阅读说明：本技术 三维基底 (Three-dimensional substrate ) 是由 O.E.伊泽勒 J.安德斯 G.厄登 R.罗萨蒂 P.T.威斯曼 S.A.杨 M.P.伯 于 2015-03-02 设计创作，主要内容包括：本发明公开了一种用于吸收制品的液体可透过的基底。所述基底包括含有疏水性材料的第一层和含有亲水性材料的第二层。所述第一层接合至所述第二层。所述基底包括多个凹陷部、多个突出部、以及多个着陆区。所述着陆区围绕至少大部分的多个突出部和多个凹陷部。所述多个凹陷部、多个突出部、以及多个着陆区一起形成所述基底的第一侧上的第一三维表面和所述基底的第二侧上的第二三维表面。所述基底具有根据总体基底高度测试在约1000μm至约6000μm范围内的总体z方向高度。(A liquid permeable substrate for an absorbent article is disclosed. The substrate includes a first layer comprising a hydrophobic material and a second layer comprising a hydrophilic material. The first layer is bonded to the second layer. The substrate includes a plurality of recesses, a plurality of protrusions, and a plurality of landing zones. The landing zone surrounds at least a majority of the plurality of projections and the plurality of recesses. The plurality of recesses, the plurality of protrusions, and the plurality of land areas together form a first three-dimensional surface on a first side of the substrate and a second three-dimensional surface on a second side of the substrate. The substrate has an overall z-direction height in a range of about 1000 μm to about 6000 μm according to the overall substrate height test.)

1. An absorbent article comprising

A topsheet;

a negative film; and

an absorbent core disposed at least partially intermediate the topsheet and the backsheet, wherein the absorbent core comprises an absorbent material comprising at least 80% superabsorbent polymers by weight of the absorbent material,

wherein the topsheet comprises a liquid permeable substrate comprising:

a first layer comprising a hydrophobic material; and

a second layer comprising a hydrophilic material, wherein the first layer is bonded to the second layer;

wherein the substrate comprises a plurality of recesses, a plurality of protrusions, and a plurality of land areas, wherein the land areas surround at least a majority of the plurality of protrusions and a plurality of the recesses, wherein the plurality of recesses, the plurality of protrusions, and the plurality of land areas together form a first three-dimensional surface on a first side of the substrate and a second three-dimensional surface on a second side of the substrate, wherein a majority of the protrusions have a z-direction height in a range of 500 μ ι η to 4000 μ ι η according to the protrusion height test, wherein a majority of the recesses define apertures at locations furthest from the top peaks of adjacent protrusions, and wherein the majority of the recesses have a z-direction height in a range of 500 μ ι η to 2000 μ ι η according to the recess height test;

wherein the substrate has an overall z-direction height in the range of 1000 μm to 6000 μm according to the overall substrate height test,

wherein the rows of apertures and rows of projections are staggered;

wherein four apertures are formed around each projection, and wherein four projections are formed around each aperture; and is

Wherein the substrate has a basis weight of not less than 30gsm according to the basis weight test.

2. The absorbent article of claim 1, wherein a majority of the apertures have an aperture test of at 0.5mm²To 3mm²An effective pore area in the range, and wherein the substrate has an effective open area% in the range of 5% to 25% according to the pore test.

3. The absorbent article of claim 1 or 2, wherein a portion of the protrusion and a portion of the depression are formed by a portion of the first layer and a portion of the second layer.

4. The absorbent article of claim 1 or 2, wherein the first layer is joined to the second layer by adhesive bonding, by mechanical bonding, or by passing hot air through the substrate.

5. The absorbent article of claim 1 or 2, wherein the first layer comprises a plurality of first fibers, wherein the second layer comprises a plurality of second fibers, and wherein the first fibers and the second fibers are different.

6. The absorbent article of claim 1 or 2, wherein two adjacent apertures are separated by a protrusion and a landing zone along a lateral axis or a longitudinal axis of the substrate, and wherein two adjacent protrusions are separated by an aperture and a landing zone along the lateral axis or the longitudinal axis of the substrate.

7. The absorbent article of claim 1 or 2, wherein substantially all of the protrusions comprise hollow arcuate portions.

8. The absorbent article of claim 1 or 2, wherein the apertures comprise a first set of apertures that together form a first line in the substrate and a second set of apertures that together form a second line in the substrate, and wherein the first line is substantially parallel to the second line.

9. The absorbent article according to claim 1 or 2, wherein the majority of the perimeter of the apertures forms a first plane of a lowermost portion of the substrate, wherein the majority of the peaks of the protrusions form a second plane of an uppermost portion of the substrate, and wherein the landing zone is positioned intermediate the first plane and the second plane.

10. The absorbent article of claim 1 or 2, wherein the first three-dimensional surface has a geometric roughness value in a range of 3.0 to 3.6 according to the descriptive analysis roughness test.

11. The absorbent article of claim 1 or 2, wherein the first layer comprises fibers having a denier in the range of 2 to 4, wherein the second layer comprises fibers having a denier in the range of 1.5 to 3, wherein the first layer comprises fibers at least 0.5 denier greater than the fibers of the second layer, and wherein the basis weight of the first layer is in the range of at least 1 to 3 times the basis weight of the second layer.

12. The absorbent article of claim 1 or 2, wherein the substrate comprises cotton fibers.

13. The absorbent article of claim 1, wherein the absorbent core comprises an absorbent material comprising at least 90% superabsorbent polymers by weight of the absorbent material.

14. A package comprising a plurality of the absorbent articles of claim 1, wherein the package has an in-bag stack height of less than 80mm according to the in-bag stack height test.

15. The absorbent article of claim 1, wherein the absorbent article has a relative humidity of less than 70% according to the humidity test and less than 6,500g/m according to the water vapor transmission rate test²WVTR values for days.

16. The absorbent article of claim 1, wherein the absorbent article has a relative humidity of less than 60% according to the humidity test and less than 14,500g/m according to the water vapor transmission rate test²WVTR values for days.

17. The absorbent article according to claim 1 or 2, wherein the absorbent core comprises less than 5 wt.% cellulose fibers.

18. The absorbent article according to claim 1 or 2, wherein the absorbent core comprises less than 1 wt% cellulosic fibers.

Technical Field

The present disclosure relates generally to three-dimensional substrates, and more particularly to three-dimensional substrates for absorbent articles and/or to absorbent articles including three-dimensional substrates. The three-dimensional substrate may comprise a liquid permeable substrate.

Background

Absorbent articles for personal hygiene, such as disposable diapers for infants, training pants for toddlers, adult incontinence undergarments, and/or sanitary napkins, are designed to absorb and contain body exudates, especially large amounts of urine, thin fecal waste, and/or menses (collectively, "fluids"). These absorbent articles may comprise several layers providing different functions, such as a topsheet, a backsheet and an absorbent core disposed between the topsheet and the backsheet, and other layers, if desired.

The topsheet is generally liquid permeable and is configured to receive fluid being discharged from the body and to help direct the fluid toward the acquisition and/or distribution system and/or toward the absorbent core. Generally, the topsheet is made hydrophilic by a surfactant treatment applied to the topsheet such that fluid is drawn to the topsheet and then directed into the underlying acquisition and/or distribution system and/or absorbent core. One of the important qualities of a topsheet is the ability to reduce the pooling of fluid on the topsheet before it can be absorbed by the absorbent article. In other words, one design criterion of the topsheet is to reduce the amount of time fluid spends on the topsheet before being absorbed by the absorbent article. If the fluid remains on the surface of the topsheet for an extended period of time, the wearer may not feel dry and discomfort may be increased.

To address the problem of the wearer's skin feeling wet during, for example, a urination event due to prolonged residence of fluid on the topsheet, apertured topsheets have been used to allow faster penetration of fluid into the absorbent article. Although apertured topsheets have generally reduced fluid duration on the topsheet, the topsheet can be further improved by providing a three-dimensional substrate that further reduces skin/fluid contact and/or skin/fluid contact time during, for example, a urination event.

Disclosure of Invention

The present disclosure relates in general part to three-dimensional substrates that may be applied to a topsheet of an absorbent article, form part or all of a topsheet, or form other portions of an absorbent article. The three-dimensional substrate can be a liquid permeable substrate. The three-dimensional substrates of the present disclosure may reduce fluid/skin contact and/or fluid/skin contact time by providing a first element having a first z-direction height and at least a second element having a second z-direction height. These substrates may also include pores. The first z-direction height may be generally higher than the second z-direction height. This structure produces a substrate with multiple heights. These three-dimensional substrates may allow fluid to be received onto the substrate and moved into a second element having a second z-direction height (lower) and/or into and through the aperture during, for example, a urination event to at least reduce the amount of fluid in contact with the skin and/or to at least reduce the fluid/skin contact time. In other words, a first element having a first z-direction height (higher) may be in contact with the skin, while fluid moves by gravity into a second element having a second z-direction height (lower) and/or into and through the aperture. According to information and beliefs, such three-dimensional structures reduce the amount of fluid on the skin, give the wearer a drier, more comfortable feel, and/or reduce the duration of fluid/skin contact. The first element having a first z-direction height (higher) essentially serves to provide a spacer between the skin and the fluid when the substrate directs the fluid into the acquisition and/or distribution system and/or the absorbent core.

Drawings

The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of the disclosure taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a top view of an absorbent article with some layers partially removed according to the present disclosure, with the wearer-facing surface facing the viewer;

FIG. 2 is a cross-sectional view of an absorbent article taken about line 2-2 of FIG. 1 according to the present disclosure;

FIG. 3 is a cross-sectional view of an absorbent article taken about line 2-2 of FIG. 2, wherein the absorbent article has been loaded with a fluid, according to the present disclosure;

FIG. 4 is a top view of another absorbent article with portions removed, wherein the wearer-facing surface faces the viewer, according to the present disclosure;

FIG. 5 is a cross-sectional view of an absorbent article taken about line 5-5 of FIG. 4 according to the present disclosure;

FIG. 6 is a top view of an absorbent core of the absorbent article of FIG. 4 with some layers partially removed according to the present disclosure;

FIG. 7 is a cross-sectional view of the absorbent core taken about line 7-7 of FIG. 6 according to the present disclosure;

FIG. 8 is a cross-sectional view of the absorbent core taken about line 8-8 of FIG. 6 according to the present disclosure;

FIG. 9 is a top view of an absorbent article, wherein the wearer-facing surface faces the viewer, the absorbent article being a sanitary napkin with layers cut away according to the present disclosure;

FIG. 10 is a top view of an absorbent article with a wearer-facing surface facing the viewer, the absorbent article comprising a liquid permeable three-dimensional substrate according to the present disclosure;

FIG. 11 is a perspective view of the absorbent article of FIG. 10 according to the present disclosure;

FIG. 12 is an enlarged top view of a portion of the liquid permeable substrate of FIG. 10 according to the present disclosure;

FIG. 13 is another enlarged top view of a portion of the liquid permeable substrate of FIG. 10 according to the present disclosure;

FIG. 14 is a schematic view of a liquid permeable three-dimensional substrate positioned and/or joined to a topsheet for an absorbent article according to the present disclosure;

FIG. 15 is another schematic view of a liquid permeable three-dimensional substrate positioned and/or joined to a topsheet for an absorbent article according to the present disclosure;

FIG. 16 is another schematic view of a liquid permeable three-dimensional substrate positioned and/or joined to a topsheet for an absorbent article according to the present disclosure;

FIG. 17 is a front view of a portion of a liquid permeable three-dimensional substrate according to the present disclosure with the wearer-facing surface facing the viewer;

FIG. 18 is a front perspective view of a portion of the liquid permeable three-dimensional substrate of FIG. 17 according to the present disclosure;

FIG. 19 is another front view of a portion of a liquid permeable three dimensional substrate according to the present disclosure with the wearer facing surface facing the viewer;

FIG. 20 is a front perspective view of a portion of the liquid permeable substrate of FIG. 19 according to the present disclosure;

FIG. 21 is a rear view of a portion of a liquid permeable three dimensional substrate according to the present disclosure with the wearer facing surface facing the viewer;

FIG. 22 is a rear perspective view of a portion of the liquid permeable three-dimensional substrate of FIG. 21 according to the present disclosure;

FIG. 23 is another back view of a portion of a liquid permeable three-dimensional substrate according to the present disclosure with the wearer-facing surface facing the viewer;

FIG. 24 is a rear perspective view of a portion of the liquid permeable substrate of FIG. 23 according to the present disclosure;

FIG. 25 is a cross-sectional view of a liquid permeable substrate according to the present disclosure;

FIG. 26 is a schematic view of an exemplary method for forming the substrate of the present disclosure;

FIG. 27 is a view of the intermeshing engagement of portions of a first roller and a second roller according to the present disclosure;

FIG. 28 is a view of a portion of a first roller according to the present disclosure;

fig. 29 is a view of a portion of a second roller according to the present disclosure;

fig. 30 is a side view of a package of absorbent articles according to the present disclosure. For clarity, the outer surface is shown as transparent;

FIG. 31 is a front view of a mannequin for use in the wetness test herein; and is

Figure 32 is a side view of the mannequin of figure 31.

Detailed Description

Various non-limiting forms of the present disclosure will now be described in order to provide a general understanding of the structural principles, functions, manufacture, and uses of the three-dimensional substrates disclosed herein. One or more examples of these non-limiting embodiments are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the three-dimensional substrates described herein and illustrated in the drawings are non-limiting exemplary forms and that the scope of the various non-limiting forms of the present disclosure is defined solely by the claims. Features shown or described in connection with one non-limiting form may be combined with features of other non-limiting forms. Such modifications and variations are intended to be included within the scope of the present disclosure.

Introduction to the design reside in

As used herein, the term "absorbent article" refers to disposable devices, such as infant, child or adult diapers, adult incontinence products, training pants, sanitary napkins and the like, which are placed against or in proximity to the body of the wearer to absorb and contain various fluids (urine, menses, and/or runny fecal waste) or body exudates (typically solid fecal waste) discharged from the body. Typically these absorbent articles comprise a topsheet, a backsheet, an absorbent core, optionally an acquisition system and/or a distribution system (which may be composed of one or several layers), and often other components, wherein the absorbent core is typically at least partially placed between the backsheet and the acquisition and/or distribution system or between the topsheet and the backsheet. The absorbent articles of the present disclosure comprising a liquid permeable three-dimensional substrate will be further described in the following description and the accompanying drawings in the form of one or more components of a taped diaper. However, this description should not be taken as limiting the scope of the claims. Accordingly, the present disclosure is applicable to any suitable form of absorbent article (e.g., diapers, training pants, adult incontinence products, sanitary napkins).

As used herein, the term "nonwoven web" refers to a manufactured sheet, web or batt of directionally or randomly oriented fibers bonded by friction and/or cohesion and/or adhesion, or felted by wet-milling, excluding paper and products which are woven, knitted, tufted, stitch-bonded incorporating binding yarns or filaments, whether or not additionally needled. These fibers may be of natural or man-made origin and may be staple or continuous filaments or in situ formed fibers. Commercially available fibers range in diameter from less than about 0.001mm to greater than about 0.2mm and can take several different forms, such as short fibers (known as chemical staple fibers or chopped fibers), continuous single fibers (filaments or monofilaments), untwisted continuous filament bundles (tows), and twisted continuous filament bundles (yarns). Nonwoven webs can be formed by a number of processes such as, for example, melt blowing, spunbonding, solution spinning, electrospinning, carding, and airlaying. The basis weight of nonwoven webs is typically in grams per square meter (g/m)²Or gsm) representation.

As used herein, the terms "engage," "bond," or "attach" encompass configurations in which an element is directly secured to another element by attaching the element directly to the other element, and configurations in which an element is indirectly secured to another element by attaching the element to intermediate members which in turn are attached to the other element.

As used herein, the term "machine direction" or "MD" is the direction substantially parallel to the direction of travel of the substrate when it is manufactured. The "cross direction" or "CD" is the direction substantially perpendicular to the MD and within the plane generally defined by the substrate.

As used herein, The term "hydrophilic" refers to a material having a Contact Angle of less than or equal to 90 ° according to The American Chemical Society Publication "Contact Angle, wetability, and addition," edited by Robert f.

As used herein, The term "hydrophobic" refers to a material or layer having a Contact Angle greater than or equal to 90 ° according to The American Chemical Society Publication "Contact Angle, wetability, and addition," edited by Robert f.

General description of absorbent articles

An example of an absorbent article in the form of a diaper 20 is shown in figures 1-3. FIG. 1 is a plan view of an exemplary diaper 20 in a flat-out state with portions of the structure being cut-away to more clearly show the construction of the diaper 20. The wearer-facing surface of the diaper 20 of figure 1 faces the viewer. This diaper 20 is shown for illustration purposes only, as the three-dimensional substrates of the present disclosure may be used as one or more components of an absorbent article.

The absorbent article 20 may comprise a liquid pervious topsheet 24, a liquid impervious backsheet 25, an absorbent core 28 positioned at least partially intermediate the topsheet 24 and the backsheet 25, and barrier leg cuffs 34. The absorbent article may also include an acquisition and/or distribution system ("ADS") 50, which in the example shown includes a distribution layer 54 and an acquisition layer 52, which will be described further below. The absorbent article may further comprise an elasticized gasketing cuff 32 comprising an elastic component 33 joined to the chassis of the absorbent article, typically via a topsheet and/or a backsheet, and substantially planar with the chassis of the diaper.

The figures also show typical taped diaper components, such as a fastening system comprising tabs 42 attached towards the rear edge of the article and cooperating with landing zones 44 on the front of the absorbent article. The absorbent article may also include other typical elements not shown, such as a back elastic waist feature, a front elastic waist feature, one or more lateral barrier cuffs, and/or a lotion application.

The absorbent article 20 includes a front waist edge 10, a back waist edge 12 longitudinally opposing the front waist edge 10, a first side edge 3, and a second side edge 4 laterally opposing the first side edge 3. The front waist edge 10 is the edge of the article intended to be placed towards the front of the user when worn, and the back waist edge 12 is the opposite edge. The absorbent article may have a longitudinal axis 80 extending from the lateral midpoint of the front waist edge 10 to the lateral midpoint of the back waist edge 12 of the article and dividing the article into two substantially symmetrical halves with respect to the longitudinal axis 80, wherein the article is laid flat and as viewed from above in figure 1. The absorbent article may also have a lateral axis 90 extending from the longitudinal midpoint of the first side edge 3 to the longitudinal midpoint of the second side edge 4. The length L of the article can be measured along the longitudinal axis 80 from the front waist edge 10 to the back waist edge 12. The width W of the article may be measured along the lateral axis 90 from the first side edge 3 to the second side edge 4. The article may include a crotch point C, defined herein as the point disposed on the longitudinal axis at a distance of two-fifths (2/5) L from the front edge 10 of the article 20. The article may comprise a front waist region 5, a back waist region 6, and a crotch region 7. The front waist region 5, the back waist region 6, and the crotch region 7 each define 1/3 of the longitudinal length L of the absorbent article.

The topsheet 24, backsheet 25, absorbent core 28 and other article components may be assembled in a variety of configurations, particularly by gluing or hot embossing, for example. Exemplary absorbent article configurations are generally described in U.S. Pat. nos. 3,860,003, 5,221,274, 5,554,145, 5,569,234, 5,580,411; and in us patent 6,004,306.

The absorbent core 28 may comprise an absorbent material comprising at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or at least 99 wt.% of an absorbent material and a core wrap enclosing the superabsorbent polymer. The core wrap may generally comprise two materials, base or nonwoven materials 16 and 16', for the top and bottom sides of the core. The core may include one or more channels, shown in fig. 1 as four channels 26, 26 'and 27, 27'. Channels 26, 26 ', 27 and 27' are optional features. Rather, the core may have no optional channels or may have any number of channels.

These and other components of the exemplary absorbent article will now be discussed in more detail.

Topsheet

In the present disclosure, the topsheet (the portion of the absorbent article that contacts the skin of the wearer and receives fluid) may be formed from a portion or all of one or more of the three-dimensional substrates described herein and/or have one or more three-dimensional substrates positioned thereon and/or joined thereto such that the one or more three-dimensional substrates contact the skin of the wearer. Other portions of the topsheet (other than the three-dimensional substrate) may also contact the wearer's skin. Exemplary topsheets are described below, but it should be understood that the topsheet 24 or portions thereof may be replaced by the three-dimensional substrates described herein. Alternatively, the three-dimensional substrate may be positioned as a strip or patch on top of a typical topsheet 24, as described herein.

The topsheet 24 may be the portion of the absorbent article that contacts the wearer's skin. The topsheet 24 may be joined to the backsheet 25, the core 28, and/or any other layers, as is well known to those skilled in the art. Typically, the topsheet 24 and the backsheet 25 are joined directly to each other at some locations (e.g., at or near the periphery of the absorbent article) and are joined indirectly together by directly joining them to one or more other elements of the article 20 at other locations.

The topsheet 24 may be compliant, soft feeling, and non-irritating to the wearer's skin. Further, a portion or the entirety of the topsheet 24 may be liquid pervious, permitting liquids to readily penetrate through its thickness. Suitable topsheets can be made from a wide variety of different materials, such as porous foams, reticulated foams, open-cell plastic films, or woven or nonwoven materials of natural fibers (e.g., wood or cotton fibers), synthetic fibers or filaments (e.g., polyester or polypropylene fibers or PE/PP bicomponent fibers or mixtures thereof), or a combination of natural and synthetic fibers. If the topsheet 24 comprises fibers, the fibers may be processed by spunbonding, carding, wet-laying, melt blowing, hydroentangling or other methods known in the art. A suitable topsheet comprising a web of spunbond polypropylene (partially treated with a hydrophilic surfactant) is manufactured by Polymer Group, inc. of Charlotte, NC under the name P-10.

Any portion of the topsheet 24 may be coated with a lotion and/or skin care composition, as generally disclosed in the art. The topsheet 24 may also include or be treated with an antimicrobial agent, some examples of which are disclosed in PCT publication WO 95/24173. Further, the topsheet 24, the backsheet 25, or any portion of either the topsheet or the backsheet may be embossed and/or matte finished to provide a more cloth-like appearance.

The topsheet 24 may include one or more apertures to facilitate fluid penetration. At least the size of the primary orifice is important to achieve the desired fluid encapsulation performance. If the primary orifice is too small, fluid may not pass through the orifice due to misalignment of the fluid source with the orifice or due to, for example, loose stool having a larger diameter than the orifice. If the aperture is too large, the area of skin that can be contaminated with "rewet" from the article increases. Typically, the total area of the apertures at the surface of the diaper may have between about 10cm²And about 50cm²Between, or between about 15cm²And 35cm²The area in between. An example of an apertured topsheet is disclosed in U.S. patent 6632504 assigned to BBA NONWOVENS SIMPSONVILLE. Typical diaper topsheets have a basis weight of from about 10gsm to about 50gsm or from about 12gsm to about 30gsm, although other basis weights are within the scope of the present disclosure.

Negative film

The backsheet 25 is generally that portion of the absorbent article 20 which is positioned adjacent the garment-facing surface of the absorbent core 28 and which prevents, or at least inhibits, the fluids and body exudates absorbed and contained therein from soiling articles such as bed sheets and undergarments. The backsheet 25 is generally impervious, or at least substantially impervious, to fluids (e.g., urine). The backsheet may be or comprise a thin plastic film, such as a thermoplastic film having a thickness of about 0.012mm to about 0.051mm, for example. Exemplary backsheet films include those manufactured by Tredegar Corporation, headquartered, VA, and sold under the trade name CPC2 film. Other suitable backsheet materials may include breathable materials that permit vapors to escape from the absorbent article 20 while still preventing, or at least inhibiting, fluids from passing through the backsheet 25. Exemplary breathable materials may include materials such as: weaving a fiber net; a nonwoven web; composite materials such as film-coated nonwoven webs; microporous films such as those manufactured by Mitsui Toatsu Co, (Japan) under the name ESPOIR NO and manufactured by Tredegar Corporation (Richmond, VA) and sold under the name EXAIRE; and monolithic films such as those manufactured by Clopay Corporation (Cincinnati, OH) under the name HYTREL blend P18-3097.

The backsheet 25 may be joined to the topsheet 24, the absorbent core 28, and/or any other elements of the absorbent article 20 by any attachment method known to those skilled in the art. Suitable attachment methods are described above with respect to methods for joining the topsheet 24 to other elements of the article 20.

The outer cover 23 may cover at least a portion or all of the backsheet 25 to form the soft, garment-facing surface of the absorbent article. The outer cover 23 may be formed of one or more nonwoven materials. The outer cover 23 is shown in figure 2, for example, in dashed lines. The outer cover 23 may be joined to at least a portion of the backsheet 25 by mechanical bonds, adhesive bonds, or other suitable attachment methods.

Absorbent core

As used herein, the term "absorbent core" refers to the component of an absorbent article having the greatest absorbent capacity and comprising an absorbent material and a core wrap or core pocket enclosing the absorbent material. The term "absorbent core" does not include acquisition and/or distribution systems or any other components of the article that are neither an integral part of the core wrap or core bag nor disposed within the core wrap or core bag. The absorbent core may comprise, consist essentially of, or consist of the core wrap, the absorbent material in question (e.g. superabsorbent polymer), and the glue.

The absorbent core 28 may comprise an absorbent material having a high content of superabsorbent polymers (abbreviated herein as "SAP") enclosed within a core wrap. The SAP content may represent 70% -100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99% or 100% by weight of the absorbent material comprised in the core wrap. For the purpose of evaluating the percentage of SAP in the absorbent core, the core wrap is not considered as an absorbent material. The core may also comprise airfelt or cellulosic fibers with or without SAP.

By "absorbent material" is meant a material having some absorbent or liquid retention properties, such as SAP, cellulosic fibers, and synthetic fibers. Generally, the glue used to make the absorbent core has no or little absorption properties and is not considered an absorbent material. The SAP content may represent more than 80%, such as at least 85%, at least 90%, at least 95%, at least 99%, and even up to and including 100% of the weight of the absorbent material contained within the core wrap. This provides a relatively thin core compared to conventional cores, which typically comprise 40-60% SAP and a high content of cellulose fibres. Conventional cores are also within the scope of the present disclosure. The absorbent material may especially comprise less than 15% by weight or less than 10% by weight of natural, cellulosic or synthetic fibers, less than 5% by weight, less than 3% by weight, less than 2% by weight, less than 1% by weight, or may even be substantially free of natural, cellulosic and/or synthetic fibers.

The exemplary absorbent core 28 of the absorbent article 20 of fig. 4-5 is shown in a separate form in fig. 6-8. The absorbent core 28 may comprise a front side 280, a back side 282, and two longitudinal sides 284, 286 joining the front side 280 and the back side 282. The absorbent core 28 may also include a generally planar top side and a generally planar bottom side. The front side 280 of the core is the side of the core intended to be placed towards the front waist edge 10 of the absorbent article. The core 28 may have a longitudinal axis 80' that substantially corresponds to the longitudinal axis 80 of the absorbent article 20, as viewed from the top in the plan view shown in fig. 1. The absorbent material may be distributed toward the front side 280 in a higher amount than toward the back side 282 because greater absorbency may be required in the front of a particular absorbent article. The front 280 and back 282 sides of the core may be shorter than the longitudinal sides 284 and 286 of the core. The core wrap may be formed from two nonwoven materials, substrates, laminates, or other materials 16, 16', which may be sealed at least partially along the sides 284, 286 of the absorbent core 28. The core wrap may be sealed at least partially along its front side 280, back side 282, and two longitudinal sides 284, 286 such that substantially no absorbent material leaks out of the absorbent core wrap. The first material, substrate, or nonwoven 16 may at least partially surround the second material, substrate, or nonwoven 16' to form a core wrap, as shown in fig. 7. The first material 16 may surround portions of the second material 16' adjacent the first and second side edges 284, 286.

The absorbent core may comprise, for example, an adhesive to help immobilize the SAP within the core wrap and/or to ensure the integrity of the core wrap, especially when the core wrap is made of two or more substrates. The adhesive may be a hot melt adhesive supplied by, for example, h.b. fuller. The core wrap may extend to a larger area than strictly necessary to contain the absorbent material therein.

Cores containing relatively high amounts of SAP with a variety of core designs are disclosed in U.S. patent No. 5,599,335(Goldman), EP 1,447,066(Busam), WO 95/11652(Tanzer), U.S. patent publication No. 2008/0312622a1 (huntorf), and WO 2012/052172(Van Malderen).

The absorbent material may be a continuous layer present within the core wrap. Alternatively, the absorbent material may be constituted by a separate bag or strip of absorbent material enclosed within the core wrap. In the first case, the absorbent material may be obtained, for example, by applying a single continuous layer of absorbent material. A continuous layer of absorbent material, in particular SAP, may also be obtained by combining two absorbent layers having a discontinuous absorbent material application pattern, wherein the resulting layer is substantially continuously distributed in the absorbent particulate polymer material area, as disclosed for example in U.S. patent application publication 2008/0312622a1 (Hundorf). The absorbent core 28 may comprise a first absorbent layer and a second absorbent layer. The first absorbent layer may comprise the first material 16 and a first layer 61 of absorbent material, which may be 100% or less SAP. The second absorbent layer may comprise a second material 16' and a second layer 62 of absorbent material, which may be 100% or less SAP. The absorbent core 28 may also comprise a fibrous thermoplastic adhesive material 51 at least partially bonding each layer 61, 62 of absorbent material to its respective material 16 or 16'. This is illustrated in fig. 7-8, for example, where the first and second SAP layers have been applied to their respective substrates in the form of transverse stripes or "landing zones" having the same width as the desired absorbent material deposition area, and then combined. The strips may include different amounts of absorbent material (SAP) to provide a basis weight distributed along the longitudinal axis of the core 80. The first material 16 and the second material 16' may form a core wrap.

The fibrous thermoplastic adhesive material 51 may at least partially contact the absorbent material 61, 62 in the landing zone and at least partially contact the materials 16 and 16' in the landing zone. This gives the fibrous layer of thermoplastic adhesive material 51 a substantially three-dimensional structure which is itself a substantially two-dimensional structure with a relatively small thickness compared to the dimensions in the length and width directions. Thus, the fibrous thermoplastic adhesive material may provide cavities to cover the absorbent material in the landing zone, which may be 100% or less SAP, to immobilize the absorbent material.

The thermoplastic adhesive used for the fibrous layer may have elastomeric properties such that a web formed from fibers on the SAP layer is capable of being stretched when the SAP swells. These types of elastomeric hot melt adhesives are more particularly described in U.S. patent 4,731,066 to Korpman, 3-15, 1988. The thermoplastic binder material may be applied in the form of fibers.

Superabsorbent polymers (SAP)

As used herein, "superabsorbent polymer" ("SAP") refers to absorbent materials that are crosslinked polymeric materials capable of absorbing at least 10 times their weight in an aqueous 0.9% saline solution when measured using the Centrifuge Retention Capacity (CRC) test (EDANA method WSP 241.2-05E). The SAP used may have a CRC value of greater than 20g/g, greater than 24g/g, 20g/g to 50g/g, 20g/g to 40g/g, or 24g/g to 30g/g, specifically listing all 0.1g/g increments within the above-specified ranges and any ranges formed therein or thereby. SAPs useful in the present disclosure may comprise a variety of water-insoluble, but water-swellable polymers capable of absorbing large amounts of fluids.

The superabsorbent polymers may be in particulate form so as to be flowable in the dry state. The particulate absorbent polymer material may be made of a poly (meth) acrylic acid polymer. However, starch-based particulate absorbent polymer materials may also be used, as well as starch-grafted copolymers of polyacrylamide copolymers, ethylene maleic anhydride copolymers, cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and polyacrylonitrile.

The SAP may be in a variety of shapes. The term "particles" refers to granules, fibers, flakes, spheres, powders, sheets, and other shapes and forms known to those skilled in the art of superabsorbent polymer particles. The SAP particles may be in the shape of fibers, i.e. elongated acicular superabsorbent polymer particles. The fibers may also be in the form of woven filaments. The SAP may be spherical particles. The absorbent core may comprise one or more types of SAP.

With most absorbent articles, the liquid discharge of the wearer is mainly carried out in the front half of the absorbent article, in particular the diaper. Thus, the front half of the article (as defined by the area between the front edge and the transverse line disposed at a distance of half L from the front waist edge 10 or the back waist edge 12) may comprise the majority of the absorbent capacity of the core. Thus, at least 60% of the SAP, or at least 65%, 70%, 75%, 80%, or 85% of the SAP may be present in the front half of the absorbent article, while the remainder of the SAP may be disposed in the back half of the absorbent article. Alternatively, the SAP distribution may be uniform throughout the core or may have other suitable distributions.

The total amount of SAP present in the absorbent core may also vary depending on the intended user. Diapers for newborns may require more urine than infant diapers, child diapers or adult incontinenceLess SAP is distributed. The amount of SAP in the core may be about 5g to 60g or 5g to 50g, specifically listing the specified range and all 0.1 increments formed therein or any range formed thereby. The average SAP basis weight within the deposition area 8 (or "at least one" if there are several) of SAP may be at least 50g/m²、100g/m²、200g/m²、300g/m²、400g/m²、500g/m²Or more. The area of the channels (e.g. 26, 26 ', 27') present in the absorbent material deposition area 8 is deduced from the absorbent material deposition area to calculate the average basis weight.

Core wrap

The core wrap may be made from a single substrate, material, or nonwoven folded around the absorbent material, or may comprise two (or more) substrates, materials, or nonwovens attached to each other. Typical attachments are so-called C-wraps and/or sandwich wraps. In a C-wrap, as shown, for example, in fig. 2 and 7, the longitudinal and/or lateral edges of one of the substrates are folded over the other substrate to form side flaps. These flaps are then bonded to the outer surface of the other substrate, typically by gluing.

The core wrap may be formed of any material suitable for receiving and containing an absorbent material. Typical substrate materials used to make conventional cores may be used, in particular, paper, tissue, film, woven or non-woven fabric, or laminates or composites of any of these materials.

The substrate may also be breathable (in addition to being liquid or fluid permeable). Membranes useful herein may therefore include micropores.

The core wrap may be sealed at least partially along all sides of the absorbent core such that substantially no absorbent material leaks out of the core. By "substantially free of absorbent material", it is meant less than 5%, less than 2%, less than 1%, or about 0% by weight of absorbent material escapes the core wrap. The term "sealing" should be understood in a broad sense. The seal need not be continuous along the entire perimeter of the core wrap, but may be discontinuous along part or all of it, such as formed by a series of seal points spaced in a line. The seal may be formed by gluing and/or heat bonding.

If the core wrap is formed from two substrates 16, 16', four seals may be used to enclose the absorbent material 60 within the core wrap. For example, the first substrate 16 may be disposed on one side of the core (shown as the top side in the figures) and extend around the longitudinal edges of the core to at least partially wrap the opposite bottom side of the core. The second substrate 16' may be present between the wrapped side flaps of the first substrate 16 and the absorbent material 60. The side flaps of the first substrate 16 may be glued to the second substrate 16' to provide a strong seal. This so-called C-wrap configuration may provide benefits compared to sandwich seals, such as improved resistance to rupture under wet loading conditions. The front and back sides of the core wrap may then also be sealed by gluing the first and second substrates to each other to provide a complete enclosure of the absorbent material across the entire periphery of the core. The first and second substrates may extend in a substantially planar direction for the front and back sides of the core and may be joined together to form a so-called sandwich construction for these edges. In so-called sandwich constructions, the first and second substrates may also extend outwardly on all sides of the core and be sealed flat or substantially flat, typically by gluing and/or heat/pressure bonding, along all or part of the periphery of the core. In one example, neither the first substrate nor the second substrate need be shaped such that they can be cut rectangularly for ease of manufacture, although other shapes are within the scope of the present disclosure.

The core wrap may also be formed from a single substrate that can enclose the absorbent material in the wrap and be sealed along the front and back sides of the core and one longitudinal seal.

SAP deposition area

The absorbent material deposition area 8 may be defined by the perimeter of the layer formed by the absorbent material 60 within the core wrap, seen from the top side of the absorbent core. The absorbent material deposition area 8 may have a variety of shapes, in particular, a so-called "dog bone" or "hourglass" shape, which exhibits a taper along its width toward the middle or "crotch" region of the core. In this way, the absorbent material deposition area 8 may have a relatively narrow width in the core area intended to be placed in the crotch region of the absorbent article, as shown in fig. 1. This may provide better wearing comfort. The absorbent material deposition area 8 may also be generally rectangular, for example as shown in fig. 4-6, although other deposition areas, such as rectangular, "T", "Y", "hourglass" or "dog bone" shapes are also within the scope of the present disclosure. The absorbent material may be deposited using any suitable technique that may allow relatively precise deposition of SAP at relatively high speeds.

Channel

The absorbent material deposition area 8 may include at least one channel 26 that is at least partially oriented in the longitudinal direction of the article 80 (i.e., has a longitudinal vector component). The other channels may be at least partially oriented in a lateral direction (i.e., having a lateral vector component) or in any other direction. Hereinafter, the plural form "channel" will be used to refer to "at least one channel". The channel may have a length L' projected onto the longitudinal axis 80 of the article that is at least 10% of the length L of the article. The channels may be formed in various ways. For example, the channels may be formed by areas within the absorbent material deposition area 8 that may be substantially free or free of absorbent material, in particular SAP. Additionally or alternatively, the one or more channels may also be formed by continuously or discontinuously bonding the top side of the core wrap to the bottom side of the core wrap in the absorbent material deposition area 8. The channels may be continuous, but it is also contemplated that the channels may be discontinuous. The acquisition-distribution system or layer 50 or other layers of the article may also include channels, which may or may not correspond to the channels of the absorbent core.

In some cases, a channel may be present at least at the same longitudinal position as the crotch point C or lateral axis 60 in the absorbent article, as represented by the two longitudinally extending channels 26, 26' in fig. 1. Channels may also extend from the crotch region 7 or may be present in the front waist region 5 and/or the back waist region 6 of the article.

The absorbent core 28 may also include more than two channels, such as at least 3, at least 4, at least 5, or at least 6 or more channels. Shorter channels may also be present, for example, in the back waist region 6 or the front waist region 5 of the core, as represented by the pair of channels 27, 27' in fig. 1 toward the front of the article. The channels may include one or more pairs of channels arranged symmetrically, or otherwise, with respect to the longitudinal axis 80.

Channels may be particularly useful for absorbent cores when the absorbent material deposition area is rectangular, as the channels may improve the flexibility of the core to the extent that advantages are less when using non-rectangular (shaped) cores. Of course, channels may also be present in the SAP layer with profiled deposition areas.

The channel may be oriented completely longitudinally and parallel to the longitudinal axis or completely transversely and parallel to the lateral axis, but may also have at least portions that are curved.

To reduce the risk of fluid leakage, the longitudinal main channels may not extend to either edge of the absorbent material deposition area 8 and may therefore be completely comprised within the absorbent material deposition area 8 of the core. The minimum distance between the channel and the nearest edge of the absorbent material deposition area 8 may be at least 5 mm.

The channel may have a width Wc along at least a portion of its length, for example at least 2mm, at least 3mm, at least 4mm, up to, for example, 20mm, 16mm, or 12 mm. The width of the channel may be constant over substantially the entire length of the channel, or may vary along its length. When the channels are formed by absorbent material-free zones within the absorbent material deposition area 8, the width of the channels is considered to be the width of the material-free zones, regardless of the possibility of the presence of a core wrap within the channels. If the channels are not formed by absorbent material free zones, e.g. mainly by core wrap bonding within the whole absorbent material zone, the width of the channels is the width of the bond.

At least some or all of the channels may be permanent channels, meaning that their integrity is at least partially maintained in both the dry and wet states. Permanent channels may be obtained by providing one or more adhesive materials, such as a fibrous layer of adhesive material or a construction glue that helps adhere the substrate and absorbent material within the channel walls. The permanent channels may also be formed by bonding the upper and lower sides of the core wrap (e.g., the first and second substrates 16, 16') and/or bonding the topsheet 24 and backsheet 25 together via the channels. Typically, an adhesive may be used to bond the two sides or topsheet and backsheet of the core wrap through the channels, but it may be bonded by other known methods, such as pressure bonding, ultrasonic bonding, thermal bonding, or combinations thereof. The core wrap or topsheet 24 and backsheet 25 may be continuously bonded or intermittently bonded along the channel. The channels may advantageously remain or become visible at least through the topsheet and/or backsheet when the absorbent article is fully loaded with fluid. This may be achieved by making the channel substantially free of SAP so that it will not swell and large enough so that it will not close when wetted. In addition, it may be advantageous to bond the core wrap to itself or the topsheet to the backsheet through the channels.

Barrier leg cuff

The absorbent article may comprise a pair of barrier leg cuffs 34. Each barrier leg cuff may be formed from a sheet of material that is bonded to the article such that it may extend upwardly from the wearer-facing surface of the absorbent article and provide improved containment of fluids and other body exudates adjacent the juncture of the wearer's torso and legs. The barrier leg cuffs are defined by a proximal edge 64 joined directly or indirectly to the topsheet 24 and/or backsheet 25 and a free end edge 66 which is intended to contact the wearer's skin and form a seal. The barrier leg cuffs 34 extend at least partially between the front and back waist edges 10, 12 of the absorbent article on opposite sides of the longitudinal axis 80 and are present at least at the location of the crotch point (C) or crotch region. The barrier leg cuffs may be joined at the proximal edges 64 to the chassis of the article by bonds 65, which bonds 65 may be made by a combination of gluing, melt bonding or other suitable bonding methods. The bond 65 at the proximal edge 64 may be continuous or intermittent. The bond 65 closest to the raised section of the barrier leg cuff defines the proximal edge 64 of the upstanding section of the leg cuff.

The barrier leg cuffs may be integral with the topsheet 24 or backsheet 25 or may be a separate material joined to the chassis of the article. Each barrier leg cuff 34 may comprise one, two or more elastic bands 35 near the free end edge 66 to provide a better seal.

In addition to the barrier leg cuffs 34, the article may further comprise gasketing cuffs 32 joined to the chassis of the absorbent article (particularly the topsheet 24 and/or backsheet 25) and may be placed exteriorly with respect to the barrier leg cuffs. The gasket cuff 32 may provide a better seal around the wearer's thighs. Each gasketing leg cuff may comprise one or more elastic bands or elements 33 in the chassis of the absorbent article between the topsheet 24 and the backsheet 25 in the leg opening area. All or a portion of the barrier leg cuff and/or the gasket cuff may be treated with a lotion or another skin care composition.

Collection-distribution system

Absorbent articles of the present disclosure may include an acquisition-distribution layer or system 50 ("ADS"). One function of the ADS is to rapidly acquire one or more fluids and distribute them to the absorbent core in an efficient manner. The ADS may include one, two, or more layers, which may form a unitary layer or may remain as discrete layers that may be attached to one another. In one example, the ADS may include two layers: a distribution layer 54 and an acquisition layer 52 disposed between the absorbent core and the topsheet, although the disclosure is not so limited.

The ADS may contain SAP as this slows the acquisition and distribution of fluid. Suitable ADSs are described, for example, in WO 2000/59430(Daley), WO 95/10996(Richards), us 5,700,254(McDowall) and WO 02/067809 (Graef).

In one example, the ADS may not be provided, or only one layer of the ADS may be provided, such as only a distribution layer or only an acquisition layer. When one of the liquid permeable three-dimensional substrates of the present disclosure is used as part or all of a topsheet, or positioned on a topsheet, the drying performance of the liquid permeable substrate may be improved if only one layer of ADS or no layer of ADS is present. This is due to the fact that: fluid (e.g., urine) can readily wick directly into the absorbent core 28 through the liquid permeable substrate and/or into a layer of the ADS.

Distribution layer

The distribution layer of the ADS may comprise at least 50% by weight of crosslinked cellulosic fibers. The crosslinked cellulosic fibers can be crimped, twisted, or crimped, or a combination thereof (including crimped, twisted, and crimped). This type of material is disclosed in U.S. patent publication 2008/0312622a1 (Hundorf). The crosslinked cellulosic fibers provide higher elasticity and therefore higher resistance of the first absorbent layer to compression in the product packaging or under conditions of use (e.g., under the weight of the wearer). This can provide higher void volume, permeability and liquid absorption to the core, thereby reducing leakage and improving dryness.

The distribution layer comprising crosslinked cellulosic fibers of the present disclosure may comprise other fibers, but the layer may advantageously comprise at least 50%, or 60%, or 70%, or 80%, or 90%, or even up to 100%, by weight of the layer, of crosslinked cellulosic fibers (including crosslinking agents). An example of such a mixed crosslinked cellulosic fiber layer may include about 70 weight percent chemically crosslinked cellulosic fibers, about 10 weight percent Polyester (PET) fibers, and about 20 weight percent untreated pulp fibers. In another example, the layer of crosslinked cellulosic fibers may comprise about 70 weight percent chemically crosslinked cellulosic fibers, about 20 weight percent lyocell fibers, and about 10 weight percent PET fibers. In another example, the layer may comprise about 68% by weight chemically cross-linked cellulosic fibers, about 16% by weight untreated pulp fibers, and about 16% by weight PET fibers. In another example, the layer of crosslinked cellulosic fibers can comprise from about 90% to about 100% by weight of chemically crosslinked cellulosic fibers.

Acquisition layer

The ADS 50 may include an acquisition layer 52. The acquisition layer may be disposed between the distribution layer 54 and the topsheet 24. The acquisition layer 52 may be or may include a nonwoven material, such as a hydrophilic SMS or SMMS material, including a spunbond layer, a meltblown layer, and other spunbond layers or alternatively a carded staple fiber chemically bonded nonwoven. The nonwoven material may be latex bonded.

In addition to the first acquisition layer described above, other acquisition layers may be used. For example, a tissue layer may be placed between the first acquisition layer and the distribution layer. The tissue may have enhanced capillary distribution characteristics as compared to the acquisition layers described above.

Fastening system

The absorbent article may comprise a fastening system. The fastening system may be used to provide lateral tension around the circumference of the absorbent article to hold the absorbent article on the wearer, as is typical for taped diapers. The fastening system may not be necessary for training pant articles because the waist regions of these articles have been bonded. The fastening system may include fasteners, such as tape tabs, hook and loop fastening components, interlocking fasteners such as tabs and slits, buckles, buttons, snaps, and/or hermaphroditic fastening components, although any other suitable fastening mechanism is within the scope of the present disclosure. A landing zone 44 is generally disposed on the garment-facing surface of the first waist region 5 for releasable attachment of fasteners thereto.

Front and back ear

The absorbent article may comprise front ears 46 and back ears 40. The ears may be an integral part of the chassis, such as being formed by the topsheet 24 and/or the backsheet 26 in the form of side panels. Alternatively, as shown in fig. 1, the ear panel may be a separate element attached by gluing, heat embossing and/or pressure bonding. The back ears 40 may be stretchable to facilitate attachment of the tabs 42 to the landing zone 44 and to hold the taped diaper in place around the waist of the wearer. The back ears 40 may also be elastic or extensible to provide a more comfortable and conformable fit for the wearer by initially conformably fitting the absorbent article and to maintain this fit throughout the wear when the absorbent article is loaded with fluid or other bodily exudates because the elasticized ears allow the sides of the absorbent article to expand and contract.

Elastic waist structure

The absorbent article 20 may also include at least one elastic waist feature (not shown) that helps provide improved fit and containment. Elastic waist structures are generally intended to elastically expand and contract to dynamically fit the waist of a wearer. The elastic waist feature may extend at least longitudinally outwardly from at least one waist edge of the absorbent core 28 and generally forms at least a portion of an end edge of the absorbent article. The disposable diaper may be constructed so as to have two elastic waist features, one positioned in the front waist region and the other positioned in the back waist region.

Relationships between layers

Typically adjacent layers and components may be joined together using conventional bonding methods such as adhesive coating by slot coating or spraying onto all or part of the surface of the layers, thermal bonding, pressure bonding, or combinations thereof. For clarity and readability, the bond is not shown in the figures (except for the bond between the tab element of the leg cuff 65 and the topsheet 24), but the layer-to-layer bond of the article should be considered to be present unless specifically excluded. Adhesives may be used to improve the adhesion of the different layers between the backsheet 25 and the core wrap. The glue may be any suitable hot melt glue known in the art.

Sanitary napkin

The three-dimensional substrate of the present disclosure may form a portion of the topsheet, form a portion or all of the secondary topsheet, or be positioned or joined to at least a portion of the topsheet of the sanitary napkin. Referring to fig. 9, the absorbent article may comprise a sanitary napkin 300. The sanitary napkin 300 may comprise a liquid pervious topsheet 314, a liquid impervious or substantially liquid impervious backsheet 316, and an absorbent core 308. The absorbent core 308 may have any or all of the features described herein for the absorbent core 28, and in some forms, may have a secondary topsheet in place of the acquisition-distribution system disclosed above. The sanitary napkin 300 may further comprise flaps 320 that extend outwardly relative to the longitudinal axis 380 of the sanitary napkin 300. The sanitary napkin 300 may also include a lateral axis 390. The wings 320 can be joined to the topsheet 314, the backsheet 316, and/or the absorbent core 308. The sanitary napkin 300 can further comprise a front edge 322, a back edge 324 longitudinally opposed to the front edge 322, a first side edge 326, and a second side edge 328 longitudinally opposed to the first side edge 326. The longitudinal axis 380 may extend from a midpoint of the front edge 322 to a midpoint of the back edge 324. A lateral axis 390 may extend from a midpoint of the first side edge 326 to a midpoint of the second side edge 328. The sanitary napkin 300 can also be provided with additional features, such as, for example, a secondary topsheet 319, as is commonly found in sanitary napkins as is well known in the art.

Three-dimensional substrate

The liquid permeable three-dimensional substrates of the present disclosure may comprise a substrate having a first element (e.g., a protrusion) having a first z-direction height and at least a second element (e.g., a landing zone) having a second z-direction height. The substrate may also have a plurality of apertures. The substrate may further include at least a third element having at least a third z-direction height. With such a structure, the fluid can move quickly away from the wearer's skin, first off the first element contacting the wearer's skin having a first z-direction height, causing the wearer to feel drier. The fluid may flow by gravity or by a capillary gradient into the second element having the second z-direction height and/or into and through the apertures such that the fluid may be absorbed into the absorbent article. By providing the three-dimensional substrate of the present disclosure, the time of fluid/skin contact and fluid contact with the wearer's skin may be reduced. Further, the first element having the first z-direction height may act as a spacer between the fluid and the wearer's skin as the fluid is absorbed into the absorbent article.

Referring to fig. 10-13, a liquid permeable three-dimensional substrate 400 (referred to herein as a three-dimensional substrate or liquid permeable substrate) is shown on an absorbent article 402. Fig. 10 is a top view of an absorbent article 402 with the wearer-facing surface facing the viewer. Fig. 11 is a perspective view of an absorbent article 402 with the wearer-facing surface facing the viewer. Figure 12 is a top view of a portion of a liquid permeable substrate 400 on an absorbent article with the wearer-facing surface facing the viewer. Figure 13 is another top view of a portion of a liquid permeable substrate 400 on an absorbent article 402 with the wearer-facing surface facing the viewer.

In one form, the liquid permeable substrate 400 or other liquid permeable substrates described herein may comprise a patch or strip positioned and/or joined to the topsheet of the absorbent article 402. The patch or strip may be bonded to the topsheet, adhered to the topsheet, cold-welded to the topsheet, ultrasonically bonded to the topsheet, and/or otherwise joined to the topsheet. Alternatively, the liquid permeable substrate of the present disclosure may constitute, form all of, or form a portion of the topsheet (e.g., topsheet 24). Further, the topsheet 24 may be composed solely of one or more of the liquid permeable substrates of the present disclosure. In any of the various configurations, the liquid permeable substrate of the present disclosure is intended to form at least a portion of the wearer-facing surface of the absorbent article and at least partially contact the skin of the wearer.

Referring to fig. 14-16, the liquid permeable substrate 400 joined to the topsheet 24 in the form of a patch or strip, or other liquid permeable substrate described herein, may have a transverse width W1, while the topsheet 24 may have a transverse width W2. W1 may be less than width W2, the same as width W2, substantially the same, or greater (not shown) than width W2. The width W1 may also vary or be constant throughout the longitudinal length of the liquid permeable substrate. Still referring to fig. 14-16, the liquid permeable substrate 400 in the form of a patch or strip or other liquid permeable substrate described herein may have a longitudinal length L1, while the topsheet 24 may have a longitudinal length L2. L1 may be less than length L2, the same as length L2, substantially the same, or greater (not shown) than length L2. The length L1 may vary or be constant across the width W1 of the liquid permeable substrate. Although not shown in fig. 14-16, the length and width of the topsheet 24 and the liquid permeable substrate may be the same or substantially the same.

Although the patches or strips of the liquid permeable substrate 400 are shown in figures 14-16 as rectangular, the liquid permeable substrates of the present disclosure may have any other suitable shape, such as a front/back contoured shape (i.e., wider front, wider back, and/or narrower crotch), a square shape, an oval shape, or other suitable shape. The side edges 404 and/or the end edges 406 of the liquid permeable substrate 400 may have one or more curved portions, designs, and/or shapes cut therefrom to provide an aesthetic appearance to the liquid permeable substrate 400. One side edge 404 may or may not be symmetrical with the other side edge 404 about the longitudinal axis 408 of the topsheet 24. Likewise, one end edge 406 may or may not be symmetrical with the other end edge 406 with respect to the lateral axis 410 of the topsheet 24.

The liquid permeable substrate 400 may comprise one or more layers. If more than one layer is provided, the layers may be joined together or attached to each other by mechanical bonding, adhesive bonding, pressure bonding, thermal bonding, passing hot air through the two layers, or by other joining methods to form the multilayer substrate 400. Alternatively, the layer is formed in a subsequent fiber deposition step, such as a first carding operation and a second carding operation for the first and second types of staple fibers or two subsequent bundles of spunlaid polymer filaments containing the additive. The first layer may comprise one or more hydrophobic materials, or may be completely hydrophobic, and the second layer may comprise one or more hydrophilic materials, or may be completely hydrophilic. One layer may comprise a material that is more hydrophobic or more hydrophilic than the material comprising the other layer (e.g., both layers are hydrophilic but one layer is more hydrophilic, or both layers are hydrophobic but one layer is more hydrophobic) as opposed to one layer comprising a hydrophobic material and the other layer comprising a hydrophilic material. The first layer may constitute a hydrophobic layer and the second layer may constitute a hydrophilic layer, or vice versa. The first layer can be used as part or all of the wearer-facing surface of the absorbent article. Alternatively, the second layer may be used as part or all of the wearer-facing surface of the absorbent article.

The theoretical basis for having the first layer (or wearer-facing layer) composed of a hydrophobic material is twofold. First, if the liquid permeable substrate is apertured, the hydrophobic layer will not hold as much liquid as the hydrophilic second layer, and thus there will be less fluid (e.g., urine) in direct contact with the wearer's skin. Second, the protrusions (described below) in the first and second layers typically form hollow portions or domes on the garment-facing side of the liquid-permeable substrate that are not in direct contact with the ADS or core, so fluids can be trapped in the hollow domes. Without good connectivity between the hollow domes and the ADS or core, the liquid permeable substrate can hold more fluid and feel more moist to the wearer. However, in the case of a first layer having hydrophobic properties, any liquid that is wicked into the hollow domes will be mostly on the garment-facing or downward-facing hydrophilic side of the liquid permeable substrate, leaving a drier first hydrophobic layer. In principle, this can be achieved using a hydrophilic or capillary gradient from the first layer to the second layer (e.g. finer fibers in the second layer having the same hydrophilic properties (i.e. contact angle with liquid)). The pores in the substrate can play an important role to allow initial and rapid fluid flow (strike-through), regardless of the first hydrophobic layer. Thus, the first hydrophobic layer cooperates with the protrusions, the hollow domes and the apertures to reduce wettability on the wearer-facing surface of the liquid-permeable substrate. In other cases, the second layer may be used as part of the wearer-facing surface.

The first layer may comprise a plurality of first fibers and/or filaments (hereinafter collectively referred to as fibers). The plurality of first fibers may comprise fibers of the same, substantially the same, or different size, shape, composition, denier, fiber diameter, fiber length, and/or weight. The second layer may include a plurality of second fibers. The plurality of second fibers may comprise fibers of the same, substantially the same, or different size, shape, composition, denier, fiber diameter, fiber length, and/or weight. The plurality of first fibers and the plurality of second fibers may be the same, substantially the same, or different. The additional layers may have the same or different configurations.

The first and/or second layer may comprise bicomponent fibers having a sheath and a core. The sheath may comprise polyethylene and the core may comprise polyethylene terephthalate (PET). The sheath and core may also comprise any other suitable material known to those skilled in the art. The sheath and core may each comprise about 50% fiber by weight of the fiber, although other variations (e.g., sheath 60%, core 40%; sheath 30%, core 70%, etc.) are also within the scope of the present disclosure. The bicomponent or other fibers comprising the first and/or second layers can have a denier in the range of about 0.5 to about 6, about 0.75 to about 4, about 1.0 to about 4, about 1.5 to about 3, about 1.5 to about 2.5, or about 2, specifically including all 0.1 denier increments within the specified ranges and all ranges formed therein or thereby. Denier is defined as the mass (grams) per 9000 meters of fiber length. In other instances, the fibers of the first layer may have a denier in the range of from about 1.5 denier to about 6 denier or from about 2 denier to about 4 denier and the fibers of the second layer may have a denier in the range of from about 1.2 denier to about 3 denier or from about 1.5 denier to about 3 denier, specifically listing all 0.1 denier increments within the specified ranges and all ranges formed therein or thereby. In some instances, the fibers of the first layer may be at least 0.5 denier, at least 1 denier, at least 1.5 denier, or at least 2 denier greater than the denier of the fibers of the second layer, depending at least in part on the particular acquisition and/or distribution system used in an absorbent article. By providing fibers of the first layer having a denier that is higher than the denier of the fibers of the second layer, a pore gradient is provided in the liquid permeable substrate. The pore gradient can provide better drying and/or acquisition in a liquid permeable substrate. The larger denier fibers in the first layer provide larger pores than the smaller denier fibers in the second layer, thereby creating a pore gradient between the layers.

The plurality of first fibers and second fibers may also include any other suitable type of fiber, such as polypropylene fibers, other polyolefins, other polyesters other than PET, such as polylactic acid, thermoplastic starch-containing sustainable resins, other sustainable resins, Bio-PE (Bio-PE), Bio-PP (Bio-PP), and Bio-PET (Bio-PET), viscose, rayon, or other suitable nonwoven fibers. These fibers may have any suitable denier or range of deniers and/or fiber lengths or ranges of fiber lengths. Where the plurality of first fibers and the second fibers are the same or substantially the same, the plurality of second fibers may be treated with a hydrophilic agent, such as a surfactant, to render the plurality of second fibers hydrophilic or at least less hydrophobic. The plurality of first fibers may be not treated with a surfactant such that they remain in their naturally hydrophobic state or the plurality of first fibers may be treated with a surfactant to become less hydrophobic.

The first layer may have a basis weight in a range of about 10gsm to about 25 gsm. The second layer may have a basis weight in the range of about 10gsm to about 45 gsm. The basis weight of the substrate (both the first and second layers) may range, for example, from about 20gsm to about 70gsm, from about 20gsm to about 60gsm, from about 25gsm to about 50gsm, from about 30gsm to about 40gsm, about 30gsm, about 35gsm, or about 40 gsm.

In one form, the basis weight of the substrate may be from about 30gsm to about 40gsm or about 35 gsm. In such examples, the first layer may have a basis weight in a range of about 10gsm to about 20gsm, or about 15gsm, and the second layer may have a basis weight in a range of about 15gsm to about 25gsm, or about 20 gsm. In another example, the basis weight of the substrate may be about 20 gsm. In such an example, the first layer may have a basis weight of about 10gsm and the second layer may have a basis weight of about 10 gsm. In another example, the basis weight of the substrate may be about 60 gsm. In such an example, the first layer may have a basis weight of about 24gsm and the second layer may have a basis weight of 36 gsm. All other suitable basis weight ranges for the first and second layers and the substrate are within the scope of the present disclosure. Thus, the basis weights of the layers and substrates may be designed for specific product requirements.

Specifically listed herein are all 0.1gsm increments within the basis weight ranges specified above and all ranges formed therein or therefrom.

In some cases, it may be desirable to have a higher basis weight in the first layer as compared to the second layer. For example, the basis weight of the first layer may be at least about 1 to about 4 times, at least about 1 to about 3.5 times, about 1.5 to about 3 times, about 2 times, about 2.5 times, or about 3 times the basis weight of the second layer. In some cases, for example, the basis weight of the first layer may be in the range of about 20gsm to about 30gsm, and the basis weight of the second layer may be in the range of about 10gsm to about 20 gsm. Specifically listed herein are all 0.1gsm increments within the basis weight ranges specified above and all ranges formed therein or therefrom. By providing a first layer (hydrophobic) having a higher basis weight than a second layer (hydrophilic), a material is provided in the liquid permeable substrate that is more hydrophobic than the hydrophilic material. According to information and beliefs, more hydrophobic and less hydrophilic materials in the liquid permeable substrate provide better acquisition and/or drying. The surface tension of the hydrophilic layer may be reduced to at least inhibit the hydrophilic layer (second layer) from contaminating (and making more hydrophilic) the hydrophobic layer (first layer) when the liquid permeable substrate receives the one or more ejecta.

The liquid permeable substrate of the present disclosure may also form a portion or all of the outer cover 23 joined to at least a portion of the backsheet 25. In other instances, the outer cover 23 may include a pattern (e.g., an embossed pattern, a printed pattern) and/or a three-dimensional structure that is the same or similar in appearance to the liquid permeable substrate of the present disclosure. Generally, the appearance of at least a portion of the liquid permeable substrate on the wearer-facing surface may match or substantially match at least a portion of the outer cover 23 or another portion of the absorbent article.

Figure 17 is a front view of a portion of a liquid permeable three-dimensional substrate with the wearer-facing surface facing the viewer. FIG. 18 is a front perspective view of a portion of the liquid permeable three-dimensional substrate of FIG. 17. Figure 19 is another front view of a portion of a liquid permeable three-dimensional substrate with the wearer-facing surface facing the viewer. Figure 20 is a front perspective view of a portion of the liquid permeable substrate of figure 19. Figure 21 is a back view of a portion of a liquid permeable three-dimensional substrate with the wearer-facing surface facing the viewer. FIG. 22 is a rear perspective view of a portion of the liquid permeable three-dimensional substrate of FIG. 21. Figure 23 is another back view of a portion of a liquid permeable three-dimensional substrate with the wearer-facing surface facing the viewer. Figure 24 is a rear perspective view of a portion of the liquid permeable substrate of figure 23. Figure 25 is a cross-sectional view of a liquid permeable substrate.

Referring generally to fig. 17-25, the liquid permeable substrate 400 may include a first layer and a second layer, or more than two or one layer. The substrate 400 may include a plurality of landing areas 412, a plurality of recesses 414, and a plurality of protrusions 416. The plurality of projections 416 may form a first element having a first z-direction height, and the landing zone 412 may form a second element having a second z-direction height, as described above. The plurality of landing zones 412, the plurality of recesses 414, and the plurality of protrusions 416 may together form a first three-dimensional surface on a first side 418 of the substrate 400. The plurality of landing zones 412, the plurality of recesses 414, and the plurality of protrusions 416 may also form a second three-dimensional surface on the second side 420 of the substrate 400. The projections 416 may be generally dome-shaped on the wearer-facing surface of the liquid permeable substrate 400 and may be hollow dome-shaped on the garment-facing surface of the substrate 400. All, most (i.e., greater than 50%, or greater than 75%), or substantially all, of the depressions 414 may define apertures 422 therein at locations farthest from the peaks 425 of adjacent projections 416. The perimeters 423 of most or all of the apertures 422 may form the lowest portion or plane of the substrate 400, while the peaks 425 (i.e., the uppermost portions) of most or all of the projections 416 may form the highest portion or plane of the substrate 400. In other cases, the substrate may have no holes within the recesses 414 and the portions of the recesses 414 furthest from the peaks 425 of the projections 416 may form the lowest portion or plane of the substrate 400. The holes 422 may extend through the first and second layers of the substrate 400.

The landing zone 412 may be intermediately positioned: (1) adjacent to the projection 416; (2) adjacent the recess 414 and/or adjacent the aperture 422. The landing zone 412 may also surround at least a portion, or all, a majority, or all of the depression 414 and/or aperture and at least a majority, or all of the protrusion 416. The land areas 412 may be positioned between the plane of at least a majority of the perimeter of the apertures 422 and the plane of at least a majority of the crests 425 of the projections 416.

The protrusions 416 may alternate with the recesses 414 and/or apertures 422 in a direction generally parallel to the lateral axis 424 of the liquid permeable substrate 400. The lateral axis 424 is substantially parallel to the lateral axis 410 shown in fig. 14-16. The protrusions 416 may also alternate with the recesses 414 and/or apertures 422 in a direction generally parallel to the longitudinal axis 426 of the liquid permeable substrate 400. The longitudinal axis 426 is generally parallel to the longitudinal axis 408 shown in fig. 14-16. In this configuration, the projections 416 and recesses 414 and/or holes 422 alternate (i.e., projections, recesses and/or holes) in a direction generally parallel to the lateral axis 424 or in a direction generally parallel to the longitudinal axis 426. This feature provides better flexibility to the substrate 400 because of the presence of the flexible protrusion peaks 425 in the middle of most or all of the adjacent depressions 414 and/or apertures 422. This feature also helps to keep the wearer's skin away from the landing zone 412 and/or fluid in the depression 414, as the protrusion 416 essentially forms a spacer between the skin and the fluid.

Two or more adjacent projections 416 may be separated from each other by a recess 414 and/or an aperture 422 and one or more land areas 412 in a direction generally parallel to the lateral axis 424 or in a direction generally parallel to the longitudinal axis 426. Two or more adjacent recesses 414 and/or apertures 422 may be separated from each other by a protrusion 416 and one or more land areas 412 in a direction substantially parallel to the lateral axis 424 or in a direction substantially parallel to the longitudinal axis 426. The landing zone 412 may completely surround the aperture 422 and the protrusion 416. The landing zones 412 may together form a substantially continuous grid across the substrate 400, while the projections 416 and depressions 414 and/or apertures 422 may be discrete elements across the substrate.

In some cases, two or more (such as four) projections 416 may be positioned around at least most, substantially all, or all of the recesses 414 and/or apertures 422 (which does not include the lands 412 intermediate the projections 416 and the recesses 414 and/or apertures 422). Two or more recesses 414 and/or apertures 422 (such as four) may be positioned around at least most, substantially all, or all of the projections 416 (which does not include the lands 412 intermediate the recesses 414 and/or apertures 422 and the projections 416). The protrusion 416, recess 414, aperture 422, and landing zone 412 may all be formed from portions of the first and second layers of the substrate. If more than two layers are provided in the substrate, the protrusion 416, recess 414, hole 422, and landing zone 412 may all be formed by portions of the first, second, and third layers of the substrate. The same is true if more than three layers are provided in a particular substrate. In other cases, the landing zone 412 may be formed only in the first layer.

The apertures 422 and/or recesses 414 may include a first set of apertures and/or recesses 414 that together form a first line in the substrate 400 and a second set of apertures 422 and/or recesses 414 that together form a second line in the substrate 400. The first line may be substantially parallel or substantially perpendicular to the second line. The first line may also form an acute or obtuse angle with the second line. The projections 416 may include a first set of projections 416 that together form a first line in the substrate 400 and a second set of projections 416 that together form a second line in the substrate 400. The first line may be substantially parallel or substantially perpendicular to the second line. The first line may also form an acute or obtuse angle with the second line.

The substrate 400 may be generally symmetrical about the lateral axis 424 and/or generally symmetrical about the longitudinal axis 426. In other cases, the substrate may not be symmetric about the lateral axis 424 and/or the longitudinal axis 426.

In one form, the substrate 400 may include a first line including alternating holes 422 and protrusions 416 extending in a direction parallel to the lateral axis 424 and a second adjacent line including alternating holes 422 and protrusions 416 extending in a direction substantially parallel to the lateral axis 424. The wire will pass through the hole 422 and the center of the projection 416. See, e.g., fig. 17, lines a and B. If line C is drawn in a direction generally parallel to longitudinal axis 426 and intersects lines A and B, then hole 422 will be located at the intersection of lines A and C and protrusion 416 will be located at the intersection of lines B and C. The same is true if lines a and B are drawn in a direction parallel to the longitudinal axis 426 and line C is drawn in a direction substantially parallel to the lateral axis 424, as shown in fig. 19. If the line is drawn at a different location, the intersection of line A and line C may have a protrusion 416 and the intersection of line B and line C may have a hole 422. The point is that the rows of holes and the rows of projections are staggered. By staggering the apertures and protrusions in this manner, better flexibility is achieved on the wearer-facing surface of the substrate 400 due to the soft protrusion or protrusion ridge being intermediate the two apertures.

Parameters of three-dimensional substrates

All or a majority of the projections 416 may have a z-direction height in the range of about 300 μm to about 6000 μm, about 500 μm to about 5000 μm, about 500 μm to about 4000 μm, about 300 μm to about 3000 μm, about 500 μm to about 2000 μm, about 750 μm to about 1500 μm, about 800 μm to about 1400 μm, about 900 μm to about 1300 μm, about 1000 μm to about 1300 μm, about 1100 μm to about 1200 μm, about 1165 μm, about 1166 μm, about 1167 μm, or about 1150 μm to about 1200 μm, specifically listing all 1 μm increments therein or thereby formed. The z-direction height of the protrusion 416 is measured according to the protrusion height test described herein.

All or a majority of the recesses 414 can have a z-direction height in the range of about 200 μm to about 3000 μm, about 300 μm to about 2000 μm, about 100 μm to about 2000 μm, about 500 μm to about 1500 μm, about 700 μm to about 1300 μm, about 800 μm to about 1200 μm, about 900 μm to about 1100 μm, about 900 μm to about 1000 μm, about 970 μm, or about 950 μm to about 1000 μm, specifically listing all 1 μm increments within the above-specified ranges and all ranges formed therein or thereby. The z-direction height of the depression 416 is measured according to the depression height test described herein.

Substrate 400 or portions thereof can have an overall z-direction height in a range of about 500 μm to about 6000 μm, about 750 μm to about 4000 μm, about 1000 μm to about 6000 μm, about 1500 μm to about 6000 μm, about 1000 μm to about 3000 μm, about 1500 μm to about 2500 μm, about 1750 μm to about 2300 μm, about 1900 μm to about 2300 μm, about 2000 μm to about 2300 μm, about 2100 μm to about 2250 μm, about 2136 μm, or about 2135 μm, specifically listing the above-specified ranges and all 1 μm increments formed therein or thereby. The overall z-direction height of the substrate 400 or portion thereof is measured according to the overall substrate height test described herein.

Most or all of the holes 422 may have a diameter of about 0.4mm²To about 10mm²About 0.5mm²To about 8mm²About 0.5mm²To about 3mm²About 0.5mm²To about 4mm²About 0.5mm²To about 5mm²About 0.7mm²To about 6mm²About 0.7mm²To about 3mm²About 0.8mm²To about 2mm²About 0.9mm²To about 1.4mm²About 1mm²About 1.1mm²About 1.2mm²About 1.23mm²About 1.3mm²Or about 1.4mm²Effective aperture area within the range, specifically all 0.1mm of the above specified ranges and all ranges formed therein or therefrom are listed²And (4) increasing. The effective pore area of the pores is measured according to the pore test described herein.

Most or all of the apertures 422 may have a Ferrett (length of aperture) in the range of about 0.5mm to about 4mm, about 0.8mm to about 3mm, about 1mm to about 2mm, about 1.2mm to about 1.8mm, about 1.4mm to about 1.6mm, about 1.49mm, or about 1.5mm, specifically listing all 0.1mm increments within the above-specified ranges and all ranges formed therein or thereby. Pore feret was measured according to the pore test described herein.

Most or all of the apertures 422 may have a minimum Ferrett (width of aperture) in the range of about 0.5mm to about 4mm, about 0.7mm to about 3mm, about 0.8mm to about 2mm, about 0.9mm to about 1.3mm, about 1mm to about 1.2mm, about 1mm, about 1.1mm, about 1.11mm, about 1.2mm, or about 1.3mm, specifically listing all 0.1mm increments within the above-specified ranges and all ranges formed therein or thereby. Pore minimum feret is measured according to the pore test described herein.

Most or all of the pores 422 can have a feret to minimum feret ratio within the range of about 0.3 to about 2.5, about 0.5 to about 2, about 0.8 to about 1.6, about 1 to about 1.5, about 1.1 to about 1.5, about 1.2, about 1.3, about 1.35, about 1.4, or about 1.5, specifically listing all 0.1 increments within the above-specified ranges and all ranges formed therein or thereby. The Ferrett ratio is calculated by dividing the pore Ferrett by the pore minimum Ferrett.

The average lateral axis center-to-center hole spacing of most or all adjacent holes measured across a tab is in the range of about 2mm to about 20mm, about 2mm to about 15mm, about 3mm to about 12mm, about 3mm to about 10mm, about 3mm to about 8mm, about 3mm to about 7mm, about 4mm, about 5mm, about 6mm, about 7mm, about 4mm to about 6mm, about 5mm to about 6mm, about 4.8mm, about 4.9mm, about 5.0mm, about 5.1mm, about 5.2mm, about 5.3mm, about 5.4mm, about 5.5mm, about 5.6mm, about 5.7mm, about 5.8mm, or about 5.9mm, specifically listing all 0.1mm increments therein or formed thereby. The average lateral axis center-to-center spacing of adjacent holes is measured according to the average hole spacing test (lateral axis hole spacing) described herein.

The average longitudinal axis center-to-center hole spacing of most or all adjacent holes measured across a tab is in the range of about 2mm to about 20mm, about 2mm to about 15mm, about 3mm to about 12mm, about 3mm to about 10mm, about 3mm to about 8mm, about 3mm to about 7mm, about 4mm, about 5mm, about 6mm, about 7mm, about 4mm to about 6mm, about 5mm to about 6mm, about 4.8mm, about 4.9mm, about 5.0mm, about 5.1mm, about 5.2mm, about 5.3mm, about 5.4mm, about 5.5mm, about 5.6mm, about 5.7mm, about 5.8mm, or about 5.9mm, specifically listing all 0.1mm increments therein or formed thereby. The average longitudinal axis center-to-center spacing of adjacent holes is measured according to the average hole spacing test (longitudinal axis hole spacing) described herein.

Most or all of the projections 416 may have a widest cross-sectional diameter taken in a direction parallel to the lateral axis of the absorbent article in the range of about 1mm to about 15mm, about 1mm to about 10mm, about 1mm to about 8mm, about 1mm to about 6mm, about 1.5mm to about 6mm, about 2mm to about 5mm, specifically listing all 0.1mm increments within the above-specified ranges and all ranges formed therein or thereby.

Most or all of the projections 416 may have a widest cross-sectional diameter taken in a direction parallel to the longitudinal axis of the absorbent article in the range of about 1mm to about 15mm, about 1mm to about 10mm, about 1mm to about 8mm, about 1mm to about 6mm, about 1.5mm to about 6mm, about 2mm to about 5mm, specifically listing all 0.1mm increments within the above-specified ranges and all ranges formed therein or thereby.

The substrates of the present disclosure may have an effective open area in the range of about 1% to about 50%, about 1% to about 40%, about 3% to about 35%, about 5% to about 25%, about 5% to about 20%, about 6% to about 18%, about 5% to about 15%, about 5%, about 8%, about 9%, about 9.5%, about 10%, about 10.5%, about 11%, or about 12%, specifically listing all 0.1% increments within the above-specified ranges and all ranges formed therein or thereby. The effective open area% of the substrate is measured according to the pore test described herein.

The substrate of the present disclosure may have apertures having a circumference in the range of about 1mm to about 50mm, about 1mm to about 30mm, about 2mm to about 20mm, about 2mm to about 15mm, about 2mm to about 10mm, about 3mm to about 8mm, about 4mm, about 5mm, about 5.42mm, about 6mm, or about 7mm, specifically listing all 0.1mm increments within the above-specified ranges and all ranges formed therein or thereby. The perimeter of the hole is measured according to the hole test described herein.

The first side 418 of the substrate 400 of the present disclosure may have a geometric roughness value in the range of about 2 to about 4.5, about 2.5 to about 4, about 3 to about 4, about 3.1 to about 3.5, about 3.2, about 3.3, about 3.31, about 3.35, about 3.4, or about 3.5, specifically listing all 0.1 increments within the above-specified ranges and all ranges formed therein or thereby. The geometric roughness value of the first side 418 of the substrate 400 of the present disclosure is measured according to the descriptive analytical roughness test described herein. The first side 418 of the substrate 400 of the present disclosure may have a coefficient of friction value in the range of about 0.2 to about 0.4, about 0.25 to about 0.35, about 0.27 to about 0.31, about 0.27, about 0.28, about 0.29, about 0.30, or about 0.31, specifically listing all 0.01 increments therein or therefrom. The coefficient of friction values of the first side 418 of the substrate 400 of the present disclosure are measured according to the descriptive analytical roughness test described herein. The first side 418 of the substrate 400 of the present disclosure may have a slip adhesion value in the range of about 0.010 to about 0.025, about 0.015 to about 0.020, about 0.015, about 0.016, about 0.017, about 0.018, or about 0.019, specifically listing the above-specified ranges and all 0.001 increments formed therein or therein. The coefficient of friction values of the first side 418 of the substrate 400 of the present disclosure are measured according to the descriptive analytical roughness test described herein.

The second side 420 of the substrate 400 of the present disclosure may have a geometric roughness value in the range of about 2 to about 4.0, about 2.3 to about 3.5, about 2.5 to about 3.3, about 2.6 to about 3.1, about 2.6, about 2.7, about 2.8, about 2.83, about 2.9, or about 3.0, specifically listing all 0.1 increments within the above-specified ranges and all ranges formed therein or thereby. The geometric roughness value of the second side 420 of the substrate 400 of the present disclosure is measured according to the descriptive analytical roughness test described herein. The second side 420 of the substrate 400 of the present disclosure may have a coefficient of friction value in the range of about 0.2 to about 0.4, about 0.25 to about 0.35, about 0.27 to about 0.31, about 0.27, about 0.28, about 0.29, about 0.30, or about 0.31, specifically listing all 0.01 increments therein or therefrom. The coefficient of friction value of the second side 420 of the substrate 400 of the present disclosure is measured according to the descriptive analytical roughness test described herein. The second side 420 of the substrate 400 of the present disclosure can have a slip adhesion value in the range of about 0.010 to about 0.025, about 0.011 to about 0.018, about 0.012, about 0.013, about 0.014, about 0.015, or about 0.016, specifically listing the ranges specified above and all 0.001 increments formed therein or therein. The coefficient of friction value of the second side 420 of the substrate 400 of the present disclosure is measured according to the descriptive analytical roughness test described herein.

Ratio of

The ratio of the height (μm) of the protrusions to the% effective open area may be in the range of about 70 to about 160, about 80 to about 150, about 100 to about 145, about 95 to about 150, about 100 to about 140, about 110 to about 130, about 115 to about 130, about 118 to about 125, about 120, about 121, about 122, about 122.74, about 123, or about 124, specifically listing the specified ranges and all 0.1 increments formed therein or therein.

The ratio of the overall substrate height (μm) to the% effective open area may be in the range of about 125 to about 350, about 150 to about 300, about 175 to about 275, about 200 to about 250, about 215 to about 235, about 220 to about 230, or about 225, specifically listing the specified ranges and all 0.1 increments formed therein or therein.

The ratio of the height (μm) of the protrusions to the geometric roughness of the surface of the three-dimensional substrate (e.g., first or second; 418 or 420) can be in the range of about 250 to about 600, about 300 to about 500, about 325 to about 450, about 325 to about 425, about 350, about 352, about 410, or about 412, specifically listing all 0.1 increments specified and all ranges formed therein or thereby.

The ratio of the overall substrate height (μm) to the geometric roughness of the surface of the three-dimensional substrate (e.g., first or second; 418 or 420) can be in the range of about 500 to about 900, about 600 to about 800, about 645, about 650, about 700, about 750m, or about 755, specifically listing the specified ranges and all 0.1 increments formed therein or therefrom.

The substrate of the present disclosure may include one or more colors, dyes, inks, indicia, patterns, embossments, and/or graphics. Colors, dyes, inks, indicia, patterns, and/or graphics may contribute to the aesthetic appearance of the substrate.

The substrate of the present disclosure may be used as part or all of any suitable product, such as a wipe, a wipe (wet or dry), a cosmetic removal substrate, a paper towel, toilet tissue, facial tissue, medical gowns, a surgical substrate, packaging material, a filtration substrate, or any other suitable product.

Method of making a three-dimensional substrate or an absorbent article comprising a three-dimensional substrate

The three-dimensional substrates and absorbent articles comprising the three-dimensional substrates of the present disclosure can be prepared by any suitable method known in the art. In particular, the articles can be made manually or industrially at high speed.

Fig. 26 is a schematic view of one exemplary method for forming the substrate of the present disclosure. Fig. 27 is a view of the intermeshing engagement of portions of the first and second rollers. Fig. 28 is a view of a portion of a first roller. Fig. 29 is a view of a portion of the second roller.

Referring to fig. 26-29, the substrate of the present disclosure may be formed by: one or more layers of substrate 399 (not three-dimensional) are passed through a nip 502 formed by two intermeshing rolls 504 and 506 to form three-dimensional substrate 400. The rollers 504 and 506 may be heated. The first roller 504 may create holes 422 and depressions 414 in the substrate 400 (in combination with the second roller) and the second roller 506 may create protrusions 416 in the substrate 400 (in combination with the first roller). First roller 504 may include a plurality of conically-shaped projections 508 extending radially outward from first roller 504. First roller 504 may also include a plurality of depressions 510 formed in the radially outer surface of first roller 504. The second roller 506 may comprise a plurality of dome-shaped protrusions 512 extending radially outward from the second roller 506. The second roller 506 may also include a plurality of recesses 514 formed in a radially outer surface of the second roller 506. The protrusions 508 on the first roller 504 may have a different size, shape, height, area, width, and/or dimension than the protrusions 512 on the second roller 506. The recesses 510 formed in the first roller 504 may have a different size, shape, height, area, width, and/or dimension than the recesses 514 formed in the second roller 506. The depressions 510 in the first roll 504 may be configured to at least partially receive the dome-shaped protrusions 512, thereby creating protrusions 414 in the substrate 400. The depressions 510 may be deep enough that the portions of the base forming the projections 414 and the projection peaks 425 will not be compressed or not be sufficiently compressed. Specifically, when the dome-shaped protrusion 512 is engaged into the recess 510, a sufficient depth is left between the surfaces in the radial direction so that the thickness of the substrate in the protrusion 414 is higher than that of the recess 510. This feature provides the projections 414 with a softer feel and greater height than the base portion that is compressed to form the projections. The recesses 514 in the second roller 506 may be configured to at least partially receive the conically shaped protrusions 508, thereby creating the recesses 414 and the holes 422 in the substrate 400.

The substrates of the present disclosure may also be formed by any other suitable method known to those skilled in the art.

Package (I)

The absorbent articles of the present disclosure may be placed in a package. The package may comprise a polymeric film and/or other materials. Graphics or indicia relating to the characteristics of the absorbent article may be formed on, positioned on, and/or placed on the exterior portion of the package. Each package may include one or more absorbent articles. The absorbent articles may be stacked under compression in order to reduce the size or height of the packages while still providing a sufficient amount of absorbent articles per package. By enclosing the absorbent article under compression, the caregiver can easily handle and store the package while also providing distribution savings to the manufacturer.

Accordingly, a package of absorbent articles according to the present disclosure may have an in-bag stack height of less than about 100mm, less than about 95mm, less than about 90mm, less than about 85mm but greater than 75mm, less than about 80mm, less than about 78mm, or less than about 76mm according to the in-bag stack height test described herein. Alternatively, the package of absorbent articles of the present disclosure may have an in-bag stack height of from about 70mm to about 100mm, from about 70mm to about 95mm, from about 72mm to about 85mm, from about 72mm to about 80mm, or from about 74mm to about 78mm according to the in-bag stack height test described herein, specifically listing the specified ranges and all 0.1mm increments formed therein or therein. Additional details regarding the stack height within the bag are disclosed in U.S. patent 8,585,666 issued to Weisman et al on 11/19/2013.

Relative humidity

Without being bound by any particular theory, it is believed that softer materials are desirable on the outer cover nonwoven material of the backsheet and/or the topsheet to reduce skin irritation and provide comfort to the wearer. However, these softer materials may often require an increase in the basis weight of these materials to achieve such softness benefits. A problem with higher basis weight materials (such as the liquid permeable substrates of the present disclosure), especially when used as topsheets or portions thereof, is that they may retain more moisture at or near the skin than lower basis weight materials. Most of this moisture can be wicked through the high basis weight material of the topsheet, through the acquisition/distribution system comprising one or more layers, into a conventional absorbent core comprising a significant amount of cellulose fibers (e.g., 30% or more) by weight of the absorbent core, mixed with superabsorbent polymer. The high concentration of cellulose fibers in conventional cores may not be able to completely "lock" moisture after, for example, one or more urination events as well as the superabsorbent polymer. In contrast, the cellulose fibers allow moisture to evaporate back toward the topsheet. This evaporation results in more moisture and water vapor partial pressure within the absorbent article, resulting in more moisture contacting the wearer's skin. To reduce moisture contact with the skin of a wearer, the present disclosure provides, in part, an absorbent core that is substantially cellulose free or an absorbent core that is cellulose free. Absorbent cores having no or very limited cellulose fibers or having a substantial portion of superabsorbent polymers better "lock" moisture in the absorbent core and at least inhibit the moisture and water vapor partial pressures from rising back toward the topsheet and contacting the wearer's skin. This allows the absorbent article to provide a lower relative humidity environment for the wearer within the absorbent article, resulting in reduced skin irritation, even when paired with a high basis weight topsheet (such as when using the liquid permeable substrate of the present disclosure as the topsheet of an absorbent article).

An absorbent article having a substantially cellulose-free absorbent core or a cellulose-free absorbent core, and a high basis weight outer cover nonwoven fabric of a high basis weight topsheet (e.g., a liquid permeable substrate of the present disclosure) and optionally a backsheet, may have a relative humidity in the range of from about 30% to about 75%, from about 40% to about 75%, from about 45% to about 74%, from about 45% to about 73%, from about 50% to about 72%, from about 50% to about 70%, from about 50% to about 68%, from about 50% to about 65%, from about 60% to about 64%, less than 76%, less than 75%, less than about 74%, less than about 73%, less than about 72%, less than about 71%, less than about 70%, less than about 68%, less than about 65%, less than about 64%, less than about 63%, about 62%, less than about 60%, less than about 58%, less than about 56%, less than about 55%, less than about 54%, less than about 53% > Or a relative humidity of about 52%, specifically listing the specified range and all 0.1% increments therein or therefrom. All relative humidity measurements were made according to the humidity test herein. A chart comparing the relative humidity% of commercially available absorbent articles with the relative humidity% of two exemplary absorbent articles having a liquid permeable substrate of the present disclosure as a topsheet is shown in table 1 below. The WVTR values of the backsheet films of the respective absorbent articles are also shown in table 1 below. It is important to note that even with a relatively high basis weight topsheet (about 35gsm in the example), absorbent articles having a liquid permeable substrate of the present disclosure achieve about the same or less relative humidity as commercially available airfelt free products (i.e., Pampers cresers) having a low basis weight topsheet (about 15.5 gsm). Thus, the benefits of low relative humidity are realized in absorbent articles having airfelt-free cores combined with high basis weight topsheets (e.g., topsheets having basis weights in excess of 25 gsm).

TABLE 1

By (AFF) -is meant that the absorbent article has an absorbent core comprising an absorbent material comprising at least 95%, at least 98%, at least 99%, or 100% superabsorbent polymers by weight of the absorbent material. These cores are substantially free of cellulose fibers or completely free of cellulose fibers.

(AF/C) -means that the absorbent article has an absorbent core comprising absorbent material comprising superabsorbent polymers and at least 30% of cellulose fibers by weight of the total absorbent material in the absorbent core.

TSBW-refers to the basis weight of the topsheet as measured by basis weight herein.

WVTR

The WVTR or water vapor transmission rate of the backsheet films of the tested absorbent articles are shown in table 1 above. The WVTR value specifies the degree of "breathability" or vapor permeability of a material, such as a backsheet film. The higher the WVTR value, the greater the degree of breathability or vapor permeability of the material and vice versaHowever. In a first form, the absorbent articles of the present disclosure may have a WVTR value of less than 7,500g/m according to the WVTR test herein²Day, less than 7,000g/m²Day, less than 6,500g/m²Day, less than 6,000g/m²Day, less than 5,800g/m²Day, less than 5,500g/m²Day, or less than 5,450g/m²And (5) day. The backsheet film of the absorbent article of the first form may have a minimum WVTR value of at least 750g/m according to the WVTR test herein²Day, at least 1,000g/m²Day, at least 1,500g/m²Day, at least 2,000g/m²Day, at least 2,500g/m²Day, at least 3,000g/m²Day, or at least 3,500g/m²And (5) day. The upper and lower WVTR numbers herein also form ranges specifically included in this disclosure (e.g., 2,000 g/m)²Day to 6,500g/m²Day). In a second form, the absorbent articles of the present disclosure may have a WVTR value of less than 16,000g/m according to the WVTR test herein²Day, less than 15,000g/m²Day, less than 14,500g/m²Day, less than 14,000g/m²Day, less than 13,800g/m²Day, less than 13,700g/m²Day, or less than 13,600g/m²And (5) day. The backsheet film of the absorbent article of the second form may have a minimum WVTR value of at least 7,000g/m according to the WVTR test herein²Day, at least 8,000g/m²Day, at least 9,000g/m²Day, at least 10,000g/m²Day, at least 11,000g/m²Day, at least 12,000g/m²Day, or at least 13,000g/m²And (5) day. The upper and lower WVTR numbers herein also form ranges specifically included in this disclosure (e.g., 10,000 g/m)²Day to 15,000g/m²Day).

Absorbent articles comprising a liquid permeable substrate of the present disclosure as a topsheet and an absorbent core comprising an absorbent material comprising at least 85%, at least 90%, at least 95%, at least 99%, or 100% superabsorbent polymer by weight of the absorbent material may have a relative humidity of less than 75%, less than 74%, less than 73%, less than 72%, less than 70%, less than 68%, less than 66%, less than 65%, less than 64%, or less than 63% according to the wetness test, or may have a relative humidity of from about 50% to 75%, about 55%To a relative humidity within a range of from about 70%, from about 55% to about 65%, from about 58% to about 65%, or from about 60% to about 64%, specifically listing all 0.1% increments within the specified ranges and all ranges formed therein or therefrom, and less than 7,500g/m according to the WVTR test herein²Day, less than 7,000g/m²Day, less than 6,500g/m²Day, less than 6,000g/m²Day, less than 5,800g/m²Day, less than 5,600g/m²Day, or less than 5,500g/m²Day, but more than 750g/m²Day, more than 1,000g/m²Day, more than 1,500g/m²Day, more than 1,750g/m²Day, or greater than 2,000g/m²WVTR values for days. The liquid permeable substrate of the topsheet may have a basis weight in excess of 30gsm, about 35gsm, in the range of about 25gsm to about 60gsm, or in the range of about 30gsm to about 40 gsm.

Absorbent articles comprising a liquid permeable substrate of the present disclosure as a topsheet and an absorbent core comprising an absorbent material comprising at least 85%, at least 90%, at least 95%, at least 99%, or 100% superabsorbent polymer, by weight of the absorbent material, can have a relative humidity of less than 75%, less than 74%, less than 73%, less than 72%, less than 70%, less than 68%, less than 65%, less than 63%, less than 60%, less than 58%, less than 56%, less than 55%, less than 54%, or less than 54%, according to the wetness test, or can have a relative humidity in the range of from about 40% to 75%, from about 45% to about 70%, from about 45% to about 65%, from about 48% to about 60%, from about 48% to about 56%, or from about 50% to about 54%, specifically listing all 0.1% increments specified ranges and all ranges formed therein or thereby, and less than 16,000g/m according to the WVTR test herein²Day, less than 15,500g/m²Day, less than 15,000g/m²Day, less than 14,500g/m²Day, less than 14,000g/m²Day, less than 13,800g/m²Day, less than 13,600g/m²Day, but greater than 8,000g/m²Day, more than 10,000g/m²Day, more than 11,000g/m²Day, more than 12,000g/m²Day, or greater than 13,000g/m²WVTR values for days. Liquid permeable base of topsheetThe base may have a basis weight in excess of 30gsm, about 35gsm, in the range of about 25gsm to about 60gsm, or in the range of about 30gsm to about 40 gsm.

Test method

Prior to testing, all samples were conditioned for 2 hours at about 23 ℃ ± 2 ℃ and about 50% ± 2% relative humidity.

Hole testing

Measurements of aperture size, effective aperture area and% effective open area were made on images generated using a flat bed scanner capable of scanning in reflection mode at a resolution of 6400dpi and 8bit grey scale (one suitable scanner is Epson Perfection V750 Pro, Epson, USA). The analysis was performed using ImageJ software (version 1.46, National Institute of Health, USA) and calibrated with a ruler certified by NIST. The samples were mounted using a steel frame (100 square millimeters, 1.5mm thick, with 60 square millimeter openings) and black glass tiles (P/N11-0050-30, available from Hunter Lab, Reston, Va.) were used as the background for the scanned images.

A steel frame is taken and a double-sided adhesive tape is placed on the bottom surface around the interior opening. To obtain a sample, the absorbent article is laid flat on a laboratory bench with the wearer-facing surface facing up. The release paper of the tape is removed and the steel frame is adhered to the topsheet of the absorbent article (the substrate described herein may form only a portion of the topsheet, e.g., by being positioned on the topsheet, the three-dimensional material being the article being sampled). The topsheet is cut from the underlying layer of the absorbent article around the outer periphery of the frame using razor blades. The sample was carefully removed so that its longitudinal and lateral extensions were retained. The top sheet sample can be removed from the underlying layers using a freezer spray (such as Cyto-Freeze, Control Company, Houston TX), if desired. Five replicates obtained from five substantially similar absorbent articles were prepared for analysis.

The ruler was placed on the scanning bed, the lid closed and a 50mm x 50mm calibration image of the ruler was taken in reflection mode at a resolution of 6400dpi and 8bit grey scale. The image is saved as an uncompressed TIFF format file. The lid is lifted and the ruler is removed. After the calibration image is obtained, all samples are scanned under the same conditions and measurements are made based on the same calibration file. Next, the framed specimen is placed in the center of the scanning bed with the wearer-facing surface of the specimen facing the glass surface of the scanner. Place a black glass tile on top of the frame, cover the sample, close the lid and take the scan image. The remaining four repetitions were scanned in a similar manner.

The calibration file is opened in ImageJ and linear calibration is performed using an imaged ruler, setting the scale to Global so that calibration will be applied to subsequent samples. The sample image is opened in ImageJ. The histogram is observed and the gray scale value of the smallest population located between the dark pixel peak of the apertures and the lighter pixel peak of the nonwoven fabric is identified. The threshold value of the image is set to the minimum gray level value to generate a binary image. In the treated image, the pores appear black and the nonwoven appears white.

The analytical particle function is selected. The minimum aperture area exclusion limit was set to 0.3mm²And edge holes were excluded for analysis purposes. The software was set up to calculate: effective aperture area, perimeter, Ferrett (length of aperture), and minimum Ferrett (width of aperture). The average effective pore area is recorded to the nearest 0.01mm²And average perimeter to the nearest 0.01 mm. The analysis particle function is again chosen, but this time the analysis is set to include edge porosity in the calculation of the effective pore area. The sum of the effective aperture areas (including whole and part apertures) is taken and divided by the total area (2500 mm) included in the image²). The effective open area% is recorded to the nearest 0.01%.

The remaining four sample images were analyzed in a similar manner. The average effective pore area of five replicates was calculated and recorded to the nearest 0.01mm²(ii) a Averaging the perimeter of the hole to 0.01 mm; ferrett and minimum Ferrett, to the nearest 0.01 mm; and effective open area% to the nearest 0.01%.

Height test

The substrate protrusion height and the overall substrate height were measured using a GFM MikroCAD Premium instrument commercially available from GFMesstechnik GmbH, Teltow/Berlin, Germany. The GFM MikroCAD Premium instrument includes the following major components: a) DLP projectors with direct digitally controlled micromirrors; b) a CCD camera having a resolution of at least 1600 x 1200 pixels; c) projection optics adapted for a measurement area of at least 60mm x 45 mm; d) recording optics adapted for a measurement area of at least 60mm x 45 mm; e) a short tripod based on small hard stone slabs; f) a blue LED light source; g) a measurement, control and evaluation computer running ODSCAD software (version 6.2, or equivalent); and h) calibration plates for lateral (x-y) and vertical (z) calibration, purchased from commercial suppliers.

The GFM MikroCAD Premium system uses digital micromirror pattern edge projection technology to measure the surface height of a specimen. The analysis results are a map of surface height (z direction or z axis) versus displacement in the x-y plane. The system has a field of view of 60 x 45mm with an x-y pixel resolution of about 40 microns. The height resolution was set at 0.5 microns/count with a height range of +/-15 mm. All tests were conducted in a conditioning chamber maintained at about 23 ± 2 ℃ and about 50 ± 2% relative humidity.

The samples were mounted using a steel frame (100 square millimeters, 1.5mm thick, with a 70 square millimeter opening). A steel frame is taken and a double-sided adhesive tape is placed on the bottom surface around the interior opening. To obtain a sample, the absorbent article is laid flat on a bench with the wearer-facing surface facing up. The release paper of the tape is removed and the steel frame is adhered to the topsheet of the absorbent article (the substrate described herein may form only a portion of the topsheet, e.g., by being positioned on the topsheet, the three-dimensional material being the article being sampled). The topsheet is cut from the underlying layer of the absorbent article around the outer periphery of the frame using razor blades. The sample was carefully removed so that its longitudinal and lateral extensions were retained. The top sheet sample can be removed from the underlying layers using a freezer spray (such as Cyto-Freeze, Control Company, Houston TX), if desired. Five replicates obtained from five substantially similar absorbent articles were prepared for analysis.

The instrument was calibrated according to the manufacturer's instructions using calibration plates for the lateral (x-y axis) and vertical (z axis) directions, purchased from the supplier.

The steel plate and sample were placed on a table, under the camera, with the wearer-facing surface oriented towards the camera. The sample is centered within the camera field of view so that only the sample surface is visible in the image. The sample is laid flat with minimal wrinkles.

The height image (z direction) of the sample is acquired following the measurement procedure recommended by the instrument manufacturer. Technical Surface/Standard measurement program with the following operating parameters was selected: a fast image recording method with a 3 frame delay is utilized. The dual phase shift is used in combination with: 1) a 16 pixel stripe width with a picture count of 12, and 2) a 32 pixel stripe width with a picture count of 8. Full gray code (gray) starts with pixel 2 and ends with pixel 512. After the measurement procedure is selected, the procedure for focusing the measurement system and making brightness adjustments continues as recommended by the instrument manufacturer. A 3D measurement is made and then the height image and camera image files are stored.

The height image is loaded into the analysis portion of the software via the clipboard. The following filtering process is then performed on each image: 1) removing invalid points; 2) removal of peaks (small local bumps); 3) polynomial filtration of a material fraction having a rank of n-5, wherein 30% of peaks and 30% of troughs are excluded from the material fraction and 5 cycles are performed.

Bump height test

A line is drawn connecting the peaks of the series of projections, wherein the line traverses a non-apertured land area positioned between each projection. A cross-sectional image of the height image is generated along the drawn line. Along the sectional line, the vertical height (z-direction) difference between the peak of the protrusion and the adjacent valley of the landing zone is measured. The height was recorded to the nearest 0.1 μm. A total of 10 different bump-to-landing zone height measurements were averaged and the value was recorded to the nearest 0.1 μm. This is the protrusion height.

Dimple height test

The depression height is obtained by subtracting the protrusion height from the overall base height. This should be done using each of the ten measurements from the protrusion height test and the overall base height test. A total of ten depression heights were averaged and the value was recorded to the nearest 0.1 μm. This is the recess height.

Total substrate height test

A line is drawn connecting the peaks of the series of projections, wherein the line crosses the center of the holes positioned between each projection and within the depression. A cross-sectional image of the height image is generated along the drawn line. Along the sectional line, the vertical height difference between the peak of the protrusion and the adjacent base of the depression is measured. The height was recorded to the nearest 0.1 μm. The height measurements of a total of 10 different protrusion peaks to depression base were averaged and the value was recorded to the nearest 0.1 μm. This is the overall substrate height.

Average hole spacing test

The lateral axis hole spacing and longitudinal axis hole spacing measurements were made on images generated using a flat bed scanner capable of scanning in reflection mode at a resolution of 6400dpi and 8bit grey scale (one suitable scanner is Epson Perfection V750 Pro, Epson, USA). The analysis was performed using ImageJ software (version 1.46, National Institute of Health, USA) and calibrated with a ruler certified by NIST. The samples were mounted using a steel frame (100 square millimeters, 1.5mm thick, with 60 square millimeter openings) and black glass tiles (P/N11-0050-30, available from Hunter Lab, Reston, Va.) were used as the background for the scanned images. The tests were conducted at about 23 ℃. + -. 2 ℃ and about 50%. + -. 2% relative humidity.

A steel frame is taken and a double-sided adhesive tape is placed on the bottom surface around the interior opening. To obtain a sample, the absorbent article is laid flat on a laboratory bench with the wearer-facing surface facing up. The release paper of the tape was removed and the steel frame was adhered to the top sheet of the absorbent article. The topsheet (i.e., the three-dimensional substrate forming all or part of the wearer-facing surface) is cut from the underlying layers of the absorbent article around the outer periphery of the frame using a razor blade. The sample was carefully removed so that its longitudinal and lateral extensions were retained. The top sheet sample can be removed from the underlying layers using a freezer spray (such as Cyto-Freeze, Control Company, Houston TX), if desired. Five replicates obtained from five substantially similar absorbent articles were prepared for analysis. Prior to testing, the samples were conditioned for 2 hours at about 23 ℃ ± 2 ℃ and about 50% ± 2% relative humidity.

The ruler was placed on the scanning bed, the lid closed and a 50mm x 50mm calibration image of the ruler was taken in reflection mode at a resolution of 6400dpi and 8bit grey scale. The image is saved as an uncompressed TIFF format file. The lid is lifted and the ruler is removed. After the calibration image is obtained, all samples are scanned under the same conditions and measurements are made based on the same calibration file. Next, the framed specimen is placed in the center of the scanning bed with the wearer-facing surface of the specimen facing the glass surface of the scanner. Place a black glass tile on top of the frame, cover the sample, close the lid and take the scan image. The remaining four repetitions were scanned in a similar manner.

The calibration file is opened in ImageJ and linear calibration is performed using an imaged ruler, setting the scale to Global so that calibration will be applied to subsequent samples. The sample image was opened in ImageJ and the following measurements were taken:

lateral axial hole spacing

The measurement is taken from the center point of one hole to the center point of an adjacent hole on the other side of the protrusion, where the protrusion is positioned between the two holes. The measurement will be made in a direction across the protrusion parallel to the lateral axis of the sample. Each distance was recorded to the nearest 0.1 mm. 5 random measurements were made in the sample. The five values were averaged and the average lateral axis center-to-center spacing was recorded to the nearest 0.1 mm. This process was repeated for four additional samples.

Longitudinal axial hole spacing

The measurement is taken from the center point of one hole to the center point of an adjacent hole on the other side of the protrusion, where the protrusion is positioned between the two holes. The measurement will be made in a direction across the protrusion parallel to the longitudinal axis of the sample. Each distance was recorded to the nearest 0.1 mm. 5 random measurements were made in the sample. The five values were averaged and the average longitudinal axis center-to-center spacing was recorded to the nearest 0.1 mm. This process was repeated for four additional samples.

Basis weight test

The basis weight of a three-dimensional substrate can be determined by several available techniques, but a simple representative technique involves obtaining an absorbent article, removing any elastics that may be present, and stretching the absorbent article to its full length. Then using a sample having a height of 45.6cm²The die of area(s) cuts a piece of substrate from approximately the center of the diaper or absorbent article in a location that avoids, to the greatest extent, any adhesive that may be used to secure the topsheet to any other layer that may be present, the substrate forming the topsheet, being positioned on the topsheet, or forming a part of the topsheet ("topsheet" in this process), and the topsheet layer is removed from the other layers (using a freezer spray, such as Cyto-Freeze, Control Company, Houston, Tx., if desired). The sample was then weighed and divided by the area of the die to give the basis weight of the topsheet. The results are reported as an average of 5 samples to the nearest 0.1 grams per square meter.

Descriptive roughness analysis method

The surface geometric roughness was measured using a Kawabata evaluation system KES FB4 friction tester (available from Kato Tech co., Japan) with a roughness sensor. The instrument measures both surface friction and geometric roughness, but only geometric roughness (SMD values) are recorded herein. All tests were conducted at about 23 ℃. + -. 2 ℃ and about 50%. + -. 2% relative humidity. Prior to testing, the samples were preconditioned for 2 hours at about 23 ℃ ± 2 ℃ and about 50% ± 2% relative humidity. The instrument was calibrated according to the manufacturer's instructions.

The wearer facing surface is placed on the laboratory bench with the absorbent article facing upward. The cuffs of the absorbent article are cut off with scissors to facilitate laying the article flat. A sample of the topsheet 20cm long in the longitudinal direction of the absorbent article and 10cm wide in the lateral direction of the absorbent article is cut off with scissors or a surgical knife. Care should be taken when removing the sample so as not to distort the dimension in the longitudinal or lateral direction. Samples were taken from a total of five substantially identical absorbent articles.

The KES FB4 is opened. The instrument should be allowed to warm up for at least 10 minutes before use. The instrument was set to an SMD sensitivity of 2x5, a test speed of 0.1 and a compression area of 2 cm. The roughness contractor compression (contact force) was adjusted to 10 gf. The topsheet sample was placed on the tester with the wearer-facing surface facing upward and the longitudinal dimension aligned with the testing direction of the instrument. The sample was clamped with an initial tension of 20 gf/cm. The test is started. The instrument will automatically make 3 measurements on the sample. MIU (coefficient of friction), MMD (slip-stick) and SMD (geometric roughness) values from each of the three measurements were recorded to the nearest 0.001 micron. Repeat in a similar fashion for the remaining four samples.

The coefficient of friction was recorded as the average of 15 recorded values to the nearest 0.01. Slip-on was recorded as the average of 15 recorded values to the nearest 0.001. The geometric roughness was recorded as the average of 15 recorded values to the nearest 0.01 micron.

In bag Stack height test

The in-bag stack height of the package of absorbent articles of the present disclosure was determined as follows:

device

A Universal Diaper Package Tester (UDPT) (model M-ROEL; machine No. MK-1071) includes a horizontal slide (horizontal plate that moves up and down in a vertical plane) for adding weights. Balanced by a hanging weight to ensure that no downward force is applied to the diaper package by the horizontal slide assembly at any time. The UDPT is purchased from Matsushita Industry Co. LTD,7-21-101, Midorigaoka-cho, Ashiya-city, Hyogo JAPAN. And (3) post code: 659-0014. A weight of 850g (+/-0.5 g).

Definition of

As shown in fig. 30, the package 1000 defines an interior space 1002 and includes a plurality of absorbent articles 1004. The absorbent articles are in a stack 1006. The package has a package width 1008. The package width 1008 is defined as the maximum distance between the two highest projection points along the same compressed stacking axis 1010 of the absorbent article package 1000.

In-bag stack height (package width/pad count per stack) x 10 absorbent articles.

Device calibration

And pulling down the horizontal sliding plate until the bottom of the horizontal sliding plate touches the bottom plate of the tester.

The digital meter located beside the horizontal sliding plate is set to zero scale.

The horizontal slide is lifted away from the tester floor.

Test procedure

One of the side panels of the absorbent article package is placed in the center of the tester chassis along its width.

It is ensured that the vertical slide (the vertical plate moving left and right in the horizontal plane) is pulled to the right so that it does not touch the package being tested.

A850 g weight was added to the vertical slide.

The horizontal slide is allowed to slide down slowly until its bottom lightly touches the desired highest point of the package.

The package width was measured in mm (distance from the top of the bottom panel to the top of the diaper package).

The reading displayed by the digital meter is recorded.

The 850g weight was removed.

The horizontal slide is lifted away from the diaper package.

The absorbent article package is removed.

Calculation/recording

The "in-bag stack height" is calculated and recorded (package width/pad count per stack) x 10. The sample identity, i.e. the complete description of the product tested (product brand/size), is recorded.

The measurement value for each width measurement was recorded to the nearest 1 mm. For a given product, at least five packages of absorbent articles having the same pad count are measured in this manner, and the in-bag stack height values are summed to calculate an average and standard deviation.

The date of manufacture of the measurement package (taken from the package number) is recorded.

Test data and the analytical method used were recorded.

Humidity test

Relative humidity within an absorbent article is measured on a heated mannequin having dimensions based on ASTM D4910-02. The tests were carried out in a laboratory strictly maintained at 23 ℃. + -. 2 ℃ and 50%. + -. 2% relative humidity. The conditions in the front portion of the absorbent article during loading with heated saline solution were monitored using sensors measuring temperature and relative humidity and four hours of relative humidity were recorded.

The hollow resin cast hard shell mannequins were manufactured to waist, hip and thigh circumference dimensions as described in ASTM D4910-02 and are summarized in Table 2 below. Referring to fig. 31 and 32, the bottom of both legs of the mannequin 2000 are vertically configured with quick disconnect fittings 2001 (right side in, left side out) to allow hot water to circulate through the internal volume of the mannequin. The temperature of the mannequin was controlled using a heated circulating bath (13 liter capacity, capable of maintaining the temperature to + -0.5 deg.C). An 1/8in stainless steel transfer tube 2002 is arranged vertically inside, entering at the top of the manikin and exiting at a point 2003 coinciding with the male urination point. On top of the manikin, two circular clamps 2004 are attached, from which the manikin can be suspended in an upright position during testing. For convenience, the mannequin may be placed on top of a bench to apply the absorbent article and then hung for testing.

Suitable humidity/temperature sensors 2005 are available from Sensirion as model SHT21, model EK-H4 multiplexing cassette, and model EK-H4 data recording software. The sensor itself is protected from liquid contact by a model SF2 filter top cover. Sensors with equivalent performance and comparable dimensions can be substituted. Sensor 2005 is attached to the front of the manikin approximately 10mm above site 2003, with its thin flat cable (shown as a black arrow in fig. 31) running along the surface and exiting at the top of the waist.

Prior to testing, the absorbent articles were conditioned outside of their packages for 24 hours in a chamber maintained at about 23 ℃ ± 2 ℃ and about 50% ± 2% relative humidity. The circulating bath was set to maintain a temperature of 37 ℃ ± 2 ℃ at sensor 2005. After temperature stabilization, the conditioned absorbent article is put on the manikin, ensuring that the waist of the absorbent article fits snugly around the waist of the manikin and positioning the cuffs as they are put on the wearer. The absorbent article was allowed to stabilize on the heated mannequin for an additional 1 hour.

The diaper was dosed with a synthetic urine solution of 0.9% NaCl (w/v). The reservoir of 0.9% saline solution was heated to 38 ℃ ± 1 ℃ in a heated water bath. Using a peristaltic pump, a size-dependent dose of 0.9% saline as defined in table 2 below was introduced through transfer tube 2002 at the rate defined in table 2 below. Two additional doses were delivered in a similar manner at five minute intervals. After completion of three doses, the relative humidity was monitored for four (4) hours. Relative humidity (%) data was recorded at a rate of 1 reading per minute to the nearest 0.1% throughout the experiment. Relative humidity (%) is recorded as the reading obtained at the 4 hour point and recorded to the nearest 0.1%. A total of nine (9) repeat diapers were tested in a similar manner and their average recorded to the nearest 1%.

TABLE 2

Water Vapor Transmission Rate (WVTR) test

The Mocon method is WSP 70.5 for WVTR. The value is in g/m²The unit of day is recorded.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Rather, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

Each document cited herein, including any cross-referenced or related patent or patent application, is hereby incorporated by reference in its entirety unless expressly excluded or limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the disclosure. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this disclosure.