 6, wherein at least some of the multiple first protrusion respectively includes having Along the first base portion of the first width of the direction interception perpendicular to the machine direction, wherein in the multiple second protrusion extremely Some less respectively includes the second base portion with the second width along the direction interception perpendicular to the machine direction, wherein described in Second width is greater than first width, wherein at least some of the multiple first recessed portion has along perpendicular to the machine The third width of the direction interception in device direction, wherein at least some of the multiple second recessed portion has along perpendicular to described 4th width of the direction interception of machine direction, and wherein the third width is greater than the 4th width.

8. method according to any of the preceding claims, wherein each performance area includes whole three in a, b and c Person.

9. method according to any of the preceding claims, the method includes on the part of the three-D elements or The constricted zone is formed on the part on the periphery in the hole.

10. method according to any of the preceding claims, wherein at least one of described performance area is about described The central longitudinal axis or central transverse of substrate are symmetrical.

11. method according to any of the preceding claims, wherein first performance area and the second performance area be not be overlapped.

12. method according to any of the preceding claims, wherein first performance area is only heavy with the second performance area part It is folded.

13. according to the method described in claim 5, wherein the precursor substrate includes first layer and the second layer, wherein described One layer has the first width along the direction interception perpendicular to the machine direction, wherein the second layer has along perpendicular to institute The second width of the direction interception of machine direction is stated, and wherein first width is greater than second width, the method Including making the part of the precursor substrate and the multiple first protrusion, the part, the multiple of the multiple first recessed portion The part of second protrusion and the part of the multiple second protrusion are Chong Die with the first layer substantially only in the second layer Place contact.

14. method according to any of the preceding claims, the method includes logical by transmission in the precursor substrate The precursor substrate is heated before crossing the roll gap and/or including heating first roller and/or second roller.

15. method according to any of the preceding claims, the method includes will be described in the machine direction Precursor substrate transports through the roll gap to form the different performance area of third, wherein the different performance area of the third have with At least the two in lower:

A. three-D elements, wherein before the precursor substrate is transmitted through the roll gap, at least most of three-dimensional element The thickness of part at least twice bigger than the thickness of the precursor substrate, and wherein the three-D elements have at least 2mm²X-Y The area of plane；

B. there is at least 0.5mm²To about 20mm²Average cell size hole；And

C. constricted zone.

16. method according to any of the preceding claims, the method includes being formed during the transfer step Three dimensional indicia, wherein the three dimensional indicia includes logo, brand name or figure.

Technical field

This disclosure relates to the Method and kit for for forming properties area in the substrate, and more particularly relate to inhaling Receive the Method and kit in forming properties area in the substrate on production of articles line.

Background technique

Three-dimensional substrates serve many purposes in various industry.To three-dimensional substrates concern industry first is that absorbent article work Industry.Absorbent article industry manufactures product, such as diaper, trousers, sanitary napkin, tampon and adult incontinence pants, diaper and product.This " absorbent article " can be ideally comprised one or more three-dimensional substrates and be used as such as top flat, acquisition layer, Distribution Layer, outer covering a bit Part material and/or other component.Three-dimensional refers to the substrate of the three-D elements with overproof general plane material.As showing Example, three-D elements can extend such as 0.5mm to 5mm or 1mm to 5mm from the flat surfaces of substrate.Three for absorbent article Wiki bottom is usually manufactured in first position, is transported to the second different position then to be incorporated in absorbent article.First position Usually three-dimensional substrates manufacturer or non-woven or film manufacturer, the second different position are usually absorbent article manufacturer.In The first problem occurred in the case of these is that three-dimensional substrates need to be closely wound and then be transported to the second difference in first position Position.Which generally lowers the three-dimensionality of substrate, because they lack the ability for bearing compression and tensioning caused by winding. The Second Problem occurred in these cases is that substrate needs to unwind and is fed to absorbent article life in the second different position In producing line.This usually further reduced the three-dimensionality of substrate, because they, which lack, bears the compression caused by unwinding and tensioning Ability.In addition, commonly used in absorbent article close package further reduced it is three-dimensionality.What is desired is that for absorbing The reliable method and tool that three-dimensional substrates are produced on production of articles line reduce three-dimensional feature compression and deformation.

In addition to that mentioned above, three-dimensional substrates usual uniform pattern having the same on its entire width and/or length.This A little uniform three-dimensional substrates may not attract the consumer for needing more " customization " products, especially include the suction of three-dimensional substrates Receive the consumer of product.

Summary of the invention

Present disclose provides the Method and kit fors for producing three-dimensional substrates on absorbent article production line.By absorbing Three-dimensional substrates are formed on production of articles line, eliminate winding, unwinding and transport.In addition, disclosed method and tool are three-dimensional Substrate, which provides, at least reduces three-dimensional feature or three-D elements (these terms are used interchangeably herein) compression (or even is being inhaled Receive product compression packing during) ability.This resistance to compression can pass through at least some three-D elements in three-dimensional substrates Middle offer constricted zone or densified area (these terms are used interchangeably herein) Lai Shixian.Constricted zone or densification Region can also surround or at least partly around hole periphery, thus when being manufactured with linear velocity stablize hole.

The disclosure also provides the Method and kit for for forming properties area in the substrate.More specifically, present disclose provides Method for the forming properties area on absorbent article production line.For example, substrate can be the top flat of absorbent article, acquisition layer, Distribution Layer and/or outer covering piece non-woven material.Performance area or part thereof can have one or more specific required performances, all As such as fluid wicking, BM absorbability, fluid management, fluid absorbency, fluid absorb resistance and/or flexibility.Performance area It may include one or more of three-D elements, hole and constricted zone or two or more.Performance area can also include three Tie up all threes in element, hole and constricted zone.Substrate also may include one or more labels.For example, label may include emblem Mark, brand name and/or figure.Label can be printed or may include three-dimensional feature, so that the three-dimensionality of label can To form logo, brand name and/or the image of figure.By the way that these performances are formed on the substrate on absorbent article production line Area and/or label, can eliminate the winding and backing off of substrate, thus make performance area in final products (such as absorbent article) more It is prominent.

Detailed description of the invention

Although this specification is related to forming the claim of subject of the present invention to particularly point out and be distinctly claimed Book is drawn a conclusion, it is believed that the disclosure may be better understood by following description with reference to the accompanying drawings, label is used in the accompanying drawings Indicate substantially the same element, and wherein:

Fig. 1 is the view of a pair of rolls, this has the substrate transmitted therebetween to roller；

Fig. 2 is the top view of the Examples section of first roller of a pair of rolls of Fig. 1；

Fig. 2A is the cross-sectional view along the line 2A-2A of Fig. 2 the first roller intercepted；

Fig. 3 is the top view of the Examples section of second roller of a pair of rolls of Fig. 1；

Fig. 3 A is the cross-sectional view along the line 3A-3A of Fig. 3 the second roller intercepted；

Fig. 4 is the simplified schematic with a part of the first roller of a part of intermeshing Fig. 2A of the second roller of Fig. 3 A Cross section diagram；

Fig. 4 A is the exploded view of the region 4A in Fig. 4；

Fig. 5 is the cross-sectional view of a part of the exemplary bumps of the second roller；

Fig. 6 is another cross-sectional view of a part of the exemplary bumps of the second roller；

Fig. 7 A-7G is the exemplary top view of a part of the distal end of the protrusion of the second roller；

Fig. 8 A-8F is the exemplary top view of a part of the protrusion of the first roller；

Fig. 9 is the top view of the Examples section of first roller of a pair of rolls of Fig. 1；

Fig. 9 A is the cross-sectional view along the line 9A-9A of Fig. 9 the first roller intercepted；

Figure 10 is the top view of the Examples section of second roller of a pair of rolls of Fig. 1；

Figure 10 A is the cross-sectional view along the line 10A-10A of Figure 10 the second roller intercepted；

Figure 11 is illustrated with simplifying for a part of the first roller of a part of intermeshing Fig. 9 A of the second roller of Figure 10 A Property cross section diagram；

Figure 12 is the top view of the Examples section of first roller of a pair of rolls of Fig. 1；

Figure 12 A is the cross-sectional view along the line 12A-12A of Figure 12 the first roller intercepted；

Figure 13 is the top view of the Examples section of second roller of a pair of rolls of Fig. 1；

Figure 13 A is the cross-sectional view along the line 13A-13A of Figure 13 the second roller intercepted；

Figure 14 is shown with the simplification of a part of the first roller of a part of intermeshing Figure 12 A of the second roller of Figure 13 A Meaning property cross section diagram；

Figure 15 is the top view of the Examples section of first roller of a pair of rolls of Fig. 1；

Figure 15 A is the cross-sectional view along the line 15A-15A of Figure 15 the first roller intercepted；

Figure 16 is the top view of the Examples section of second roller of a pair of rolls of Fig. 1；

Figure 16 A is the cross-sectional view along the line 16A-16A of Figure 16 the second roller intercepted；

Figure 17 is shown with the simplification of a part of the first roller of a part of intermeshing Figure 15 A of the second roller of Figure 16 A Meaning property cross section diagram；

Figure 18 is the cross-sectional view of a part of the first roller engaged each other Yu a part of the second roller；

Figure 18 A is the enlarged cross sectional views of the details 18A of Figure 18；

Figure 19 is the exemplary precursors that can be transmitted by the roll gap formed between the first roller and the second roller of the disclosure The top view of substrate；

Figure 20 is the cross-sectional view along the line 20-20 of Figure 19 precursor substrate intercepted；

Figure 21 is the cross-sectional view along the line 21-21 of Figure 19 precursor substrate intercepted；

Figure 22 is that after transmitting by roll gap and have the exemplary of the center longitudinal band including three-D elements and hole The top view of substrate；

Figure 23 shows the first roller and the second roller that can form the substrate with center longitudinal band as shown in figure 22；

Figure 24 is the perspective view of two draw rolls of the side for the substrate of tensile diagram 22；

Figure 25 is the cross section diagram of the ridge and groove in each roller of Figure 24；

Figure 26 is the cross section diagram for forming the alternative example roller in three-D elements and hole in precursor substrate；

Figure 27 is that the cross section of the three-dimensional substrates with the hole generated by the roller of Figure 26 illustrates；

Figure 28 is the schematic diagram to form three roller methods of substrate, which has the first substrate with three-D elements and hole The only substrate of second substantially plane with hole；

Figure 29 is the cross-sectional view intercepted along the details 29 of Figure 28；

Figure 30 is the top perspective that the exemplary three dimensional produced by the first roller of Fig. 1 and the second roller 8,10 has hole substrate；

Figure 31 is the top view that the exemplary three dimensional produced by the first roller of Fig. 1 and the second roller 8,10 has hole substrate；

Figure 32 is that the exemplary three dimensional of Figure 31 has the rearview of hole substrate；

Figure 33 is the cross-sectional view for having hole substrate to intercept by the exemplary three dimensional of Figure 31；

Figure 34 is the simplified schematic cross section example diagram of roller 8,10, and the roller is mainly configured in precursor base Three-D elements and constricted zone are formed in bottom 4 rather than hole；

Figure 35 is the simplified schematic cross section example diagram of roller 8,10, and the roller is mainly configured in precursor base Hole and constricted zone are formed in bottom 4 rather than three-D elements or compared with the roller 8,10 of Fig. 4 more limited (for example, less height) Three-D elements；

Figure 36 is the simplified schematic cross section example diagram of roller 8,10, and the roller is mainly configured in precursor base Three-D elements and constricted zone are formed in bottom 4 rather than hole；

Figure 37 is the simplified schematic cross section example diagram of roller 8,10, and the roller is mainly configured in precursor base Form hole and constricted zone in bottom 4 rather than three-D elements or with the roller 8,10 of Fig. 4 and Figure 35 compared with it is more limited (for example, less Three-D elements highly)；

Figure 38 is the simplified schematic cross section example diagram of roller 8,10, and the roller is configured in precursor substrate 4 Middle formation hole and three-D elements rather than constricted zone；

Figure 39 is the top view of the wherein substrate with three-D elements；

Figure 40 is the cross-sectional view of the substrate of Figure 39 of 40-40 interceptions along the line；

Figure 41-46 is the exemplary substrate 200 wherein with one or more performances area；

Figure 47 is the rough schematic view for the exemplary rollers in forming properties area in precursor substrate；

Figure 48 is the schematic top view example diagram of the substrate with various performance areas；

Figure 49 is the schematic top view example diagram of the substrate with various performance areas；

Figure 50 is the schematic diagram of the method for the substrate that production has first layer and the second layer, wherein the second layer include it is multiple from Dissipate patch；

Figure 51 is the schematic top view diagram of the substrate with first layer and the second layer produced by the method for Figure 50, Wherein the second layer includes multiple discrete patches；

Figure 52 is the first roller of the method that can be used for Figure 50 and the section view example of the second roller；

Figure 53 is illustrated with the simplified schematic cross section of a part of a part of intermeshing first roller of the second roller；

Figure 53 A is the exploded view of the region 39A in Figure 53；

Figure 54 is the top view of a part of exemplary first roller 8；

Figure 54 A is the cross-sectional view along a part of the line 54A-54A of Figure 54 the first roller 8 intercepted；

Figure 55 is the top view of a part of exemplary second roller 10；

Figure 55 A is the cross-sectional view along a part of the line 55A-55A of Figure 55 the second roller 10 intercepted；

Figure 56 is for making one or more substrates pass through various first rollers of the disclosure and the package configuration of the second roller Example；And

Figure 57 is for making one or more substrates pass through various first rollers of the disclosure and the package configuration of the second roller Another example.

Specific embodiment

The various non-restrictive forms that the disclosure will now be described are disclosed herein for understand on the whole The structural principle of the Method and kit in forming properties area, function, manufacture and purposes in substrate.One of these non-restrictive forms Or multiple examples are illustrated in attached drawing.It will be understood by those skilled in the art that specifically described herein and attached drawing The shown Method and kit for for forming properties area in the substrate is non-limited exemplary forms, and the disclosure is each The range of kind non-restrictive form is defined by the claims completely.The feature in conjunction with shown or described in a non-restrictive form It can be combined with the feature of other non-restrictive forms.Such modifications and variations are intended to be included in the scope of the present disclosure.

The disclosure relates in part to the Method and kit for for manufacturing three-dimensional substrates on absorbent article production line.Three Wikis Bottom can be porose.It referring to Fig.1, can be by transporting through precursor substrate 4 (for example, precursor top flat) in 8 He of the first roller The roll gap 6 formed between second roller 10 forms three-dimensional substrates or three-dimensional apertured substrate 2.At least part of first roller 8 can be with It is engaged with intermeshing at least part of the second roller 10.The part of the contact of not intermeshing of first roller and the second roller can be with It is to be in rolling contact or do not contact.The details of first roller and the second roller 8,10 will be shown in the figure below.It can heat Precursor substrate 4, the first roller 8, the second roller 10 and/or three-dimensional substrates or three-dimensional apertured substrate 2, to promote three-D elements preferably to protect It holds in substrate 2 and allows to be more easily formed three-D elements and hole.

Precursor substrate 4 can have thermoplastic component (for example, one or more films and/or one or more non-woven materials Material).Precursor substrate 4 can have any appropriate number of layer, such as one, two or three.Any or all layer may include One or more non-woven materials (or non-woven fibre), spin (coform) material, cellulosic material (or cellulose fiber at film Dimension), cotton material (or fiber), natural material (or natural fiber) or their combination.As an example, precursor substrate can have two A or more non-woven material layer, one or more film layer and one or more non-woven material layers, and/or two or more A film layer.Each layer can be of the same size, shape, density, base weight and composition, or can have different sizes, is shape, close Degree, base weight and composition, this will be discussed in further detail below.

Referring again to Fig. 1, the first roller and the second roller 8 and 10 can be configured to only form three-dimensional element in precursor substrate 4 Part, or can be configured to be formed three-D elements and hole in precursor substrate 4 to form three-dimensional apertured substrate 2.First roller 8 can Just to be rotated upward around first rotation 12 as shown in the arrow on the first roller 8, and the second roller 10 can by It is just rotated upward around the second rotation axis 14 shown in arrow on second roller 10.In other cases, for example, the first roller 8 Can be rotated along the direction opposite with the arrow on the first roller 8, and the second roller 10 can along with the arrow phase on the second roller 10 Anti- direction rotates.First roller 8 may include the first radially-outer surface 16, and the second roller 10 may include the second radially-outer surface 18.First rotation 12 and the second rotation axis 14 can position generally parallel to each other with the first roller and the second roller 8,10 it Between formed roll gap 6.Can by roll gap 6 on absorbent article production line in a machine direction (arrow MD) transmit precursor substrate 4.

Fig. 2 is the front view of exemplary a part of the first roller 8.Fig. 2A be along 2A-2A interception Fig. 2 cross-sectional view. First roller 8 may include from the first radially-outer surface 16 at least partly outwardly extending multiple first protrusions 20.Multiple first is convex Playing 20 can be configured to form or be at least partially formed hole in precursor substrate 4.In some cases, the distal end portion of protrusion 20 Portion can be it is circular, only to form three-D elements rather than hole in precursor substrate 4.First roller 8, which may also include, is limited to Multiple first recessed portions 22 in one radially-outer surface 16.At least some of multiple first protrusions 20 largely or entirely may be used Including the first distal part 24, which includes elongate aperture structure.First distal end portion of the first distal part 24 Portion 26 can form tip.Term " tip " as used herein can at least partly rounding, but still precursor can be pierced through Substrate.Term " tip " further includes wherein selling the construction extended from distal end, wherein pin-shaped pore-forming.First distal part 24 can Including one or more side walls 28.At least some of multiple first protrusions 20 largely or entirely can respectively include the first base Portion 30.Multiple first protrusions 20 may include the central longitudinal axis 32 intersected with tip or the first distal end 26.Base portion 30 can Including sidewall 34, which, which can be parallel to the first central longitudinal axis 32 or be roughly parallel to the first central longitudinal axis 32, prolongs It stretches.In other cases, sidewall 34 can extend in +/- 25 degree of the first central longitudinal axis 32.In some cases, side wall 34 are also possible to bowed or have arcuate section.

Referring still to Fig. 2 and Fig. 2A, the first distal part 24 can form cone or pyramidal structure.In such cases, First distal part 24 can have the single side wall 28 around the first central longitudinal axis 32.In other cases, first is remote Side section 24 can form other polygonal shapes, wherein forming two or more side walls 28.As an example, the first distal portion Dividing 24 can form tool, there are three the tetrahedral structures of independent side wall.In either case, one or more side walls 28 can Completely continuous not surround the first central longitudinal axis 32, this will be described in further detail below.One or more side walls 28, It is either continuous or discontinuous, can have about 5 degree to about 50 degree, about 10 degree to about 30 degree, about 15 degree to about 25 degree, About 18 degree, about 20 degree to about 80 degree, about 30 degree to about 70 degree, about 35 degree to about 65 degree, about 40 degree to about 60 degree, about 40 degree to about The first angle relative to the first central longitudinal axis 32 in the range of 55 degree or about 40 degree to about 50 degree, is specifically enumerated All 0.1 degree of increments in specified range and all ranges for being formed in wherein or being consequently formed.Referring to Fig. 2, for example, more At least some protrusions of a first protrusion 20 can be surrounded by four recessed portions of multiple first recessed portions 22.Referring again to Fig. 2, For example, at least some recessed portions of multiple first recessed portions 22 can be surrounded by four protrusions of multiple first protrusions 20.

Referring to Fig. 2A, at least some of base portion 30 of multiple first protrusions 20 or whole can have the first width W1, First width W1 is along the direction interception for being roughly parallel to first rotation 12 (or perpendicular to first central longitudinal axis 32). In at least some of the region adjacent with base portion 30, recessed portion 22 can have edge and be roughly parallel to first rotation line 12 Direction interception the second width W2.First width W1 can it is identical as the second width W2, be different from, be less than or greater than it is second wide Spend W2.

Fig. 3 is the front view of exemplary a part of the second roller 10.Fig. 3 A be along 3A-3A interception Fig. 3 cross-sectional view. Second roller 10 may include from the second radially-outer surface 18 at least partly outwardly extending multiple second protrusions 36.Multiple second is convex 36 are played to be configured to form three-D elements in precursor substrate 4.Multiple second protrusions 36, which have, is limited to the second radially-outer surface Multiple second recessed portions 38 in 18.At least some of multiple second protrusions 36 largely or entirely include the second distal portion Points 40 and second distal end 42.Multiple second protrusions 36 include base portion 44.At least some of multiple second protrusions 36, big portion Point or all respectively include the shoulder 46 being positioned among base portion 44 and the second distal end 42.Multiple second protrusions 36 are respectively wrapped Central longitudinal axis 48 is included, which upwardly extends in the side for being approximately perpendicular to the second rotation axis 14.Relative to Second central longitudinal axis 48, shoulder 46 can have about 2 degree to about 40 degree, about 3 degree to about 30 degree, about 5 degree to about 20 degree, About 3 degree to about 15 degree, about 10 degree, about 20 degree to about 80 degree, about 30 degree to about 70 degree, about 35 degree to about 65 degree, about 40 degree to about Second relative to the second central longitudinal axis 48 in the range of 60 degree, about 40 degree to about 55 degree or about 40 degree to about 50 degree Angle specifically enumerates all 0.1 degree of increments in specified range and all ranges for being formed in wherein or being consequently formed. The first angle of first distal part 24 can be identical or different with the second angle of shoulder 46.As an example, first angle can With within about +/- 0.01 degree to about 15 degree of second angle, or within about +/- 0.01 degree to about 10 degree, specifically wrap Include all 0.001 degree of increments in specified range and all ranges for being formed in wherein or being consequently formed.Show as another Example, first angle can be +/- the 8 of second angle, 6,5,4,3,2,1.5,1,0.75,0.5,0.25 or 0.1 degree.As another A example, first angle can (for example, +/- 0.5 degree) essentially identical with second angle, or it is identical as second angle.Make One angle and second angle is mutually the same, purpose essentially identical or be relatively close to is at least partially or fully around precursor A part of three-D elements in substrate 4 generates constricted zone or densified area.These constricted zones or densified area have Help resist compression (such as from packaging) and helps to maintain three-D elements.Constricted zone can be formed in the part of three-D elements It above and/or can be at least partly around the periphery in hole so that three-D elements and/or hole are stablized.Constricted zone or densified area Not only for the majority fibers binding part (that is, for holding the fibers in binding part together) for forming nonwoven substrate.

Referring to Fig. 3, at least some protrusions of multiple second protrusions 36 can be by four recess of multiple second recessed portions 38 Portion surrounds.Referring again to Fig. 3, at least some recessed portions of multiple second recessed portions 38 can be by four of multiple second protrusions 36 Protrusion surrounds.

Referring to Fig. 3 A, at least some of base portion 44 of multiple second protrusions 36 or whole can have are being roughly parallel to The first width W3 on the direction of second rotation axis 14.In at least some of the region adjacent with base portion 44, recessed portion 38 can To have the second width W4 on the direction for being roughly parallel to the second rotation axis 14.First width W1 can be with the second width W2 is identical, be different from, is less than or greater than the second width W2.

Fig. 4 is shown with the simplification of a part of the first roller 8 of a part of intermeshing Fig. 2A of the second roller 10 of Fig. 3 A Meaning property cross-sectional view.If desired, the outer surface of the first roller 8 with multiple first protrusions 20 and multiple first recessed portions 22 The rest part of rest part and the second roller 10 with multiple second protrusions 36 and multiple second recessed portions 38 will be most of In the case of intermesh in an identical manner.In some cases, it can be possible to wish only to generate three-dimensional element in the longitudinal band of center Part and hole, this will be discussed in greater detail below.Precursor substrate 4 is not shown for the sake of understanding in specification tool, in Fig. 4, But in the gap between two rollers 8,10, there are precursor substrates 4.In Fig. 4, the portion of multiple first protrusions 20 of the first roller 8 Divide and intermeshes with the part of multiple second recessed portions 38 in the second roller 10.Moreover, multiple second protrusions 36 of the second roller 10 Part and the parts of multiple first recessed portions 22 of the first roller 8 intermesh.In this way, the one of the first distal part 24 The part of a or multiple side walls 28 close to the second distal part 40 shoulder 46 part.Side wall 28 and shoulder 46 together can be to 4 applied force of precursor substrate to compress precursor substrate 4 therebetween.When precursor substrate 4 is positioned between the first roller 8 and the second roller 8 When in roll gap, a part of shoulder 46 and one or more side walls 28 can be used for forming constricted zone or cause in precursor substrate 4 Densification zone.Constricted zone or densified area in substrate can help to resist the compression of three-D elements.Compression can be sorted out For the reversible elastic deformation of precursor substrate 4 (for example, non-woven material).Compression means to squeeze out air into bulk precursor substrate And cause precursor substrate fiber be straightened and/or it is nested.Compression is not meant to for example to cause the polymerization in non-woven material Object starts flowing to fill air void and then solidify (referred to as irreversible flexible deformation).Irreversible flexible deformation can be preceding Rigid region is generated in body substrate, to reduce the pliability of precursor substrate.Therefore, reversible elastic deformation ratio can not dielasticity change Shape is more preferable, because it provides better flexibility, while still providing the resistance of the compression to three-D elements.Therefore, There is provided gap between side wall 28 and shoulder 46, only to allow therebetween compress precursor substrate, thus control fusing and it is cured Amount.

Fig. 4 A is the exploded view of the region 4A of Fig. 4.Fig. 4 A shows the exemplary optional construction of shoulder 46 and side wall 28, Respectively there are two offset surfaces for tool for middle shoulder 46 and side wall 28.Any one of shoulder 46 and side wall 28 disclosed herein can have There is such offset surface.In other cases, shoulder 46 and side wall 28 can not have two offset surfaces.

Multiple first protrusions 20 can not exclusively engage multiple second recessed portions 38, and multiple second protrusions 36 can not It is fully engaged multiple first recessed portions 22.It is and more as described above, multiple first protrusions 20, i.e. tip and the first distal part 24 A second recessed portion 38 is combined for forming hole in precursor substrate 4.Multiple second protrusions 36, i.e. the second distal end 42 and Two distal parts 40 are combined with multiple first recessed portions 22 for forming three-D elements in precursor substrate 4.Constricted zone can be with It is formed in three-D elements, to help three-D elements to resist compression, such as compression caused by packing.

Referring to Fig. 5, at least some of multiple second protrusions 36 can have in the second distal end 42 and the second distal portion Divide the sloping portion 50 among 40.This prevents or at least inhibits precursor substrate 4 to contact sharp comer and tear in precursor substrate 4 Or form sharp edges.Referring to Fig. 6, at least some of multiple second protrusions 36 can have in the second distal end 42 and second Fillet 52 among distal part 40.This prevents or at least inhibits precursor substrate 4 to contact sharp comer and tear in precursor substrate 4 Split or formed sharp edges.

Fig. 7 A-7G is the exemplary top view schematic diagram of the different configuration of multiple second protrusion 36'.In such example, Second distal part 40' can be the variform shape with the second distal end 42' (see, for example, Fig. 7 B-7G).Another In one example, the second distal part 40' can be with the same or similar shape of the shape of the second distal end (see, for example, Fig. 7 A).Referring to Fig. 7 C-7E, the second distal part 40' can be halfway around the second center longitudinal direction of multiple second protrusion 36' Axis 48'.In this case, the constricted zone in substrate 2 or densified area may be halfway around three-dimensional features.Reference Fig. 7 E and 7G, the second distal part 40' can be entirely around the second central longitudinal axis 48' of multiple second protrusion 36'.Herein In the case of kind, constricted zone or densified area in substrate 2 can be entirely around three-dimensional features.

Fig. 8 A-8F is the exemplary top view schematic diagram of the different configuration of multiple first protrusion 20'.Side wall 28' can be complete Entirely around the first central longitudinal axis 32'(see, for example, Fig. 8 C, 8E and 8F).In other cases, side wall 28' can be incomplete Around the first central longitudinal axis 32'(see, for example, Fig. 8 A, 8B and 8D).In some instances, the side of multiple first protrusions 20 The construction of wall can be matched or can be mismatched with the construction of the second distal part of multiple second protrusions.

Fig. 9-17 shows other constructions of the part of following the first roller within the scope of this disclosure and the second roller 8,10. Fig. 9 is the top view of the Examples section of first roller of a pair of rolls of Fig. 1.Fig. 9 A is the first roller intercepted along the line 9A-9A of Fig. 9 Cross-sectional view.Figure 10 is the top view of the Examples section of second roller of a pair of rolls of Fig. 1.Figure 10 A is cut along the line 10A-10A of Figure 10 The cross-sectional view of the second roller taken.Figure 11 is one with the first roller of a part of intermeshing Fig. 9 A of the second roller of Figure 10 A The schematic cross-section example diagram divided.Figure 12 is the top view of the Examples section of first roller of a pair of rolls of Fig. 1.Figure 12 A is The cross-sectional view of the first roller intercepted along the line 12A-12A of Figure 12.Figure 13 is the top of the Examples section of second roller of a pair of rolls of Fig. 1 View.Figure 13 A is the cross-sectional view along the line 13A-13A of Figure 13 the second roller intercepted.Figure 14 is one with the second roller of Figure 13 A Divide the schematic cross-section example diagram of a part of the first roller of intermeshing Figure 12 A.Figure 15 is the of a pair of rolls of Fig. 1 The top view of the Examples section of one roller.Figure 15 A is the cross-sectional view along the line 15A-15A of Figure 15 the first roller intercepted.Figure 16 is Fig. 1 A pair of rolls the second roller Examples section top view.Figure 16 A is the section view along the line 16A-16A of Figure 16 the second roller intercepted Figure.Figure 17 is the schematic cross-section with a part of the first roller of a part of intermeshing Figure 15 A of the second roller of Figure 16 A Example diagram.In Fig. 9-17, identical identical component reference label expression and discussed about Fig. 2 to Fig. 4.

In some cases, in terms of top view, it is long that multiple first protrusions can have the machine direction shorter than transverse width Degree, this is because production substrate in the hole of formation to prevent or at least inhibit the speed deformed.In other words, machine direction is long Degree can be shorter than transverse width, so that forming round hole.If the machine direction length and transverse width phase of multiple first protrusions Together, then oval (extending in MD) hole can be formed due to the speed of production substrate.For the same reason, multiple second Protrusion can design in a similar way.

Figure 18 is the cross-sectional view of a part of the first roller 8 engaged each other Yu a part of the second roller 10.Figure 18 A is The enlarged cross sectional views of the details 18A of Figure 18.Figure 18 and 18A shows other shapes of the part of the first roller and the second roller 8,10 Formula.In Figure 18 and 18A, identical identical component reference label expression and discussed about Fig. 2 to Fig. 4.Such as at other As shown in the figure, multiple second protrusions 36 " the second distal end 42 " have arch or dome-like shape without being flat distal side End 42.It is important to note that the first roller and the second roller of Figure 18 show the form of roller 8,10, wherein three-dimensional feature shape Only occur at/aperture in the middle section of roller to form the center longitudinal band of three-D elements and hole in the substrate and be formed There is no the side in three-D elements and hole, this will be discussed in further detail below.Selective three-D elements formation/aperture can also be with (regardless of whether being center longitudinal band form) occurs in a machine direction.It in other words, in a machine direction, can be first Three-D elements/hole is formed in region, second area can not have three-D elements/hole, and then third region can have three-dimensional element Part/hole.In a machine direction, first area can be maximum upstream, and third region can be minimum upstream, wherein second Region is between first area and second area.In top flat example, for example, when being placed in absorbent article, three-D elements/ Hole can only be formed in the back waist region of top flat.

Precursor substrate 4 and thus substrate 2 can be formed by one or more layers, for example, one or more non-woven materials, One or more non-woven materials and one or more films or one or more films.Provided that more than one layer, then institute State layer can by mechanical adhesion, adhesives, pressure bonding, hot adhesion, make hot-air by two layers or connect by other Conjunction method is bonded together or is attached to each other, to form multi-layer substrate 400.It alternatively, can be in subsequent fiber deposition step Forming layer such as polymerize for the staple fiber or two subsequent filature fleece formations comprising additive of the first kind and Second Type The first carding operation and the second carding operation of the beam of object long filament.It is the base weights of one or more layers, hydrophily, material, fiber, close Degree and/or other properties can be identical or different.If there are more than one layer in precursor substrate, these layers be can have Size and shape identical with first layer, or can have the size and shape different from first layer.In other words, extra play Can be completely overlapped with first layer, or can be only partially Chong Die with first layer.The layer of precursor substrate 4 and substrate 2 can have There is different colors, such as the color with different Δ E values and/or difference L*a*b* value.Some examples can be white first Layer and the blue second layer, light blue first layer and the navy blue second layer or purple first layer and the blue second layer, or clip indigo plant The first white layer and third white layer of color middle layer.Figure 19 be can by the first roller of the disclosure and the second roller 8,10 it Between formed roll gap transmission exemplary precursors substrate top view.Figure 20 is the precursor substrate of Figure 19 of 20-20 interceptions along the line Cross-sectional view.Figure 21 is the cross-sectional view of the precursor substrate of Figure 19 of 21-21 interceptions along the line.Figure 19 is shown with 3 He of first layer The precursor substrate 4 of the second layer 5.First layer 3 is wider than the second layer 5.When precursor substrate 4 by the first roller and the second roller 8,10 by being formed Roll gap transmission when, the second layer 5 can be positioned on or below first layer 3.The extra play of different in width can also be provided, it is all Such as such as third layer.In some cases, the second layer 5 or other layers can be discontinuous rather than as shown in the figure continuous, Such as by using cutting and sliding technique.In this case, for example, first layer 3 can be top flat, and the second layer 5 can be with It is acquisition/distribution layer.When the second layer 5 does not need or be not intended to the entire spacing of absorbent article, this may be desired.Such as Shown in the cross-sectional view of Figure 20 and 21, the second layer 5 is wide unlike first layer 3 in a lateral direction.For example, first layer 3 and/or Two layer 5 of side edge can not be linear and can have arcuate section.First layer 3 can have about 10gsm to about 25gsm, about 12gsm are to about 20gsm, about 12gsm to about 18gsm, about 13gsm, about 14gsm, about 15gsm, about 16gsm, about Base weight in the range of 17gsm is specifically enumerated in specified range and all ranges for being formed in wherein or being consequently formed All 0.1gsm increments.The second layer 5 can have about 10gsm to about 40gsm, about 15gsm to about 30gsm, about 15gsm to about 25gsm, about 18gsm, about 22gsm, about 19gsm, about 20gsm, the base weight about in the range of 21gsm are specifically enumerated specified All 0.1gsm increments in range and all ranges for being formed in wherein or being consequently formed.As an example, first layer 3 can be with It is 175mm wide, and the second layer 5 can be 95mm wide.As an example, first layer 3 can be 175mm wide, and the second layer 5 can be 95mm wide.In one example, first layer 3 may include two sidepiece parts, be attached to the side of the second layer 5, to be formed Three-member type substrate.

Exemplary precursors substrate can have first layer and the second layer (or any other appropriate number of layer).First layer can wrap Containing multiple first fibers and/or long filament (being known as " fiber " sometimes along herein).Multiple first fibers may include size, shape Shape, composition, danier, fibre diameter, fibre length, and/or identical, the substantially the same or different fiber of weight.The second layer It may include multiple second fibers.Multiple second fibers may include size, shape, composition, danier, fibre diameter, fibre length, And/or the fiber that weight is identical, substantially the same or different.Multiple first fibers and multiple second fibers can be it is identical, It is substantially the same or different.Extra play can have identical or different configuration.

First layer and/or the second layer may include the bicomponent fibre with crust and core.Crust may include polyethylene, and Core may include polyethylene terephthalate (PET).Crust and core also may include known to those skilled in the art any Other suitable materials.Crust and core can respectively contain based on the weight of fiber about 50% fiber, but other modification (examples Such as, crust 60%, core 40%；Crust 30%, core 70% etc.) also within the scope of this disclosure.Constitute first layer and/or the second layer Bicomponent fibre or other fibers can have about 0.5 to about 10, about 0.5 to about 6, about 0.75 to about 4, about 1.0 to about 4, Danier in the range of about 1.5 to about 4, about 1.5 to about 3, about 1.5 to about 2.5 or about 2, is specifically comprised in specified range And all 0.1 danier increments in all ranges for being formed in wherein or being consequently formed.Danier is defined as every 9000 meters The quality (gram) of fibre length.In other cases, the danier of the fiber of first layer can be in about 1.5 daniers to about 6 denier Buddhist nuns In the range of that or about 2 daniers to about 4 daniers and the danier of the fiber of the second layer can be in about 1.2 daniers to about 3 In the range of danier or about 1.5 daniers to about 3 daniers, specifically enumerate within the specified range and be formed in wherein or All 0.1 danier increments in all ranges being consequently formed.In some cases, the fiber of first layer is than the second layer The danier of fiber at least 0.5 danier, at least 1 danier, at least 1.5 daniers or at least 2 daniers greatly, this at least portion Point ground depend on a certain absorbent article used in specifically acquisition and/or distribution system.By providing possessed danier Higher than the fiber of the first layer of the danier of the fiber of the second layer, gradient pores are provided in liquid permeable substrate.Hole ladder Degree can provide better drying property and/or acquisition in liquid permeable substrate.With the fibre of larger danier in first layer Dimension is provided than having the hole bigger compared with the fiber of denier in the second layer, to generate gradient pores between said layers.

Multiple first fibers and the second fiber may also include the fiber of any other suitable type, such as polypropylene fibre, Other polyolefin, it is the amyloid sustainable resin of such as polylactic acid, thermoplasticity of other polyester other than PET, other sustainable Resin, biology PE (bio-PE), biology PP (bio-PP) and biology PET (Bio-PET), viscose rayon, rayon fiber or Other suitable non-woven fibres.These fibers can have any suitable danier or danier range and/or fibre length Or fiber length ranges.In the case where multiple first fibers and identical or substantially the same the second fiber, multiple second fibers It can be handled with hydrophilic agent such as surfactant, so that multiple second fibers become hydrophilic or at least hydrophobicity is smaller.It is more A first fiber can not have to surfactant and handle, so that they keep native hydrophobic state or multiple first fibres in them Dimension can be handled with surfactant to become to have less hydrophobicity.

First layer can have the base weight within the scope of about 10gsm to about 25gsm.The second layer can have in about 10gsm to about Base weight within the scope of 45gsm.The base weight of substrate (both first layer and the second layer) can in for example, about 20gsm to about 70gsm, about 20gsm to about 60gsm, about 25gsm are to about 50gsm, about 30gsm to about 40gsm, about 30gsm, about 35gsm or about 40gsm In range.

In one form, the base weight of precursor substrate 4 can be about 30gsm to about 40gsm or about 35gsm.In this example In, first layer can have the base weight within the scope of about 10gsm to about 20gsm or about 15gsm, and the second layer can have about Base weight within the scope of 15gsm to about 25gsm or about 20gsm.In another example, the base weight of substrate can be about 20gsm.In In this example, first layer can have the base weight of about 10gsm and the second layer can have the base weight of about 10gsm.Show at another In example, the base weight of substrate can be about 60gsm.In such examples, first layer can have the base weight of about 24gsm and the second layer can Base weight with 36gsm.All other suitable basis weight range of first layer and the second layer and substrate is in the scope of the present disclosure It is interior.Therefore, the base weight of specific product requirement design level and substrate can be directed to.

Specifically enumerated herein is in basis weight range specified above and all models for being formed in wherein or being consequently formed Enclose interior all 0.1gsm increments.

In some cases, it can be possible to wish that there is the base weight high compared to the second layer in first layer.For example, first layer Base weight can greatly at least about 1 to about 4 times of base weight than the second layer, at least about 1 to about 3.5 times, about 1.5 to about 3 times, about 1.5 times To about 3 times, about 2 times, about 2.5 times or about 3 times.In some cases, for example, the base weight of first layer can be in about 20gsm to about In the range of 30gsm, and the base weight of the second layer can be in the range of about 10gsm to about 20gsm.Specifically enumerated herein be All 0.1gsm increments in basis weight range specified above and all ranges for being formed in wherein or being consequently formed.By mentioning For having the first layer (hydrophobicity) of the base weight higher than the second layer (hydrophily), provide in liquid permeable substrate than parent The more hydrophobic material of water-based material.More hydrophobic material according to information and conviction, in liquid permeable substrate Preferably acquisition and/or drying property are provided with the lesser material of hydrophily.The surface tension of hydrophilic layer can reduce, with can in liquid The substrate of transmission at least inhibit when receiving one or more ejectas hydrophilic layer (second layer) pollution hydrophobic layer (first layer) (and Keep its more hydrophilic).

Fiber can be spun-bonded fibre, spun lacing fiber, carded fiber, meltblown fibers, nanofiber (less than 1 micron) or its The fiber of his suitable type.Fiber can be curling.Fiber can have circular cross section or non-circular cross sections, such as oval Or trilobal.

In one example, referring to Fig.1 9, first layer 3 and the second layer 5 can be formed together the top flat of absorbent article.First Layer 3 can be located at the surface towards baby or the side towards wearer.First layer 3 (side towards wearer) can be thin Water and the second layer 5 can be hydrophilic (side towards clothes) or the second layer 5 can be it is hydrophobic (towards wearer's Side) and first layer 3 can be hydrophilic (side towards clothes).In some constructions, both layers 3,5 (or other layers) It can be same degree or in various degree hydrophobic or hydrophilic.Any one of layer 3,5 or both can have as described herein Three-D elements and/or hole.In the case where both layers 3,5 have three-D elements and hole, three-D elements and hole can be formed in two In a layer/pass through two layers.When precursor substrate 4 is transmitted through roll gap, two layers 3,5 (or other layers) can pass through first Roller and the second roller 8,10 link together without the use of adhesive.In other cases, adhesive can be used for connecting various layers.

In some cases, binding part 9 can be formed around the part on the periphery of the second layer 5, to help to connect the second layer 5 To first layer 3.Binding part 9 can also be in other regions of first layer formed therein and second layer overlapping.Binding part 9 can be Constricted zone in first layer and the second layer 3,5.Binding part 9 can the upstream of roll gap, in roll gap (that is, pass through the first roller With the second roller 8,10) or in the downstream of roll gap it is applied to first layer and the second layer (or to extra play).For applying binding part 9 Tool can be a pair of rolls, there is with knob and on another roller flat surfaces or warty on a roller Object.If providing knob on two rollers, they can be in contact with each other to form binding part 9.If will be in roll gap Apply binding part 9, then the first roller and the second roller 8,10 may include knob and/or flat surfaces.

In some cases, it may be used as the outer covering of absorbent article by the substrate of disclosed method and tool production Part material or other parts as absorbent article.

Precursor web 4 and/or substrate 2 (after the roll gap between the first roller and the second roller 8,10) can be subjected to various Processing.Some exemplary process are chemical treatment, mechanical treatment and/or heat treatment.Chemically treated example can be first Apply before, after, or during roll gap between roller and the second roller 8,10 one or more lotions, surfactant, vitamin, PH adjusting agent, ink, enzyme, hydrophilic material, hydrophobic material and/or other substances.These chemical treatments can be sprayed onto It in precursor substrate or substrate, is wound up into precursor substrate or substrate, by the first roller and the second roller 8,10 or part of it One or more applies, and/or can be applied by other methods.In some cases, chemical treatment can be applied to more A first and/or second protrusion 20,36, the substrate being then transferred into roll gap.As an example, hydrophobic composition can be applied It is added to the precursor substrate 4 of solid non-ferrous, it then can be by the first distal part 24 of at least some of multiple first protrusions 20 Hydrophily processing coated with the periphery that can be transferred to the hole formed by protrusion 20.In this case, substrate 2 can be main It is hydrophobic, but there is hydrophilic region on or near the periphery in hole.The example of mechanical treatment can be before roll gap or it Embossing, transverse direction tensioning and/or machine direction tensioning afterwards.Such mechanical treatment can pass through the first roller and the second roller 8,10 Other of upstream and/or downstream roller or other equipment apply.The example of heat treatment may include heating precursors substrate before the nip 4, the heating precursors substrate in roll gap, and/or substrate is heated after the nip.For example, can be by making hot-air blow over precursor Substrate 4 or substrate 2 (that is, " ventilation "), by running entire precursor substrate 4 or substrate 2 by heat tunnel, by making precursor base Bottom 4 or the surface of substrate 2 are on heating roller (with heating two between (only heating surface) or roll gap between two heating rollers Surface) operation, by radiation, and/or by the first roller of heating and/or the second roller 8,10 come heating precursors substrate 4 or substrate 2. It can also be blown into hot-air by the conduit in one or more of roller 8,10, with heating precursors substrate 4.In precursor substrate 4 Heating precursors substrate 4 can make precursor substrate 4 absorb enough heats to allow precursor substrate 4 or precursor base before into roll gap Polymer in bottom 4 flows under stress and forms binding part so that hole 56 and/or three-D elements 54 are stablized.After the nip plus Hot substrate 2 can make three-D elements 54 and hole 56 " fixation " into substrate.In some cases, it can be possible to which wish will be before energy input To contribute to form three-D elements 54 and hole 56 and/or help " fixation " three-D elements and/or hole in body substrate or substrate.This is defeated Entering energy can also contribute to stabilized baseplate and can promote better fibre fusion in substrate.Basad offer input energy Can also provide substrate three-D elements or entire substrate, due to packaging better against the ability of compression.

If precursor substrate 4 is heated in the upstream of roll gap, it can be cooled in roll gap or in the downstream of roll gap. Cooling by the operation substrate 2 on chill roll, or can be passed through by the way that the first roller and the second roller 8,10 are maintained at environment temperature The first roller and the second roller 8,10 are cooled down to complete.First roller and the second roller 8,10 can be in the temperature of the temperature lower than precursor substrate Under degree.Cooling can also be realized in roll gap by the way that surrounding air or cooling air to be blown into roll gap.Cooling can also pass through On surrounding air or the substrate by the way that surrounding air to be blown to roll gap downstream or by provide blow in substrate cooling source (such as Cooling air), or realized by chill roll.It is cooling to pass through in roll gap (cooling the first roller and the second roller 8,10) It is cooling to realize with roll gap downstream (cooling roller is blown into surrounding air or blows cooling air).

It, can be in the cooling precursor substrate 4 in the downstream of roll gap if the heating precursors substrate 4 in roll gap.It can be in roll gap Downstream by surrounding air, by being blown into surrounding air, or by providing cooling source (such as blowing cooling air or cooling Roller) realize cooling.

Referring now to Fig. 22, show the top view of continuous substrate 2.The substrate 2 be by the first roller and the second roller 8, 10 form after three-D elements 54 and/or hole 56 in substrate 2.Three-D elements 54 and hole 56 are generally illustrated in Figure 22 The purpose being merely to illustrate.As described herein, substrate 2 can be formed by one or more layers.The two layers can have identical Transverse direction width or different transverse direction width.Transverse direction in Figure 22 is perpendicular to arrow " MD ".In an example In, extra play or the second layer can be placed only in the center longitudinal band 7 in substrate 2.

In single layer format or two or more layer of format, wherein all layers transverse direction width having the same, three Dimension element 54 and/or hole 56 can only be formed in center longitudinal band 7, wherein the region outside center longitudinal band 7 does not have Three-D elements 54 and/or hole 56.Therefore, method may include only making the center longitudinal band 7 of precursor substrate 4 and multiple first convex Play 20 part, the part of multiple first recessed portions 22, the part of multiple second protrusions 36 and multiple second recessed portions 38 Part contacts.In this way, the first roller and the second roller 8,10 can have representative configuration shown in Figure 23, wherein far from roller 8,10 The no any protrusion in the first area 58 at center or any recessed portion, and wherein close to the second area 59 at the center of roller 8,10 Including multiple first protrusions and the second protrusion 20,36 and multiple first recessed portions and the second recessed portion 22,38.As a result, three-dimensional Element 54 and/or hole 56 can be made only in the center longitudinal band 7 of substrate 4.In one example, logo, brand name Or other labels 61 can be formed in side 60 and/or center longitudinal band 7.For example, the logo, brand name or other marks Note 61 can be used tools as described herein or by be embossed (the roll gap formed by tools as described herein upstream or under In the independent roll gap of trip) it is formed.Under any circumstance, logo, brand name or other labels 61 can have three-D elements or Person can be formed by three-D elements, recessed portion and/or hole.

In two or more layer of precursor substrate, wherein one layer has the transverse direction side different from other one or more layers To width, three-D elements 54 and/or hole 56 can only have the place being overlapped between layers, such as in center longitudinal band 7 Or it is formed in another part.In this case, method may include transmitting the first precursor web, In in a machine direction First precursor web below or above transmits the second precursor web in a machine direction.Before first precursor web and second Body web can be connected by binding part, through-air bonded portion, adhesive, or can be only in contact with each other and in roll gap It links together.First precursor web can have the first transverse direction width, and the second precursor web can have second Smaller transverse direction width.This method may include making the part of precursor substrate and the second precursor substrate and multiple first protrusions, The part of multiple first recessed portions, the part of multiple second protrusions and the part of multiple second recessed portions are substantially only in first It is contacted in the case that precursor substrate is overlapped with the second precursor substrate or only in roll gap in this case.Obtained substrate also has There is appearance shown in Figure 22, has materials at two layers in center longitudinal band 7, and have one layer outside center longitudinal band 7.

Once three-D elements 54 and/or hole 56 are formed in center longitudinal band 7 (either one or more layers), side 60 Or in its region, then it can be stretched in transverse direction without three-D elements 54 and/or hole 56 to reduce the base weight of side 60.If Substrate is used as the top flat in absorbent article (such as diaper or adult incontinence product), then at least region of side 60 can be positioned at Below the leg cuff of absorbent article.In this way, these regions or entire side 60 of side 60 can not contact the skin of wearer simultaneously And it may be invisible to consumer or nursing staff.As a result, can be by stretching at least these regions or whole in a lateral direction A side come realize material save.For example, if the side 60 before stretching has the base weight of 15gsm (gram/m), side 60 can stretch in a lateral direction, so that their base weight becomes 10gsm.This transverse direction stretching can be in many ways It completes.

Referring to Figure 24 and 25, the first draw roll 62 and the second draw roll 64 can be used to realize that transverse direction stretches side A kind of 60 or part thereof suitable exemplary approach.First draw roll and the second draw roll 62 and 64 can respectively have usual It is radial and without the middle section of any three-D elements 66.First draw roll 62 may include multiple the in outside 68,70 One ridge 72 and multiple first grooves 74.Second draw roll 64 may include multiple second ridges 76 and multiple the in outside 68,70 Two grooves 78.At least some of multiple first ridges 62 on first roller 62 or can all engage on the second roller 64 multiple At least some of two grooves 78 are whole.Similarly, at least some of multiple second ridges 76 on the second roller 64 or whole At least some of multiple first grooves 74 on the first roller 62 or whole can be engaged.Multiple first ridges 72 on first roller 62 Top 80 can enter multiple second grooves 78 on the second roller 64 to certain depth of engagement " E ".Similarly, the second roller 64 On the tops 82 of multiple second ridges 76 can enter multiple first grooves 74 on the first roller 62 to certain depth of engagement E. The degree that depth of engagement E control side 60 stretches in transverse direction.Lower depth of engagement causes less transverse direction to stretch, And higher depth of engagement causes more transverse direction to stretch.As a result, the transverse direction level of stretch of side 60 can root Change according to depth of engagement E.

The side 60 of substrate 2 can be positioned in the outside 68 and 70 on the first draw roll and the second draw roll 62 and 64 Between.Center longitudinal band 7 can be positioned at the centre of the middle section 66 of the first draw roll and the second draw roll 62 and 64.With this Kind mode, center longitudinal band 7 can not stretch in a lateral direction, and side 60 can stretch in a lateral direction.In addition, In this way, center longitudinal band 7 can not actually be contacted with the middle section 66 of roller 62,64, so that center longitudinally oriented strip It is not compressed with the three-D elements 54 in 7.

In double-layer structural, the second layer is existed only in the longitudinal band of center, and method may include in transverse direction first Layer stretches first layer with the not be overlapped place of the second layer or only at this (that is, except the longitudinal band of center).The stretching step can To occur in the upstream of roll gap or the downstream of roll gap.

Referring again to Figure 22, no matter whether substrate 2 (have three-dimensional in the longitudinal band of center or in entire substrate 2 Element 54 and hole 56) it can be cut into the component of absorbent article, such as, top flat, acquisition layer, Distribution Layer or outer covering piece The final spacing of non-woven material.Substrate 2 can be cut along line 88.Although line 88 is shown as perpendicular to machine direction, Be those skilled in the art will appreciate that practical cutting path can be not orthogonal to machine direction, but can be transverse to machine side To the speed to consider the mobile substrate in cutting process.In other words, cutting path can be angled relative to transverse direction, To consider the substrate velocity on absorbent article production line.Then the substrate of cutting can be connected on absorbent article production line In a part of absorbent article.

Referring again to Figure 22, center longitudinal band 7 can be located in the layer on another layer.In an example of top flat In, top flat can have solid, generally planar layer on its surface towards clothes, and in its table towards wearer With the patch of center longitudinal band 7 on face.Patch may include precursor substrate, which travels through the first roller and Its roll gap between two rollers 8,10 and include three-D elements 54 and/or hole 56.The patch can be or can not be completely Absorbent article spacing.In other words, patch can not be the overall length of top flat and/or absorbent article.In addition, patch can be or can Not to be the entire width of top flat.

Figure 26 is for generating three-D elements and exemplary first roller in hole and replacing for the second roller 8,10 in precursor substrate For the cross section diagram of part.Figure 27 is the cross of the three-dimensional substrates 134 with the hole generated by the first roller of Figure 26 and the second roller Cross sectional view.Referring to Figure 26, the first roller 8 may include that (it can be with multiple first protrusions for being discussed herein for multiple first protrusions 120 20 is similar or similar, including base portion, the first distal part and the first distal end) and multiple first recessed portions 122.Multiple first At least some or whole recessed portions of recessed portion 122 may include that hole forms protrusion 118.Hole, which forms protrusion 118, can be cone Or it is configured for forming any other suitable shape in hole.It may include tip 124 (such as this paper institute that hole, which forms protrusion 118, " tip " stated) to help to form hole in precursor substrate 4.Hole, which forms protrusion 118, can be configured to three-dimensional in precursor substrate 4 Hole 129 is formed in element 128.May want in three-D elements 128 have hole 129 with allow fluid (for example, urine, through liquid, Dilute BM) enter the voidage 126 formed on the downside of three-D elements 128 and fluid is at least inhibited to keep with wearer's Skin contact.First roller 8 may include at least part or complete for surrounding the periphery of at least some of multiple first recessed portions 122 The densification protrusion 130 in portion.In other words, fine and close protrusion 130 can be entirely around recessed portion 122 or can be only partially about recess Portion 122.Fine and close protrusion 130 can be continuous or discontinuous.Fine and close protrusion 130 can be used for forming pressure in precursor substrate 4 Contracting region or densified area 132.By having constricted zone or densified area 132 in substrate 4, three-D elements can be made 128 stablize.

Referring again to Figure 26 and 27, the second roller 10 may include multiple second protrusions 136 and multiple second recessed portion, 138 (its It can be similar or similar with multiple second recessed portions 22 as described herein).At least some of multiple second protrusions 136 may include limit The recessed portion 140 being scheduled in its second distal end 142.Recessed portion 140 is configured at least partly receiver hole and forms protrusion 118 at least part, including tip 124, so that 128 aperture of three-D elements.Second roller 10 may include one or more recess Portion 148 is at least part for receiving fine and close protrusion 130.Recessed portion 148 may or may not entirely around protrusion 136, And it can be continuous or discontinuous.

Figure 28 is the schematic diagram to form three roller methods of substrate, which has the first substrate with three-D elements and hole The only substrate of second substantially plane with hole.Figure 29 is the cross-sectional view intercepted along the details 29 of Figure 28.In Figure 28, first Roller 208 and the second roller 210 can be identical as the first roller as described herein and the second roller 8,10, are simply shown in FIG. 28.The Three rollers 212 can be the roller with radially-outer surface 214, has and is defined in multiple recessed portions 216 therein.In third roller 212 Recessed portion can be same or similar with the recessed portion of multiple first recessed portions 22 in the first roller 8.Third roller 212 can not have There is any protrusion.In such three rollers technique, precursor substrate 204 can transmit between the first roller and the second roller 208 and 210, To form three-D elements as described herein and hole.Then, precursor substrate 204 can continue around the rotation of the first roller 208, wherein more A first protrusion 20 is engaged with precursor substrate 204.Second precursor substrate 205 be sent to the first roller 208 and third roller 212 it Between in the roll gap that is formed.Then, protrusion 20 enters the recessed portion 216 in third roller, with the first roller 208 and third roller 212 it Between roll gap in pierce through hole in the second precursor substrate 205.Exemplary resulting structures are shown in the roll gap of Figure 29.

After through the roll gap transmission between the first roller and third roller 208 and 212, the second substrate 205 be can be substantially Plane, there is hole.Obtained structure be have three-dimensional top substrate 204 and general plane bottom substrate 205 it is biradical Bottom compound.As the first roller and third roller 208 and 212 as a result, hole would extend through two substrates 204,205.As showing Example, three-dimensional top substrate 204 can be top flat, and the bottom substrate 205 of general plane can be acquisition layer.As another Example, three-dimensional top substrate 204 can be a part of top flat, and the bottom substrate 205 of general plane can be acquisition layer A part.The bottom substrate 205 of three-dimensional top substrate 204 and general plane can each freely one or more layers or material shape At.

Two substrate lamilates provide integrality for structure and are locked in three-D elements and hole.First substrate and second Substrate 204,205 can be without heat-shrinkable fiber.One or more adhesives can be sprayed to the second precursor substrate 205 Above or it is otherwise applied to the second precursor substrate 205, so that it adheres to the first precursor substrate 204 in roll gap.At certain In a little situations, adhesive may not be needed between the first precursor substrate and the second precursor substrate 204,205.In such case Under, the power and hole opening technology of the roll gap between the first roller and third roller can be enough to connect two layers.

Figure 30 is the top perspective that the exemplary three dimensional produced by the first roller of the disclosure and the second roller 8,10 has hole substrate Figure.Figure 31 is the top view that the exemplary three dimensional produced by the first roller of the disclosure and the second roller 8,10 has hole substrate.Figure 32 is The exemplary three dimensional of Figure 31 has the rearview of hole substrate.Figure 33 is the section view for having hole substrate to intercept by the exemplary three dimensional of Figure 31 Figure.

Figure 34 shows the simplified schematic cross section example diagram of roller 8,10, and the roller is mainly configured for preceding Three-D elements and constricted zone are formed in body substrate 4 rather than hole.In Figure 34, the distal end 126 of multiple first protrusions 120 Flat or circular surface can be formed, so as not to make precursor substrate aperture.Multiple second protrusions 36 and the second roller 10 usually can be with Keep same as described above.Figure 36 shows the simplified schematic cross section example diagram of the roller 8,10 of Figure 34 less engagement each other. For example, the engagement level can be used for thicker substrate when needing lesser compression.

Figure 35 shows the simplified schematic cross section example diagram of roller 8,10, and the roller is mainly configured for preceding Form hole and constricted zone in body substrate 4 rather than three-D elements or with the roller 8,10 of Fig. 4 compared with it is more limited (for example, less height Degree) three-D elements.In Figure 35, the second distal end 142 of multiple second protrusions 136 can form flat or round table Face, such as to eliminate three-dimensional feature formation or reduce the height of the three-D elements in precursor substrate 4.Multiple first protrusions 20 and the One roller 8 can usually keep same as described above.The simplified schematic that Figure 37 shows the less engagement each other of the roller 8,10 of Figure 35 is horizontal Section example diagram.For example, the engagement level can be used for thicker substrate when needing lesser compression and/or lesser hole.

Figure 38 show the roller 8,10 similar with Fig. 4 simplified schematic cross section example diagram, but roller 8,10 it Between there are more intervals.In this case, roller 8,10 can be separated from each other so that only formed in precursor substrate 2 hole and Three-D elements, and constricted zone is not formed between side wall 28 and shoulder 46.In some cases, the part of precursor substrate 4 It can slightly be compressed between side wall 28 and shoulder 46, but less than the compression degree of the generation of roller 8,10 by Fig. 4.Therefore, first First central longitudinal axis 32 of roller can be into centre distance relative to the center of the second central longitudinal axis 32 of the second roller Row is adjusted, the decrement in part to determine the precursor substrate 4 between side wall 28 and shoulder 46.In some cases, it can be possible to It needs more to compress, and in other cases, it may be necessary to less compression.The thickness of precursor substrate 4 is also possible to set The factor the to be considered when center of fixed roll 8,10 is to centre distance.The center for setting roller can also be with to this concept of centre distance Suitable for any of other exemplary rollers as described herein construction.

As described above, the exemplary rollers of Figure 34 and 36 can be used for only forming three-D elements and compressional zone in precursor substrate 4 Domain.In addition, as described above, the exemplary rollers of Figure 35 and 37 can be used for only forming hole and constricted zone in precursor substrate 4.Cause This, has elaborated how to generate herein: 1) hole and constricted zone without or have limited three-D elements (see, for example, Figure 35 and 37)；2) three-D elements and constricted zone are without hole (see, for example, Figure 34 and 36)；3) three-D elements and hole and do not have Have or there is limited constricted zone (see, for example, Figure 38)；With 4) three-D elements, hole and constricted zone (see, for example, Fig. 4, 11、14、17)。

In the context of absorbent article, such as top flat substrate or top flat laminated base, it may be desirable to provide one Or multiple, two or more or three or more performance areas.As mentioned above, performance area can be designed in substrate Specific region in obtain certain result.For example, in top flat or absorbent article (for example, diaper, adult incontinence diapers or trousers) In context, the first performance area in the front area of top flat or absorbent article may be configured to receive and absorb urine and The second performance area in the Background Region of top flat or absorbent article can be designed for receiving and absorbing or keeping BM or dilute BM. Top flat or absorbent article can have central transverse, and front area can be located on the first side of central transverse, and Background Region can be located in second side of central transverse.As another example, in top flat or absorbent article (for example, female Sex hygiene pad) context in, first performance area can be with the central transverse and center longitudinal axis of top flat or absorbent article Line overlap, and the second performance area can surround first performance area.First performance area can be configured to receive and absorb through liquid And the second performance area can be configured to that first performance area will be led back to through liquid and prevent or at least inhibit through liquid from absorbent article Leakage.

Figure 39 is the top view with the exemplary precursors substrate 4 of three-D elements 54 formed therein.In Figure 39, three Element is tieed up to extend except page-out.Three-D elements 54 can have in about 1mm²To about 50mm², about 2mm²To about 50mm², about 2mm²Extremely About 25mm², about 2mm²To about 15mm², about 2mm²To about 10mm²In range or at least about 2mm²X-Y plane area, or extremely Few about 2mm2, specifically enumerates all 0.1mm in specified range and all ranges for being formed in wherein or being consequently formed² Increment.Figure 40 is the cross-sectional view of the precursor substrate 4 of Figure 39 of 40-40 interceptions along the line.Three-D elements 54 can have thickness C2, Its thickness C1 than the precursor substrate 4 before the roll gap that precursor substrate 4 is transmitted through between the first roller and the second roller 8,10 Big at least twice, it is at least three times greater, it is at least four times larger, but greatly less than 30 times.

Referring again to Figure 22, as an example, substrate 2 can have hole 56, which has in about 0.25mm²To about 50mm², about 0.5mm²To about 40mm², about 0.5mm²To about 30mm², about 0.5mm²To about 20mm², about 1mm²To about 15mm², about 1mm²To about 10mm²In the range of average cell size, specifically enumerate in specified range and be formed in wherein or thus shape At all ranges in all 0.1mm²Increment.

Figure 41-46 is in the exemplary substrate 200 wherein with one or more performances area.Performance area shown in figure is only It is only example, and it is at least 500mm that the disclosure, which covers area,²Or at least 1000mm²Any other suitable dimension and/or The performance area of suitable shape (from the perspective of X-Y plane).Less than 500mm²Or it is less than 1000mm²Other performance areas can also It is present in substrate.Performance area can respectively have at least one of following, both at least or all: 1) hole, and 2) compressional zone Domain and 3) three-D elements.Substrate 200 can respectively have central transverse 202 and central longitudinal axis 204.In the upper of top flat Hereinafter, top flat can have front area 206 and Background Region 208, and front area 206 is configured to be positioned at absorbent article In front waist region (that is, on the first side of the central transverse of absorbent article), Background Region 208 is configured to be positioned at absorption The back waist region (that is, in second side of the central transverse of absorbent article) of product.For example, top flat can be positioned at diaper, On trousers, adult incontinence products or sanitary napkin.

Referring to Figure 41, Liang Ge performance area may be present.Region except performance area can be without processing, i.e., they do not have Hole, constricted zone and three-D elements.Such untreated areas can still include such as figure, color, ink, surface-active Agent, hydrophobic treatment, hydrophilic treated and/or logo.Front area 206 may include the first performance area for being configured to receive urine 210, and Background Region 208 may include the second performance area 212 for being configured to receive BM or dilute BM.First performance area and second Performance area 210 and 212 can about substrate 200 central longitudinal axis 204 it is symmetrical.During first performance area 210 can not surround Heart transverse axis 202 and the second performance area 212 are symmetrical.It is flat that first performance area and the second performance area can have identical X---Y Face region or different X---Y plane domains.First performance area and the second performance area 210,212 can not overlap each other.Third Can be completely overlapped with one of first performance area and the second performance area 210,212 or partly overlap in performance area 214.It retouches herein Any performance area stated can be overlapped each other or can not be overlapped or partly overlap.

The performance area of the disclosure can have in about 100mm²To about 100,000mm², about 500mm²To about 100,000mm², about 750mm²To about 75,000mm², about 1,000mm²To about 75,000mm², about 2,000mm²To about 75,000², about 3,000mm²Extremely About 75,000mm², about 5000mm²To about 75,000mm²X-Y plane area, specifically enumerate in specified range and formation In all 0.1mm wherein or in all ranges for being consequently formed²Increment.Under any circumstance, performance area is likely less than top flat The gross area.

Referring to Figure 42, Liang Ge performance area be can reside in substrate 200.As described above, the region except Liang Ge performance area It can be without processing.It is symmetrical that second performance area 212 can be not in relation to central longitudinal axis 204, and first performance area 210 can be with It is symmetrical about central longitudinal axis 204.It first performance area 210 can not be with the second performance area 212 about central transverse 202 Symmetrically.

Referring to Figure 43, three performance areas be can reside in substrate 200.As described above, the region except three performance areas It can be without processing.First performance area 210 can be in front area 206, and the second performance area 212 can be in Background Region In 208, and third performance area 214 can part be in front area 206 and part is in Background Region 208.The primary Energy area, the second performance area and third performance area 210,212 and 214 may or may not be symmetrical about central longitudinal axis 204.The One performance area, the second performance area and third performance area 210,212 and 214 may or may not be right about central transverse 202 Claim.

Referring to Figure 44, a performance area 210 be can reside in substrate 200.As described above, the area outside performance area 210 It domain can be without processing.It performance area 210 may or may not be about central longitudinal axis 204 and/or central transverse 202 Symmetrically.Performance area 210 can be the center longitudinal band in substrate 200.Center longitudinal band can extend or can not extend The entire longitudinal length of substrate 200.Single performance area can have any suitable size and/or suitable shape, as long as its X-Y plane area is at least 500mm²Or at least 1000mm².

Referring to Figure 45, a performance area 210 be can reside in substrate 200.As described above, the area outside performance area 210 It domain can be without processing.It performance area 210 may or may not be about central longitudinal axis 204 and/or central transverse 202 Symmetrically.In one case, performance area 210 can be symmetrical about central longitudinal axis 204, but is not in relation to central transverse 202 is symmetrical.Performance area 210 can be positioned in the center vertical and horizontal region in substrate 200.Performance area 210 can not prolong Stretch the entire longitudinal length of substrate 200.Single performance area can have any suitable size and/or suitable shape, as long as Its X-Y plane area is at least 500mm²Or at least 1000mm².Single performance area can occupy the pact of such as substrate surface 10% to about 90%, about 20% to about 80%, about 30% to about 70%.

Referring to Figure 46, Liang Ge performance area 210 be can reside in substrate 200.As described above, the region except performance area can Without processing.First performance area 210 can be surrounded by the second performance area 212.First performance area and the second performance area 210, 212 may or may not be symmetrical about central longitudinal axis 204 and central transverse 202.

, with the roller of different tools, different performances can be formed in precursor substrate by using at different zones Area.Referring to Figure 47, roller 300 (and/or opposite roller) can be in not same district with the different configuration of tool shown in this article.Make For simple example, the first area 302 can have the roller tool of the first kind, and the second area 304 can have the roller of Second Type Tool, and third area 306 can have the roller tool of third type.First roller tool, the second roller tool and third roller tool In both at least can be different.For example, the first roller tool can be configured to define hole and constricted zone, the second roller work Tool can be configured to define three-D elements and constricted zone, and third roller tool can be configured to define three-D elements, Hole and constricted zone.As another example, one of the firstth area, the secondth area and third area 300,302,304 can not have There is roller tool, and can only have the radially-outer surface for not forming hole, constricted zone or three-D elements.First area 302 can be with The forming properties area in the front waist region (for example, 206) of top flat, the second area 304 can be formed with central transverse (for example, 202) intersect performance area, and third area 306 can in the back waist region (for example, 208) of top flat forming properties area.Roller 300 Complete rotation can form one or more top flats with performance area.

Various precursor substrates and/or substrate as described herein are also applied for being used to form the precursor substrate in performance area and have The substrate in performance area.For example, precursor substrate can be by one or more layers with same lateral width or different transverse widths It is formed.First layer can be continuous in a machine direction, and the second layer can be continuous or discrete in a machine direction 's.In some cases, performance area can be made only in the place of first layer and second layer overlapping, or one or more performances Area can be formed in the place of first layer and second layer overlapping, and one or more performance area can be formed in first layer and the In two layers of nonoverlapping region.

As described herein, it can heat, handle and/or cool down the various precursor substrates and/or substrate for performance area.With Roller in forming properties area can also be heated as described herein, handled and/or be cooled down.

Similarly, as described above, the substrate with performance area can also include the three dimensional indicia formed by the roller in roll gap.Mark Note may include one or more logos, brand name and/or figure, for example, as further described herein.For example, label It can be formed in the upstream of roll gap 6 formed between the first roller and the second roller 8,10 or the independent roll gap in downstream.

Referring to Figure 48, the schematic top view example diagram of the substrate 2 with various performance areas is shown.First performance area 400 can have high thickness three-D elements 554 and constricted zone and no hole.Second performance area 402 can have oversized hole 556, low thickness three-D elements 554 and constricted zone.Third performance area 404 can have oversized hole 556 and constricted zone but not With three-D elements.4th performance area 406 can have the hole 556 of high thickness three-D elements 554 and constricted zone and smaller size.

Referring to Figure 49, the schematic top view example diagram of the substrate 2 with various performance areas is shown.Performance area 500 It can all three-D elements 554 with high thickness, the hole 556 of smaller size and constricted zone.Region 558 in substrate 2 It can be plane (or untreated) and do not have any three-D elements 554, hole 556 or constricted zone.

Figure 50 is the schematic diagram of the method for the substrate 2 that manufacture has first layer 3 and the second layer 5, and wherein the second layer 5 includes more A discrete patch and be discontinuous in a machine direction.Figure 51 is that have first layer 3 by what the method for Figure 50 produced It is illustrated with the schematic top view of the substrate 2 of the second layer 5, wherein the second layer 5 includes multiple discrete patches.Figure 52 is to can be used for The cross section example of the first roller and the second roller 8,10 in the method for Figure 50.

Referring to Figure 50-52, for the reason of the cost savings, it may be desirable to production have continuous first layer 3 and it is multiple from Substrate of the scattered patch as the second layer 5.This method can carry out on absorbent article production line.For example, the second layer 5 can have Have than 3 higher quality of first layer, absorbability, flexibility, cost and/or base weight.When being cut into spacing appropriate, first layer 3 and the second layer 5 can be formed together the top flat of such as absorbent article.In other cases, when being cut into spacing appropriate, the Top flat can be formed for one layer 3, and the second layer 5 can form the capturing material in absorbent article.In first layer and the second layer 3,5 Each can be made of one or more non-woven materials, cellulosic material, woven material, film and/or other materials layer.

Method shown in Figure 50 can have with lower roll: rotor 600, vacuum anvil roll 602, the first roller 8 (with it is described herein Some are similar) and the second roller 10 (with described herein similar or identical).Rotor 600 may include the knife for being radially therefrom outer surface extension Piece 607.Various rollers can respectively rotate in direction shown in the arrow on the roller in Figure 50.Rotor 600 and vacuum anvil roll 602 can one It rises and forms roll gap 601 therebetween.Rotor 600 and vacuum anvil roll 602 can produce cutting and slide together, wherein the second layer 5 are admitted in roll gap 601 and are cut into discrete patches, so that the second layer 5 surrounds the one of the outer radial face of vacuum anvil roll 602 It is transmitted in a discontinuous manner part.Discrete patch is remained into vacuum anvil roll 602 using the vacuum provided by roller 602. For example, vacuum can be provided by vacuum pump.Then, the discrete patches of the second layer 5 are transmitted through in vacuum anvil roll 602 and The roll gap 603 formed among one roller 8.Then radially-outer surface that the discrete patches of the second layer 5 surround the first roller 8 rotates and is As shown in the example in Figure 52, the first roller is remained to by vacuum 610.First roller and the second roller 8,10 can with it is as described herein It is identical, the difference is that conduit 612 is provided in the first roller 8 to allow to be supplied to the negative of the radially-outer surface of the first roller 8 Fluid pressure.For example, vacuum can be provided by vacuum pump.If necessary to blow out, the conduit 612 of the first roller 8 can also be used for mentioning For positive fluid pressure.

Once the discrete patches for forming the second layer 5 now are transmitted around a part of the radially-outer surface of the first roller 8, then They can be sent in the roll gap 611 formed among the first roller and the second roller 8,10.In roll gap 611, the second layer 5 The first roller can be used in discrete patches and the second roller 8,10 (as described herein) is combined with first layer 3.First roller and the second roller 8, 10 can form hole, compression in the overlapping region in the discrete patches of the second layer 5 and between discrete patches and first layer 3 Region and/or three-D elements.The region Chong Die with the second patch 5 not may or may not have hole, compression in first layer 3 Region and/or three-D elements.It can be in the overlapping region between the discrete patches and first layer 3 of the second layer 5 or in the second layer 5 Discrete patches and first layer 3 between in unfolded region forming properties area (as discussed herein).

Referring to Figure 51, the discrete patches of the second layer 5 can have transverse direction width, the transverse direction width and first layer 3 transverse direction is of same size or transverse direction width less than first layer 3.Discrete patches may or may not have Rectangular shape.After manufacturing substrate 2 by the method for Figure 50, substrate 2 can be cut into suitable spacing to be used to be incorporated to In absorbent article.For example, substrate 2 can be cut along cutting line 614.

Figure 53 shows transversal with the simplified schematic of a part of a part of intermeshing first roller 8 of the second roller 10 Face example diagram.Figure 53 A is the exploded view of the region 39A in Figure 53.Second roller 10 can be with the second roller 10 of Figure 37 or Figure 38 It is essentially identical or identical.At least some of protrusion 20 all may include the first distal part 24, the first distal part 24 packet Include the elongate aperture structure comprising side wall 28.Side wall 28 can have first part 150 with first angle and have second jiao The second part 152 of degree.Central longitudinal axis 32 (see, for example, Fig. 9 A and Figure 53) measurement angle relative to protrusion 20.Second It part 152 can be than first part 150 closer to the first distal end 26 or tip.First angle can lower than second angle or Person is steeper than second angle.The first angle of first part 150 can about 20 degree to about 50 degree, about 25 degree to about 40 degree, about In the range of 30 degree to about 40 degree, about 35 degree, about 36 degree or about 37 degree, specifically enumerates in specified range and be formed in wherein Or all 0.1 degree of increments in all ranges being consequently formed.The second angle of second part 152 can be at about 30 degree to about 60 In the range of degree, about 35 degree to about 55 degree, about 40 degree to about 50 degree, about 46 degree, about 47 degree or about 48 degree, specifically enumerates and referring to Determine range and all ranges for being formed in wherein or being consequently formed in all 0.1 degree of increments.By in first part 150 There is biggish angle and less steep side wall with lesser angle or steeper side wall and in second part 152, with Protrusion with the first distal part for only having an angle is compared, and total longitudinal length of protrusion 20 can be shorter.Shorter Protrusion allows to be easier between the first roller and the second roller 8,10 to engage.Any exemplary rollers for being configured for aperture can have With reference to the feature of Figure 53 and 53A multiple first protrusions 20 described in this paragraph.In addition, the feature of multiple first protrusions 20 can To use (for example, Figure 35 and 37) when only forming hole rather than three-dimensional protrusion.

Shoulder 46 can towards multiple first protrusions 20 tip inward it is tapered, or can have and first part 150 Identical angle.

Various rollers can be by with thermal conductive resin and being easy to mach material and being formed.Examples material includes for example Copper, aluminium and brass.In some cases, roller can be steel or hardened steel.Roller can have various surface coverings to reduce abrasion.

Figure 54 is the top view of a part of exemplary first roller 8 of a pair of rolls of Fig. 1.Figure 54 A is the line along Figure 54 The cross-sectional view of a part of first roller 8 of a pair of rolls of Fig. 1 of 54A-54A interception.First roller 8 may include multiple first protrusions 20, multiple first recessed portions 22 and the first radially-outer surface 16.Multiple first protrusions 20 can respectively include the base comprising sidewall 34 Portion 30.At least some or most of of multiple first protrusions 20 can respectively include the first distal part 24, the first distal part 24 The first distal end 26 including forming tip.Term " tip " defines herein.Multiple first protrusions 20 can respectively include Central longitudinal axis 32.First distal part 24 may include side wall 28.Side wall 28 can have in the first part close to base portion 30 There is first angle A, and there is second angle B in the second part far from base portion 30.First angle and second angle all phases For central longitudinal axis 32.First angle A can be at about 5 degree to about 60 degree, about 10 degree to about 50 degree, about 10 degree to about 40 Degree, about 10 degree to about 35 degree, about 10 degree to about 30 degree, about 10 degree to about 25 degree, about 15 degree to about 21 degree or about 18 degree of range It is interior, specifically enumerate all 0.1 degree of increments in specified range and all ranges for being formed in wherein or being consequently formed.The Two angle Bs can be at about 15 degree to about 70 degree, about 15 degree to about 50 degree, about 15 degree to about 40 degree, about 20 degree to about 40 degree, about 25 It spends in the range of about 35 degree, about 27 degree to about 29 degree or about 28 degree, specifically enumerates in specified range and be formed in wherein Or all 0.1 degree of increments in all ranges being consequently formed.

Figure 55 is the top view of a part of exemplary second roller 10 of a pair of rolls of Fig. 1.Figure 55 A is the line along Figure 55 The cross-sectional view of a part of the second roller 10 of 55A-55A interception.Second roller 10 may include multiple second protrusions 36, multiple second recessed Concave portion 38 and the second radially-outer surface 18.Multiple second protrusions 36 may include the base portion 44 comprising side wall.Multiple second lug bosses At least some of 36 or most of can respectively include the second distal part 40, which includes the second distal end portion Portion 42.Second distal end can be flat or substantially flat, or may include arcuate section or individual dome-like structures. Multiple second protrusions 36 can respectively include central longitudinal axis 48.Second distal part 40 may include shoulder 46.Shoulder 46 can be There is first angle C in the first part of base portion 44, and there is second angle in the second part far from base portion 44 D.First angle and second angle are both relative to central longitudinal axis 48.First angle C can be at about 2 degree to about 50 degree, about 2 degree To about 40 degree, about 2 degree to about 30 degree, about 2 degree to about 20 degree, about 5 degree to about 20 degree, about 5 degree to about 15 degree, about 8 degree to about 12 Degree or about 10 degree in the range of, specifically enumerate in specified range and all ranges for being formed in wherein or being consequently formed All 0.1 degree of increments.Second angle D can be at about 2 degree to about 50 degree, about 2 degree to about 40 degree, about 2 degree to about 30 degree, about 2 It spends in the range of about 20 degree, about 3 degree to about 20 degree, about 3 degree to about 15 degree, about 5 degree to about 10 degree or about 7 degree, specifically arranges Lift all 0.1 degree of increments in specified range and all ranges for being formed in wherein or being consequently formed.

According to information and conviction, in certain cases, it may be desirable to keep first angle A different with first angle C, to allow The constricted zone for more concentrating (smaller) is formed in the substrate among the shoulder 46 and side wall 28 of the first distal part 24.In other words Say, have different first angle A and first angle C can make constricted zone formed cyclic structure, this with work as angle A and C phase With or part conic structure when essentially identical (for example, within several years) compared with.If first angle A is identical with first angle C Or it is essentially identical, then the constricted zone formed in the substrate can be bigger, so as to influence the pliability for being formed by substrate. Constricted zone with cyclic structure can provide the improved pliability for being formed by substrate.

Figure 56 is the package configuration of one or more substrates of various first rollers and the second roller 8,10 across the disclosure Example.First roller 8 can be rotated around first rotation 12 in the direction of the arrow.Second roller 10 can be in arrow institute The side shown is rotated upward around the second rotation axis 14.Before entering roll gap 6, precursor substrate 4 is passed partially around the first roller 8 It send.This allows precursor substrate 4 to lock on the first roller 8 in place, because multiple first protrusions 20 and its first distal end 26 are pierced Wear precursor substrate 4.Then, precursor substrate 4 is transmitted through roll gap 6, is then transmitted, is made at least partly around the second roller 10 The substrate 2 that must be formed keeps engaging with multiple second protrusions 36 on the second roller 10, and three-dimensional structure is locked to the base to be formed In bottom 2.Such package configuration can be described as " S-shaped package " configuration.As discussed herein, the first roller and second can be heated Roller 8,10 and/or precursor substrate 4 are to help to form substrate 2.Any one of first roller and the second roller as described herein can be with Using this package configuration or using Figure 57 exemplary package configuration or such as institute in the example of fig. 1 can be transmitted through The roll gap shown.Other wrap up configurations also within the scope of this disclosure.

Figure 57 is the package configuration by one or more substrates of various first rollers and the second roller 8,10 of the disclosure Another example.First roller 8 can be rotated around first rotation 12 in the direction of the arrow.Second roller 10 can be in arrow It is just rotated upward around the second rotation axis 14 shown in head.Before entering roll gap 6, precursor substrate 4 is partially around first Roller 8 is transmitted.This allows precursor substrate 4 to lock on the first roller 8 in place, because of multiple first protrusions 20 and its first distal end portion Pierce through precursor substrate 4 in portion 26.Then, precursor substrate 4 is transmitted through roll gap 6, then at least partly around 10 quilt of the second roller Three-dimensional structure is locked to shape so that the substrate 2 formed keeps engaging with multiple second protrusions 36 on the second roller 10 by transmission At substrate 2 in.As discussed herein, the first roller and the second roller 8,10 and/or precursor substrate can be heated to form base to help Bottom 2.

Method

The present invention provides a kind of method that substrate is formed on absorbent article production line.This method may include in absorbent article Precursor substrate is transmitted on production line in a machine direction, provides the first roller with first rotation, and provide with second Second roller of rotation axis.First rotation and the second rotation axis can be generally parallel to each other or be positioned in an essentially parallel manner, To form roll gap between the first roller and the second roller.This method may include that precursor substrate is transported through roller in a machine direction Gap is to form two different performance areas.Each performance area or some performance areas can have at least the two or complete in following Portion: a) three-D elements, b) hole and c) constricted zone.Before precursor substrate is transmitted through roll gap, in three-D elements at least Can largely or entirely have the thickness of at least twice bigger than the thickness of precursor substrate.Three-D elements or some three-D elements can have There is at least 2mm²X-Y plane region.Hole can have at least 0.5mm²To about 20mm²Average cell size.This method may include Substrate is cut into the required spacing of absorbent article, and the substrate of cutting is applied to absorbent article.For example, substrate can be top Piece, and absorbent article can be diaper, trousers, adult incontinence products or sanitary napkin.At least one performance area or all properties area There can be at least 1000mm²X---Y plane domain.

First roller may include the first radially-outer surface, from the first radially-outer surface it is outwardly extending it is multiple first protrusion, with And it is limited to multiple first recessed portions in the first radially-outer surface.Second roller may include the second radially-outer surface, from the second diameter Multiple second recessed portions exterior surface outwardly extending multiple second protrusions and be limited in the second radially-outer surface.It should Method may include engaging the part of multiple first protrusions with intermeshing with the part of multiple second recessed portions, and make more The part of a second protrusion engages with intermeshing with the part of multiple first recessed portions.At least some of multiple first protrusions Or whole may include the first distal part to form elongate aperture structure.First distal end of the first distal part can form point It holds (as described herein).Multiple first protrusions can have the first central longitudinal axis.Elongate aperture structure may include one or more A side wall.The part of side wall can have first jiao relative to central longitudinal axis in the range of about 5 degree to about 40 degree It spends (or other angles as described herein).At least some of multiple second protrusions may include all the second distal part.It is more At least some of a second protrusion may include shoulder.Multiple second protrusions may include the second central longitudinal axis.The portion of shoulder It point can have second angle (or this paper institute relative to the second central longitudinal axis in the range of about 3 degree to about 20 degree The other angles stated).First angle can be identical or essentially identical with second angle, as described herein.In second distal end It is at least some may include flat, substantially flat and/or bowed surface.

At least some of multiple first protrusions all may include having along the direction interception perpendicular to machine direction First base portion of the first width.At least some of multiple second protrusions all may include along the direction perpendicular to machine direction The second base portion with the second width of interception.Second width can be greater than, be less than or equal to the first width.Multiple first recess At least some of portion or the first width all intercepted with edge perpendicular to the direction of machine direction.In multiple second recessed portions It is at least some or all with along perpendicular to machine direction direction interception the second width.First width can be greater than, and be less than Or it is equal to the second width.

Precursor substrate may include first layer and the second layer.First layer has the along the direction interception perpendicular to machine direction One width.The second layer has the second width along the direction interception perpendicular to machine direction.It is wide that first width can be greater than second Degree.This method may include include make precursor substrate and it is multiple first protrusion parts, the part of multiple first recessed portions, Duo Ge The part of two protrusions and the part of multiple second protrusions are contacted substantially only in the second layer with the place that first layer is overlapped.First layer It can be continuous in a machine direction, and the second layer can be continuous or discrete in a machine direction.

This method may include the part for making precursor substrate and multiple first protrusions, the part, multiple of multiple first recessed portions The part of second protrusion and the part of multiple second protrusions are contacted only along the center strip of precursor substrate.Center strip can be It is continuous in machine direction.This method may include the basad application processing after substrate to be transported through to roll gap.This method can Heating precursors substrate before roll gap is transmitted through to be included in precursor substrate.This method may include the first roller of heating and/or the Two rollers.This method may include the precursor substrate heated in roll gap.This method may include in a machine direction passing precursor substrate It send through roll gap to form one or more, two or more or three or more different performance areas.

This method may include that precursor substrate is transported through roll gap to form one or more three dimensional indicia/labels.Example Such as, label may include logo, brand name and/or figure.Label (indicia/indicium) can reside in various performances In area or it is present in the region of substrate in no performance area.

Dimension disclosed herein and value are not understood as being strictly limited to cited exact numerical.On the contrary, unless in addition It indicates, otherwise each such dimension is intended to indicate that described value and the range functionally equivalent around the value.For example, being disclosed as The dimension of " 40mm " is intended to indicate that " about 40mm ".

Unless expressly excluded or in other words it is limited, otherwise by every herein cited document, including any intersection Reference or related patents or application, full text are herein incorporated by reference.Reference to any document is not to recognize that it is The prior art of disclosed herein or claimed any embodiment or recognize its independently or with it is any Any combination of mode of other one or more bibliography proposes, suggests or discloses any such embodiment.In addition, working as Any meaning of term or any meaning or definition of definition and same term in document incorporated by reference in the present invention When contradiction, the meaning or definition for assigning the term in the present invention should be obeyed.

Although the specific embodiment of the disclosure has had been illustrated and described, for those skilled in the art It is readily apparent that in the case where not departing from the spirit and scope of the disclosure, many other variations and modifications may be made.Cause This, is intended to all such changes and modifications for covering in the appended claims and belonging in the scope of the present disclosure.