阅读说明：本技术 衣服样的吸收制品 (Garment-like absorbent article ) 是由 A.V.史密斯 C.S.卡梅隆 N.L.拉莫斯梅迪纳 V.M.梅伦德兹 B.D.坎菲尔德 于 2019-09-19 设计创作，主要内容包括：本发明公开了衣服样的吸收制品。该衣服样的吸收制品可包括具有孔和/或粘结部的重复图案的一个或多个非织造部件。该非织造部件也可具有特定的重复单元面积、重复单元宽度和重复单元长度以有助于柔软性并向消费者提供改善的美学外观。(The invention discloses a garment-like absorbent article. The garment-like absorbent article may include one or more nonwoven components having a repeating pattern of apertures and/or bonds. The nonwoven component may also have a specific repeat unit area, repeat unit width, and repeat unit length to aid in softness and provide an improved aesthetic appearance to the consumer.)

1. An absorbent article, comprising:

a lateral axis;

a front waist region located on a first side of the lateral axis;

a rear waist region located on a second side of the lateral axis;

a liquid pervious topsheet;

a liquid impervious backsheet;

an absorbent core positioned at least partially intermediate the topsheet and the backsheet; and

an outer cover nonwoven in facing relationship with the backsheet, wherein the outer cover forms a portion of the garment-facing surface of the absorbent article;

wherein the outer cover nonwoven material comprises a pattern on the portion of the garment-facing surface, the pattern comprising:

a repeating pattern of bonds comprising a plurality of repeating units;

wherein a portion of the pattern within each of the repeating units is substantially identical;

wherein at least some of the repeating units have a molecular weight of at least about 25mm according to the repeating unit measurement test²To about 100mm²Repeat unit area within the range;

wherein at least some of the repeat units have a repeat unit width in the range of about 5mm to about 30mm according to the repeat unit measurement test; and is

Wherein at least some of the repeat units have a repeat unit length in the range of about 1mm to about 15mm according to the repeat unit measurement test.

2. The absorbent article of claim 1, wherein the repeat unit has a caliper of about 50mm according to the repeat unit measurement test²To about 80mm²Repeat unit area within the range.

3. The absorbent article of claim 1 or 2, wherein the repeat unit has a repeat unit width in the range of about 5mm to about 20mm, according to the repeat unit measurement test.

4. The absorbent article of any of the preceding claims, wherein the repeat unit has a repeat unit length in the range of about 1mm to about 8mm, according to the repeat unit measurement test.

5. The absorbent article of any of the preceding claims, wherein the repeating pattern of bonds comprising the plurality of repeating units forms a herringbone pattern.

6. The absorbent article of any of the preceding claims, wherein at least some of the repeating units comprise discontinuous bonds.

7. The absorbent article of claim 6 wherein the discontinuous bonds in the at least some of the repeating units comprise a first line of discontinuity, a second line of discontinuity, a third line of discontinuity, and a fourth line of discontinuity.

8. The absorbent article of claim 7, wherein at least some of the first, second, third, and fourth lines of discontinuity comprise two elements, and wherein the two elements have different sizes, shapes, and/or specifications.

9. The absorbent article according to any of the preceding claims, comprising a discrete landing zone or a discrete non-elasticized front belt joined to the front waist region adjacent the waist edge of the absorbent article, and wherein the discrete landing zone or the discrete non-elasticized front belt forms a second portion of the garment-facing surface of the absorbent article.

10. The absorbent article of claim 9, wherein the discrete landing zone or the discrete non-elasticized front belt comprises a second pattern on the second portion of the garment-facing surface, the second pattern comprising:

a second repeating pattern of bonded portions comprising a plurality of second repeating units;

wherein a portion of the second pattern within each of the second repeating units is substantially identical;

wherein at least some of the second repeat units have a molecular weight of at least about 25mm according to the repeat unit measurement test²To about 100mm²A second repeat unit area within the range; and is

Wherein at least some of the second repeat units have a width in the range of about 5mm to about 30mm according to the repeat unit measurement test.

11. The absorbent article of claim 10, wherein at least some of the second repeat units have a length in a range from about 1mm to about 10mm, according to the repeat unit measurement test.

12. The absorbent article of claim 11, wherein the repeating pattern of bonds comprising the plurality of second repeating units forms a herringbone pattern.

13. The absorbent article of claim 12, wherein the at least some of the second repeating units comprise discontinuous bonds.

14. The absorbent article of claim 13, wherein the discontinuous bonds in the at least some of the second repeating units comprise a first discontinuous line, a second discontinuous line, a third discontinuous line, and a fourth discontinuous line.

15. The absorbent article of claim 14, wherein at least some of the first, second, third, and fourth lines of discontinuity comprise two elements, and wherein the two elements have different sizes, shapes, and/or specifications.

Technical Field

The present disclosure relates generally to garment-like absorbent articles, and more particularly, to garment-like absorbent articles having a pattern of apertures or bonds forming a repeating unit on one or more nonwoven components.

Background

Absorbent articles are used to absorb and contain body exudates (e.g., urine, menses, and fecal waste) from infants, children, and adults. Absorbent articles may include, for example, diapers, pants, adult incontinence products, and sanitary napkins. Absorbent articles typically comprise a liquid pervious topsheet, a liquid impervious backsheet and an absorbent core positioned at least partially intermediate the topsheet and the backsheet. Various components of the absorbent article include nonwoven materials. Some examples are outer cover nonwoven materials, nonwoven ear materials, nonwoven landing zones, nonwoven topsheets, nonwoven leg cuff materials and nonwoven belt materials. The nonwoven material may have a bond pattern to hold the fibers together, but it may appear to be of low quality and/or not customized. Therefore, nonwoven materials for absorbent articles should be improved.

Disclosure of Invention

The present disclosure provides a garment-like absorbent article that overcomes the disadvantages of current absorbent articles by: absorbent articles are provided having one or more nonwoven materials with an aperture and/or bond pattern formed from a plurality of repeating units. The repeat units should have sufficient repeat unit area, repeat unit width, and repeat unit length to render the nonwoven material high quality and/or tailored. In some cases, it may be desirable to have an absorbent article comprising two different nonwoven materials having the same or similar pattern of bonds and/or apertures to reduce the modular appearance of current absorbent articles having a substantially different pattern of bonds on two different nonwoven components. The repeating units formed by the apertures and/or the bonding pattern may be the same or substantially the same on the same nonwoven component and substantially similar or analogous between two or more different nonwoven components. Two or more nonwoven components may each have a high texture to increase softness and promote high quality. These features result in a consumer having a more garment-like appearance to the absorbent article, and thus a higher quality impression. The pattern may be created by, for example, printing, embossing, bonding, and/or aperturing.

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 exemplary forms thereof taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a plan view of an exemplary absorbent article in the form of a taped diaper, with the garment-facing surface facing the viewer, in a flat, unfolded state;

FIG. 2 is a plan view of the exemplary absorbent article of FIG. 1 with the wearer-facing surface facing the viewer in a flat, laid-out condition;

FIG. 3 is a front perspective view of the absorbent article of FIGS. 1 and 2 in a fastened position;

FIG. 4 is a front perspective view of an absorbent article in the form of a pant;

FIG. 5 is a rear perspective view of the absorbent article of FIG. 4;

FIG. 6 is a plan view of the absorbent article of FIG. 4, the absorbent article being laid flat with the garment-facing surface facing the viewer;

FIG. 7 is a cross-sectional view of the absorbent article taken along line 7-7 of FIG. 6;

FIG. 8 is a cross-sectional view of the absorbent article taken along line 8-8 of FIG. 6;

FIG. 9 is a plan view of an exemplary absorbent core or absorbent article;

FIG. 10 is a cross-sectional view of the absorbent core of FIG. 9 taken along line 10-10;

FIG. 11 is a cross-sectional view of the absorbent core of FIG. 10 taken along line 11-11;

FIG. 12 is a plan view of an exemplary absorbent article of the present disclosure as a sanitary napkin;

FIG. 13 is a plan view of an exemplary absorbent article in the form of a taped diaper having a discrete non-elasticized front belt with a garment-facing surface facing the viewer and in a flat, unfolded state;

FIG. 14 is a plan view of the exemplary absorbent article of FIG. 13 with discrete non-elasticized front belts with the wearer-facing surface facing the viewer in a flat unfolded state;

FIG. 15 is a front perspective view of the absorbent article of FIG. 13 and FIG. 14 with a discrete non-elasticized front belt in a partially fastened position and with a first pattern and a second pattern on two different components;

FIG. 16 is a front perspective view of the absorbent article of FIG. 13 and FIG. 14 with discrete non-elasticized front belts in a partially fastened position and with a third pattern and a fourth pattern on two different components;

FIG. 17 is a plan view of a discrete non-elasticized front belt having first and second support members adjacent first and second ends thereof;

FIG. 18 is a cross-sectional view of the discrete non-elasticized front belt taken along line 18-18 of FIG. 17;

fig. 19-26 are exemplary patterns for components of absorbent articles, such as outer cover nonwovens, discrete landing zones, or discrete non-elasticized front belts;

FIGS. 27 and 28 are enlarged examples of discontinuous bond patterns having a herringbone pattern;

FIG. 29 is a graphical representation of Sq values (texture) for the disclosed samples compared to related art samples;

FIG. 30 is an exemplary repeating cell boundary identification connected to the repeating cell measurement test herein;

FIG. 31 is an exemplary repeating cell boundary identification made in a substrate comprising a repeating pattern of holes, prints, or bonds comprising a plurality of repeating cells connected to a repeating cell measurement test herein; and is

Fig. 32 is an exemplary absorbent article having a topsheet comprising a repeating pattern of apertures, prints, or bonds comprising a plurality of repeating units joined to the repeating unit measurement test herein.

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 garment-like absorbent articles disclosed herein. One or more examples of these non-limiting forms are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the garment-like absorbent articles described herein and illustrated in the accompanying 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.

General description of absorbent articles

An exemplary absorbent article 10 in the form of a diaper according to the present disclosure is shown in fig. 1-3. Fig. 1 is a plan view of an exemplary absorbent article 10 with a garment-facing surface 2 facing the viewer in a flat, unfolded state (i.e., without elastic contraction). Fig. 2 is a plan view of the exemplary absorbent article 10 of fig. 1, with the wearer-facing surface 4 facing the viewer, in a flat, unfolded state. Fig. 3 is a front perspective view of the absorbent article 10 of fig. 1 and 2 in a fastened configuration. The absorbent article 10 of fig. 1-3 is shown for purposes of illustration only, as the present disclosure may be used to manufacture a variety of diapers, including, for example, adult incontinence products, pants, or other absorbent articles such as sanitary napkins and absorbent pads.

The absorbent article 10 may include a front waist region 12, a crotch region 14, and a back waist region 16. The crotch region 14 may extend intermediate the front waist region 12 and the back waist region 16. The front waist region 12, the crotch region 14, and the back waist region 16 may each be 1/3 of the length of the absorbent article 10. The absorbent article 10 may comprise a front end edge 18, a back end edge 20 opposite the front end edge 18, and longitudinally extending laterally opposite side edges 22 and 24 defined by a chassis 52.

The absorbent article 10 may comprise a liquid pervious topsheet 26, a liquid impervious backsheet 28, and an absorbent core 30 positioned at least partially intermediate the topsheet 26 and the backsheet 28. The absorbent article 10 may also comprise one or more pairs of barrier leg cuffs 32 with or without elastics 33, one or more pairs of leg elastics 34, one or more elastic waistbands 36, and/or one or more acquisition materials 38. One or more acquisition materials 38 may be positioned intermediate the topsheet 26 and the absorbent core 30. An outer cover material 40 such as a nonwoven material may cover the garment-facing side of the backsheet 28. The absorbent article 10 may include back ears 42 located in the back waist region 16. The back ear panels 42 may comprise fasteners 46 on an adhesive tape and may extend from the back waist region 16 of the absorbent article 10 and attach (using fasteners 46) to a landing zone area or landing zone material 44 on the garment-facing portion of the front waist region 12 of the absorbent article 10. The absorbent article 10 may also have front ears 47 in the front waist region 12. The absorbent article 10 may have a central lateral (or transverse) axis 48 and a central longitudinal axis 50. The central lateral axis 48 extends perpendicular to the central longitudinal axis 50.

In other cases, the absorbent article may be in the form of a pant having permanent or refastenable side seams. Suitable refastenable seams are disclosed in U.S. patent application publication 2014/0005020 and U.S. patent 9,421,137. Referring to fig. 4-8, an exemplary absorbent article 10 in the form of a pant is shown. Fig. 4 is a front perspective view of the absorbent article 10. Fig. 5 is a rear perspective view of the absorbent article 10. Fig. 6 is a plan view of an absorbent article 10 that is laid flat with the garment-facing surface facing the viewer. Elements of fig. 4-8 having the same reference numbers as described above with respect to fig. 1-3 may be the same elements (e.g., absorbent core 30). Fig. 7 is an exemplary cross-sectional view of the absorbent article taken along line 7-7 of fig. 6. Fig. 8 is an exemplary cross-sectional view of the absorbent article taken along line 8-8 of fig. 6. Figures 7 and 8 show exemplary forms of the front belt 54 and the back belt 56. The absorbent article 10 may have a front waist region 12, a crotch region 14, and a back waist region 16. Each of the zones 12, 14, and 16 may be 1/3 of the length of the absorbent article 10. The absorbent article 10 may have a chassis 52 (sometimes referred to as a central chassis or central panel) comprising a topsheet 26, a backsheet 28, and an absorbent core 30 disposed at least partially intermediate the topsheet 26 and the backsheet 28, and optionally an acquisition material 38 similar to the acquisition materials described above with respect to fig. 1-3. The absorbent article 10 may include a front belt 54 located in the front waist region 12 and a back belt 56 located in the back waist region 16. The chassis 52 may be joined to the wearer-facing surface 4 of the front and back belt 54, 56 or to the garment-facing surface 2 of the belts 54, 56. The side edges 23 and 25 of the front belt 54 may be joined to the side edges 27 and 29, respectively, of the back belt 56 to form two side seams 58. The side seams 58 may be any suitable seam known to those skilled in the art, such as, for example, an abutting seam or an overlapping seam. When the side seams 58 are permanently formed or refastenably closed, the pant-form absorbent article 10 has two leg openings 60 and a waist-opening perimeter 62. The side seams 58 may be permanently joined using, for example, an adhesive or bond, or may be refastenably closed using, for example, hook and loop fasteners.

Belt

Referring to fig. 7 and 8, the front and back belts 54, 56 may include front and back inner belt layers 66, 67 and front and back outer belt layers 64, 65 having an elastomeric material (e.g., strands 68 or a film (which may be apertured)) disposed at least partially between the inner and outer belt layers. The elastic elements 68 or film may be relaxed (including cut) to reduce elastic strain on the absorbent core 30 or alternatively may be distributed continuously throughout the absorbent core 30. The elastic elements 68 may have uniform or variable spacing between them in any portion of the belt. The elastic elements 68 may also be pre-strained by the same amount or by different amounts. The front belt 54 and/or the back belt 56 may have one or more elastic element free zones 70 where the chassis 52 overlaps the front belt 54 and the back belt 56. In other cases, at least some of the elastic elements 68 may extend continuously over the chassis 52.

The front and back inner belt layers 66, 67 and the front and back outer belt layers 64, 65 may be joined using adhesives, heat bonds, pressure bonds, or thermoplastic bonds. Various suitable belt layer constructions can be found in U.S. patent application publication 2013/0211363.

The front belt end edge 55 and the back belt end edge 57 may extend longitudinally beyond the front chassis end edge 19 and the back chassis end edge 21 (as shown in figure 6), or they may be coterminous. The front and back belt side edges 23, 25, 27 and 29 may extend laterally beyond the chassis side edges 22 and 24. The front belt 54 and the back belt 56 may be continuous (i.e., have at least one continuous layer) from belt side edge to belt side edge (e.g., a lateral distance from 23 to 25 and from 27 to 29). Alternatively, the front belt 54 and the back belt 56 may be discontinuous from belt side edge to belt side edge (e.g., a lateral distance from 23 to 25 and from 27 to 29) such that they are discrete.

As disclosed in U.S. patent 7,901,393, the longitudinal length (along the central longitudinal axis 50) of the back belt 56 may be greater than the longitudinal length of the front belt 54, and this may be particularly useful for increasing hip coverage when the back belt 56 has a greater longitudinal length than the front belt 54 adjacent or immediately adjacent to the side seams 58.

The front and back outer belt layers 64, 65 may be separated from each other such that the layers are discrete, or the layers may be continuous such that the layers extend continuously from the front belt end edge 55 to the back belt end edge 57. The same may be true for the front and back inner belt layers 66 and 67-i.e., they may also be longitudinally discrete or continuous. Further, the front and back outer belt layers 64, 65 may be longitudinally continuous while the front and back inner belt layers 66, 67 are longitudinally discrete such that a gap is formed therebetween-the gap between the front and back inner and outer belt layers 64, 65, 66 and 67 is shown in figure 7 and the gap between the front and back inner belt layers 66, 67 is shown in figure 8.

The front belt 54 and the back belt 56 may include slits, holes, and/or perforations that provide increased breathability, softness, and garment-like texture. The underwear-like appearance may be enhanced by substantially aligning the waist and leg edges at the side seams 58 (see fig. 4 and 5).

The front belt 54 and the back belt 56 may include graphics (see, e.g., 78 of fig. 1). The graphic may extend substantially around the entire circumference of the absorbent article 10 and may be disposed across the side seams 58 and/or across the proximal front belt seam 15 and the back belt seam 17; alternatively, seams 58, 15 and 17 may be adjacent in the manner shown in U.S. patent 9,498,389 to form an article that more closely resembles underwear. The image may also be discontinuous.

Alternatively, discrete side panels may be connected to the side edges 22 and 24 of the chassis instead of attaching the belts 54 and 56 to the chassis 52 to form a pant. Suitable forms of pants including discrete side panels are disclosed in U.S. patent 6,645,190; 8,747,379, respectively; 8,372,052, respectively; 8,361,048, respectively; 6,761,711; 6,817,994, respectively; 8,007,485, respectively; 7,862,550, respectively; 6,969,377, respectively; 7,497,851, respectively; 6,849,067, respectively; 6,893,426, respectively; 6,953,452, respectively; 6,840,928, respectively; 8,579,876, respectively; 7,682,349, respectively; 7,156,833, respectively; and 7,201,744.

Topsheet

The topsheet 26 is the portion of the absorbent article 10 that contacts the wearer's skin. As known to those of ordinary skill in the art, the topsheet 26 may be joined to portions of the backsheet 28, the absorbent core 30, the barrier leg cuffs 32, and/or any other layers. The topsheet 26 may be compliant, soft feeling, and non-irritating to the wearer's skin. Further, at least a portion or all of the topsheet may be liquid pervious, permitting liquid bodily exudates 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, woven materials, nonwoven materials, 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. The topsheet may have one or more layers. The topsheet may be apertured (fig. 2, element 31), may have any suitable three-dimensional feature, and/or may have a plurality of embossments (e.g., bond patterns). The topsheet may be apertured by overbonding the material and then rupturing the overbonds by ring rolling, as disclosed, for example, in U.S. patent No. 5,628,097 to Benson et al, 5-13, 1997 and in U.S. patent application publication No. US 2016/0136014 to Arora et al. Any portion of the topsheet can be coated with a skin care composition, an antimicrobial agent, a surfactant, and/or other benefit agents. The topsheet may be hydrophilic or hydrophobic or may have hydrophilic and/or hydrophobic portions or layers. If the topsheet is hydrophobic, there will typically be apertures so that body exudates can pass through the topsheet. The topsheet may include a bond pattern, apertures, and/or three-dimensional features.

Negative film

The backsheet 28 is generally that portion of the absorbent article 10 positioned adjacent the garment-facing surface of the absorbent core 30. The backsheet 28 may be joined to portions of the topsheet 26, the outer cover material 40, the absorbent core 30, and/or any other layers of the absorbent article by any attachment method known to those skilled in the art. The backsheet film 28 prevents, or at least inhibits, the body exudates absorbed and contained by the absorbent core 10 from soiling articles, such as bed sheets, undergarments, and/or clothing. The backsheet is generally liquid impervious, or at least substantially liquid impervious. The backsheet may be or comprise a thin plastic film, such as a thermoplastic film, for example, having a thickness of about 0.012mm to about 0.051 mm. Other suitable backsheet materials may include breathable materials that permit vapors to escape from the absorbent article while still preventing, or at least inhibiting, body exudates from passing through the backsheet.

Outer cover material

The outer cover material (sometimes referred to as a backsheet nonwoven) 40 may comprise one or more nonwovens joined to the backsheet 28 and covering the backsheet 28. The outer cover material 40 forms at least a portion of the garment-facing surface 2 of the absorbent article 10 and effectively "covers" the backsheet 28 such that the film is not present on the garment-facing surface 2. The outer cover material 40 may include bond patterns, apertures, and/or three-dimensional features.

Absorbent core

As used herein, the term "absorbent core" 30 refers to the component of the absorbent article 10 having the greatest absorbent capacity and comprising absorbent material. Referring to fig. 9-11, in some cases, the absorbent material 72 may be positioned within a core bag or core wrap 74. The absorbent material may or may not be shaped, depending on the particular absorbent article. The absorbent core 30 may comprise, consist essentially of, or consist of a core wrap, an absorbent material 72, and a glue enclosed within the core wrap. The absorbent material may comprise superabsorbent polymer, a mixture of superabsorbent polymer and airfelt, airfelt only, and/or high internal phase emulsion foam. In some cases, the absorbent material may comprise at least 80%, at least 85%, at least 90%, at least 95%, at least 99%, or at most 100% superabsorbent polymers by weight of the absorbent material. In such cases, the absorbent material may be free of airfelt, or at least largely free of airfelt. The absorbent core perimeter (which may be the perimeter of the core wrap) may define any suitable shape, such as, for example, a rectangular "T", "Y", "hourglass" or "dog bone" shape. The absorbent core perimeter having a generally "dog bone" or "hourglass" shape may taper along its width toward the crotch region 14 of the absorbent article 10.

Referring to fig. 9-11, the absorbent core 30 may have an area with little or no absorbent material 72, wherein the wearer-facing surface of the core pocket 74 may be joined to the garment-facing surface of the core pocket 74. These areas with little or no absorbent material may be referred to as "channels" 76. The channels may embody any suitable shape and any suitable number of channels may be provided. In other cases, the absorbent core may be embossed to create an impression of the channels. The absorbent cores in fig. 9-11 are merely exemplary absorbent cores. Many other absorbent cores, with or without channels, are also within the scope of the present disclosure.

Barrier leg cuff/leg elastics

Referring to fig. 1 and 2, for example, the absorbent article 10 may comprise one or more pairs of barrier leg cuffs 32 and one or more pairs of leg elastics 34. The barrier leg cuffs 32 may be positioned laterally inboard of the leg elastics 34. Each barrier leg cuff 32 may be formed from a piece of material that is bonded to the absorbent article 10 such that it may extend upwardly from the wearer-facing surface 4 of the absorbent article 10 and provide improved containment of bodily exudates adjacent the juncture of the wearer's torso and legs. The barrier leg cuffs 32 are defined by proximal edges joined directly or indirectly to the topsheet and/or backsheet and free end edges which are intended to contact and form a seal with the skin of the wearer. The barrier leg cuff 32 may extend at least partially between the front end edge 18 and the back end edge 20 of the absorbent article 10 on opposite sides of the central longitudinal axis 50 and is present at least in the crotch region 14. The barrier leg cuffs 32 may each comprise one or more elastic members 33 (e.g., elastic strands or strips) near or at the free end edges. These elastics 33 cause the barrier leg cuffs 32 to help form a seal around the legs and torso of the wearer. The leg elastics 34 extend at least partially between the front end edge 18 and the back end edge 20. The leg elastics 34 substantially contribute to the portions of the absorbent article 10 adjacent the chassis side edges 22, 24 forming seals around the legs of the wearer. The leg elastics 34 may extend at least in the crotch region 14. The barrier leg cuffs may comprise a nonwoven material comprising a bond pattern and/or three-dimensional features.

Elastic waistband

Referring to fig. 1 and 2, the absorbent article 10 may include one or more elastic waistbands 36. The elastic waistband 36 can be positioned on the garment facing surface 2 or the wearer facing surface 4. By way of example, the first elastic waistband 36 may be present in the front waist region 12 near the front belt end edge 18, and the second elastic waistband 36 may be present in the back waist region 16 near the back end edge 20. The elastic waistband 36 can help seal the absorbent article 10 about the waist of the wearer and at least inhibit body exudates from escaping the absorbent article 10 through the waist opening periphery. In some cases, the elastic waistband may completely surround the waist opening of the absorbent article. The elastic waistband may comprise a nonwoven material comprising a bond pattern, apertures, and/or three-dimensional features.

Collection material

Referring to fig. 1, fig. 2, fig. 7, and fig. 8, one or more acquisition materials 38 may be present at least partially intermediate the topsheet 26 and the absorbent core 30. The acquisition material 38 is typically a hydrophilic material that provides significant wicking of body exudates. These materials may dehydrate topsheet 26 and rapidly move body exudates into absorbent core 30. The acquisition material 38 may comprise, for example, one or more nonwovens, foams, cellulosic materials, crosslinked cellulosic materials, airlaid cellulosic nonwovens, hydroentangled materials, or combinations thereof. In some cases, portions of the acquisition material 38 may extend through portions of the topsheet 26, portions of the topsheet 26 may extend through portions of the acquisition material 38, and/or the topsheet 26 may be nested with the acquisition material 38. Generally, the width and length of the acquisition material 38 may be less than the width and length of the topsheet 26. The acquisition material may be a secondary topsheet in the context of a feminine pad. The acquisition material may have one or more channels as described above with reference to the absorbent core 30 (including the embossed pattern). The channels in the acquisition material may or may not be aligned with the channels in the absorbent core 30. In one example, the first acquisition material may comprise a nonwoven material and may comprise a cross-linked cellulosic material as the second acquisition material.

Landing zone

Referring to fig. 1 and 2, the absorbent article 10 may have a landing zone area 44 formed in a portion of the garment-facing surface 2 of the outer cover material 40. The landing zone area 44 may be located in the back waist region 16 if the absorbent article 10 is fastened from front to back; or the landing zone area may be located in the front waist region 12 if the absorbent article 10 is fastened from back to front. In some cases, the landing zone 44 may be or include one or more discrete nonwoven materials attached to a portion of the outer cover material 40 in the front waist region 12 or the back waist region 16 depending on whether the absorbent article is front or back fastened. In essence, the landing zone 44 is configured to receive the fastener 46 and may include, for example, a plurality of loops configured to engage a plurality of hooks on the fastener 46, or vice versa. The landing zone 44 may comprise a nonwoven material that includes a bond pattern, apertures, and/or three-dimensional features.

Wetness indicator/graphic

Referring to fig. 1, the absorbent article 10 of the present disclosure may include a graphic 78 and/or a wetness indicator 80 visible from the garment-facing surface 2. The graphic 78 may be printed on the landing zone 40, backsheet 28, and/or elsewhere. The wetness indicators 80 are typically applied to the absorbent core-facing side of the backsheet 28 such that they may be contacted by the body exudates within the absorbent core 30. In some cases, the wetness indicator 80 may form part of the graphic 78. For example, the wetness indicator may appear or disappear and create/remove characters within some graphics. In other cases, the wetness indicator 80 may or may not match the graphic 78 (e.g., same design, same pattern, same color).

Front and back ear

Referring to fig. 1 and 2 mentioned above, the absorbent article 10 may have front ears 47 and/or back ears 42 in a taped diaper. In most taped diapers, only one set of ears is required. A single set of ears may include fasteners 46 configured to engage a landing zone or landing zone area 44. If two sets of ears are provided, in most cases, only one set of ears may have fasteners 46 while the other set of ears does not have fasteners. The ear panels or portions thereof may be elastic or may have elastic panels. In one example, the elastic film or elastic strands may be positioned intermediate the first nonwoven and the second nonwoven. The elastic film may or may not be apertured. The ear may be formed. The ears may be unitary (e.g., extensions of the outer cover material 40, backsheet 28, and/or topsheet 26) or may be discrete components attached to the chassis 52 of the absorbent article on the wearer-facing surface 4, on the garment-facing surface 2, or intermediate the two surfaces 4, 2. The ear may comprise one or more nonwoven materials comprising a bond pattern, apertures, and/or three-dimensional features. The back ear panels and/or the front ear panels may each comprise an adhesive tape comprising the fasteners 46. The tape may include one or more nonwoven materials that include a bond pattern, apertures, and/or three-dimensional features.

Sensor with a sensor element

Referring again to fig. 1, the absorbent articles of the present disclosure may include a sensor system 82 for monitoring changes within the absorbent article 10. The sensor system 82 may be separate from the absorbent article 10 or integral with the absorbent article 10. The absorbent article 10 may include sensors that can sense various aspects of the absorbent article 10 associated with the insult of bodily exudates, such as urine and/or fecal waste (e.g., the sensor system 82 can sense temperature changes, humidity, the presence of ammonia or urea, various vapor components of the exudates (urine and feces), changes in the moisture vapor transmission through the garment facing layer of the absorbent article, changes in the translucency of the garment facing layer, and/or changes in color through the garment facing layer). In addition, the sensor system 82 may also sense components of urine, such as ammonia or urea, and/or byproducts generated as a result of the reaction of these components with the absorbent article 10. The sensor system 82 can sense byproducts generated when urine mixes with other components of the absorbent article 10 (e.g., adhesive, agm). The sensed component or byproduct may be present in the form of a vapor that may pass through the garment facing layer. It may also be desirable to place a reactant in the absorbent article that changes state (e.g., color, temperature) or produces a measurable by-product when mixed with urine or fecal waste. The sensor system 82 may also sense changes in pH, pressure, odor, the presence of gases, blood, chemical markers, or biological markers, or combinations thereof. The sensor system 82 may have a feature on or adjacent the absorbent article that transmits a signal to a receiver, such as an iPhone, more distal than the absorbent article. The receiver may output the results to communicate the condition of the absorbent article 10 to a caregiver. In other cases, a receiver may not be provided, instead, the condition of the absorbent article 10 may be visually or audibly apparent from a sensor on the absorbent article.

Packaging piece

The absorbent articles of the present disclosure can be placed into a package. The package may comprise a polymer film and/or other materials. Graphics and/or indicia relating to the characteristics of the absorbent article may be formed on, printed on, positioned on, and/or placed on the exterior portion of the wrapper. Each package may include a plurality of absorbent articles. The absorbent articles can be stacked under compression to reduce the size of the packages while still providing a sufficient amount of absorbent articles per package. By enclosing the absorbent articles under compression, the caregiver can easily handle and store the package while also providing dispensing savings to the manufacturer due to the size of the package. The package may have a bond pattern and/or three-dimensional features that match or are similar to the bond pattern, apertures, and/or three-dimensional features on the nonwoven material of the absorbent articles within the package.

Sanitary napkin

Referring to fig. 12, the absorbent article of the present disclosure may be a sanitary napkin 110. The sanitary napkin 110 can comprise a liquid pervious topsheet 114, a liquid impervious or substantially liquid impervious backsheet 116 and an absorbent core 118. The liquid impervious backsheet 116 may or may not be vapor pervious. The absorbent core 118 may have any or all of the features described herein with respect to the absorbent core 30, and in some forms, may have a secondary topsheet 119(STS) in place of the acquisition materials disclosed above. STS 119 may include one or more channels (including embossed patterns) as described above. In some forms, the channels in the STS 119 may be aligned with the channels in the absorbent core 118. The sanitary napkin 110 may also include flaps 120 that extend outwardly relative to the longitudinal axis 180 of the sanitary napkin 110. The sanitary napkin 110 may also contain a lateral axis 190. The wing portions 120 may be joined to the topsheet 114, backsheet 116, and/or absorbent core 118. The sanitary napkin 110 can further comprise a front edge 122, a back edge 124 longitudinally opposite the front edge 122, a first side edge 126, and a second side edge 128 longitudinally opposite the first side edge 126. The longitudinal axis 180 may extend from a midpoint of the front edge 122 to a midpoint of the back edge 124. The lateral axis 190 may extend from a midpoint of the first side edge 128 to a midpoint of the second side edge 128. The sanitary napkin 110 may also have additional features as are commonly found in sanitary napkins as is well known in the art. The sanitary napkin 110 may have a bond pattern, apertures, and/or three-dimensional features on two different nonwoven components or portions of the same nonwoven component (e.g., two different portions of the topsheet, or the topsheet and the flaps).

Garment-like absorbent article

The garment-like absorbent articles of the present disclosure may have at least one or at least two different nonwoven absorbent article components having a pattern on the garment-facing surface 2 and/or portions of the wearer-facing surface 4. In some cases, for example, one pattern may be on the garment-facing surface 2 and another pattern may be on the wearer-facing surface. The pattern may be formed by holes, bonds, printing, and/or graphics. As used herein, bonds may include, for example, thermal bonds, ultrasonic bonds, pressure bonds, thermal and pressure bonds, embossments that form three-dimensional features, and/or mechanical deformations that create three-dimensional features. The various nonwoven absorbent article components may be or include at least a portion of a topsheet, ears, leg cuffs, outer cover nonwoven, discrete landing zones, discrete non-elasticized front belts, flaps of sanitary napkins, belts of pants, waistbands, or various other absorbent article components.

The first nonwoven component of the absorbent article may comprise a first pattern on a first portion of the garment facing surface 2 and/or the wearer facing surface 4. The first pattern may include a repeating pattern of holes, bonds, prints, and/or graphics that may or may not form a plurality of first repeating units. A portion or all of the first pattern within the first repeat unit can be the same or substantially the same (e.g., process tolerances in forming the material). The first nonwoven component may have a first texture formed at least in part by apertures and/or bonds, wherein the first texture may have an Sq value in the range of from about 0.11 to about 0.4 according to the surface texture and height test herein. For example, the first nonwoven component may comprise the outer cover nonwoven material 40 or at least a portion thereof. The first nonwoven component may also comprise any other suitable nonwoven component of an absorbent article, such as, for example, at least a portion of an ear, a belt, a waistband, a topsheet, and/or a flap portion of a sanitary napkin. If a print is used and the first component is an outer cover nonwoven, the print may be present on the backsheet film and visible through the outer cover nonwoven. In some cases, only the first nonwoven component having the repeating pattern of apertures, bonds, printing, and/or graphics may be disposed on the absorbent article. Exemplary components may be an outer cover nonwoven or topsheet.

The second nonwoven component of the absorbent article may comprise a second pattern on the first portion of the garment facing surface 2 and/or the wearer facing surface 4. The second pattern may include a repeating pattern of holes, bonds, prints, and/or graphics that may or may not form a plurality of second repeating units. A portion or all of the second patterns within the second repeating unit may be the same or substantially the same (e.g., process tolerances in forming the material). The second nonwoven component may have a second texture formed at least in part by apertures and/or bonds, wherein the second texture has an Sq value in the range of from about 0.11 to about 0.4 according to the surface texture and height test herein. For example, the second nonwoven component may comprise discrete landing zones or discrete non-elasticized (or elasticized) front belts or at least a portion thereof. The second nonwoven component may also comprise any other suitable nonwoven component of the absorbent article, such as, for example, at least a portion of an ear, a belt, a waistband, a topsheet, and/or a flap portion of a sanitary napkin.

An exemplary discrete landing zone 44 is shown in FIG. 1. By discrete landing zone is meant that the landing zone is a separate component from the outer cover nonwoven, not just a portion of the outer cover nonwoven. The discrete landing zone may be one piece or may be multiple pieces, as shown in figure 1 with dashed lines. If two pieces are desired, the first piece 44 'may be spaced a distance from the second piece 44 "such that the first piece 44' does not overlap or contact the second piece 44". A discrete landing zone (whether one-piece or two-piece) may be attached to the garment-facing surface 2 of the absorbent article.

Examples of discrete non-elasticized front belts 200 are shown in figures 13-16. In some cases, the front belt 200 may be elasticized or partially elasticized. The discrete non-elasticized front belts 200 may be separate materials attached to the garment-facing surface 2 and/or the wearer-facing surface 4 of the absorbent article 10.

In one case, the first portion of the outer cover nonwoven may have a first pattern and the second portion of the outer cover nonwoven may have a second pattern. In such cases, the second portion may serve as a landing zone.

Referring to fig. 15, the outer cover nonwoven 40 (e.g., the first component) may have a first repeating pattern 204 of apertures and/or bonds 212. The first repeating pattern 204 may have a plurality of first repeating units 214. A portion of the first repeating pattern 204 within at least a majority of the first repeating units 214 may be the same or substantially the same (e.g., process tolerances). According to the surface texture and height test herein, the outer cover nonwoven 40 may have a first texture Sq value in the range of about 0.11mm to about 0.4mm, or about 0.11mm to about 0.35mm, specifically listing the specified range and all 0.0001mm increments formed therein or therefrom.

The discrete non-elasticized front belt 200 or discrete landing zone (e.g., secondary member) may have a second repeating pattern 202 of apertures and/or bonds 216. The second repeating pattern 202 may have a plurality of second repeating units 218. A portion of the second repeating pattern 202 within at least a majority of the second repeating units 218 may be the same or substantially the same (e.g., process tolerances). The discrete non-elasticized front belt 200 or discrete landing zone may have a secondary texture Sq value in the range of about 0.1mm to about 0.15mm, specifically listing all 0.0001mm increments within the specified range and all ranges formed therein or therefrom, in accordance with the surface texture and height test herein.

The first texture of the first pattern 204 and the second texture of the second pattern 202 may be the same or different. At least some or all of the first repeating units 214 comprising portions of the first pattern 204 may comprise a first shape or a first design. At least some or all of the second repeating units 218 including portions of the second pattern 202 may include a second shape or a second design. The first shape or design may be the same as or substantially similar to the second shape or design. For example, substantially similar may mean substantially the same pattern or design, but with slightly different sizes, proportions, and/or shapes. For example, first repeating unit 214 may comprise a circle and second repeating unit 218 may comprise a circle, as shown in fig. 15. As another example, the first repeating unit 214 may include a triangle, a wavy line, a square, an oval, a cloud, a heart, and/or other shapes or patterns, and the second repeating unit may also include a triangle, a wavy line, a square, an oval, a cloud, a heart, and/or other shapes or patterns. Although the first repeat unit and the second repeat unit may comprise similar shapes or designs, the size of the shape or design may be just between the first repeat unit and the second repeat unit. Further, the density and/or size of the holes and/or bonds in the various repeating units may be different. Likewise, in some cases, the first pattern 204 may be different from the second pattern 202, but such patterns may correspond to or be substantially similar to creating a garment-like impression in an absorbent article.

Although the at least two nonwoven components of the absorbent article are described herein as being complementary to each other, they may also be used separately from each other. For example, an outer cover nonwoven having the texture and repeating units discussed herein may be used in an absorbent article separately from a discrete landing zone or a discrete non-elasticized front belt having the texture and repeating units. The same applies to discrete landing zones or discrete non-elasticized front belts without outer cover nonwovens.

Referring to fig. 16, the outer cover nonwoven 40 (e.g., the first component) may include a first repeating pattern 208 of apertures and/or bonds 220. The first repeating pattern 208 may have a plurality of first repeating units 222. A portion of the first repeating pattern 206 within at least a majority of the first repeating units 222 may be the same or substantially the same (e.g., process tolerances). The first repeating pattern 208 may form a herringbone pattern. According to the surface texture and height test herein, the outer cover nonwoven 40 may have a first texture Sq value in the range of about 0.11mm to about 0.4mm, or about 0.11mm to about 0.35mm, specifically listing the specified range and all 0.0001mm increments formed therein or therefrom.

The discrete non-elasticized front belt 200 or discrete landing zone (e.g., secondary member) may have a second repeating pattern 206 of apertures and/or bonds 224. The second repeating pattern 206 may have a plurality of second repeating units 226. A portion of the second repeating pattern 206 within at least a majority of the second repeating units 226 may be the same or substantially the same (e.g., process tolerances). The second repeating pattern 206 may form a herringbone pattern. The discrete non-elasticized front belt 200 or discrete landing zone may have a secondary texture Sq value in the range of from about 0.1 to about 0.15, specifically listing all 0.0001mm increments within the specified range and all ranges formed therein or therefrom, in accordance with the surface texture and height test herein.

Referring to fig. 16-18, the discrete non-elasticized front belt 200 may have an intermediate portion 228 that overlaps with the outer cover nonwoven. The front belt 200 may include a first lateral end 230 and an opposing second lateral end 232. The first portion 234 of the front belt 200 may be positioned intermediate the first lateral end 230 and the first lateral edge of the outer cover nonwoven. The second portion 236 of the front belt 200 may be positioned intermediate the second lateral end 232 and the opposing second lateral edge of the outer cover nonwoven. These first and second portions 234, 236 do not overlap with the outer cover nonwoven material and therefore may be frangible and not appear to be high quality. To address this issue, support member 210 may overlap and engage first portion 234 and second portion 236 to provide structural support to first portion 234 and second portion 236. The support member may be a nonwoven, foam, felt, film, cellulosic material, or other suitable material for providing support to the first and second portions 234, 236 of the front belt 200 that do not overlap with the outer cover nonwoven.

Fig. 19-26 are exemplary patterns 300 for components of an absorbent article, such as an outer cover nonwoven, discrete landing zones, or discrete non-elasticized front belts. The pattern 300 of fig. 19 may be used with one or more of the first pattern 208 and the second pattern 206 of fig. 16. Fig. 20 and 21 may be used on two different nonwoven absorbent article components such as an outer cover nonwoven and discrete landing zones or discrete non-elasticized front belts. Fig. 22 and 23 may be used on two different nonwoven absorbent article components such as an outer cover nonwoven and discrete landing zones or discrete non-elasticized front belts. Fig. 26 is a pattern 300 similar to that of fig. 19, but with adjacent rows within the pattern being "offset" from one another. In the case of embossing, this helps to balance the roll.

In fig. 19-26, axis 301 may or may not be substantially parallel to central longitudinal axis 50 (see fig. 1), and axis 303 may or may not be substantially parallel to central lateral axis 48 (see fig. 1). In some cases, axis 301 may be angled relative to central longitudinal axis 50, such as at an angle in a range of, for example, about 0.5 degrees to about 20 degrees, or about 1 degree to about 15 degrees. Such angling may reduce wear on the bonding roll including the discontinuous bond or hole pattern.

Fig. 19 to 21 and 26 to 28 show a pattern of the herringbone pattern.

Figure 27 is an example of a portion of a discontinuous bond or hole pattern 300 for a landing component of an absorbent article, an outer cover nonwoven of an absorbent article, or other nonwoven absorbent article component. Figure 28 is an example of a portion of another discontinuous bond or hole pattern 300 for a landing component of an absorbent article, an outer cover nonwoven of an absorbent article, or other nonwoven absorbent article component. Referring to fig. 27, a discontinuous bond or hole pattern 300 can include a first plurality of first discontinuous elements 302 forming a first discontinuous line 304. The discontinuous bond or hole pattern 300 can include a second plurality of second discontinuous elements 306 forming second discontinuous lines 308. The discontinuous bond or hole pattern 300 can include a third plurality of third discontinuous elements 310 positioned intermediate the first and second discontinuous lines 304, 308, wherein the third plurality of discontinuous elements 310 form a third discontinuous line 312 extending in a direction transverse to the direction of extension of the first and second discontinuous lines 304, 308. The third line of discontinuity 312 may extend in a direction in a range of about 15 degrees to about 75 degrees or about 30 degrees to about 60 degrees relative to the direction of extension of the first and second lines of discontinuity 304, 308, specifically listing all 0.1 degree increments within the specified range and all ranges formed therein or therefrom. The first, second, and third discontinuous lines 304, 308, 312 may all not overlap any portion of each other. In other cases, portions of the first, second, and third discontinuities 304, 308, 312 may at least partially overlap. The distance D between the first and second discontinuous lines 304, 308 in a direction perpendicular to the first discontinuous line 304 can be in a range of about 2mm to about 20mm, about 3mm to about 15mm, about 2mm to about 12mm, about 3mm to about 10mm, about 4mm to about 8mm, about 5mm to about 7mm, about 6mm to about 7mm, or about 6.5mm, specifically listing the specified ranges and all 0.1mm increments formed therein or therefrom. The first line of discontinuity 304 may extend in a direction parallel (to account for process tolerances) or substantially parallel (e.g., +/-3 degrees) to the second line of discontinuity 308.

The first discontinuous elements 302 (any of the first discontinuous elements 302 in the first discontinuity lines 304) may include first and second elements 302a, 302b that are different in size and/or shape, and may include third and fourth elements 302c, 302d that are the same in size and/or shape or substantially the same in size and/or shape (process tolerance). The first discontinuous elements 302 in the first line 304 can also be all the same size and shape, can include two or more different sizes and/or shapes, can include three and/or more different shapes (see the pattern in fig. 28), can include four or more different sizes and/or shapes, or can include five or more different sizes and/or shapes, for example, up to 10 different sizes and/or shapes. The second discontinuous elements 306 (any of the second discontinuous elements 306 in the second discontinuous lines 308) may include first and second elements 306a, 306b that are different in size and/or shape, and may include third and fourth elements 306c, 306d that are the same in size and/or shape or substantially the same in size and/or shape (process tolerance). The second discontinuous elements 306 in the second strands 308 may also be all the same size and shape, may include two or more different sizes and/or shapes, may include three and/or more different shapes (see the pattern in fig. 28), may include four or more different sizes and/or shapes, or may include five or more different sizes and/or shapes, up to 10 different sizes and/or shapes.

The third line of discontinuity 312 may include a first element 310a and a second element 310 b. The first and second elements 310a, 310b may be the same size and/or shape, substantially the same size and/or shape (process tolerances), or may be different sizes and/or shapes. Although only two third discontinuous elements 310 are shown in the discontinuous bond or hole pattern of fig. 27 and 28, more than two (e.g., three or four) third discontinuous elements 310 may be used. When positioned on the landing member, the first element 310a may have a positive or negative slope with respect to the central lateral axis 48 of the absorbent article 10. The second element 310b may have the same positive or negative slope relative to the central lateral axis 48 of the absorbent article 10. In some cases, the first element 310a and the second element 310b may have slightly different slopes (e.g., +/-3 degrees) or different slopes (e.g., +/-10 degrees) relative to the central lateral axis 48. As can be seen in fig. 27 and 28, the first and second lines of discontinuity 304, 308 may be longer than the third line of discontinuity 312. The first and second discontinuities 304, 308 may each have the same length or substantially the same length (process tolerance).

Referring to fig. 28, the discontinuous bond or hole pattern 300 can include a fourth plurality of fourth discontinuous elements 314 forming a fourth line of discontinuity 316, wherein the fourth line of discontinuity 316 is positioned intermediate the first line of discontinuity 304 and the second line of discontinuity 312. The distance D1 between the third and fourth discontinuities 312, 316 may be in the range of about 1mm to about 12mm, about 1mm to about 8mm, about 1mm to about 6mm, about 1.5mm to about 5mm, about 2mm to about 4mm, or about 3mm in a direction parallel to the first and/or second discontinuities 304, 308, specifically listing all 0.1mm increments specified and all ranges formed therein or thereby. The third line of discontinuity 312 may or may not extend in a direction parallel or substantially parallel (e.g., +/-1 degree-3 degrees) to the fourth line of discontinuity 316. The fourth continuous line 316 may have the same features as discussed above with respect to the third discontinuous line 312.

Referring again to fig. 28, the discontinuous bond or hole pattern 300 can include a fifth plurality of fifth discontinuous elements 318 forming a fifth line of discontinuity 320. In the claims, "fifth" may refer to, for example, "fourth" or some other number, depending on the order in which the lines or elements are discussed as discontinuous. This is true for many discrete elements and lines of discontinuity. The fifth line of discontinuity 320 may be the same as the first and second lines of discontinuity 304, 308 and may have the same features as discussed above. The discontinuous bond or aperture pattern 300 can include a sixth plurality of sixth discontinuous elements 322 forming sixth discontinuous lines 324. The sixth line of discontinuity 324 may have the same features as discussed above with respect to the third line of discontinuity 312 and the fourth line of discontinuity 316. The sixth line of discontinuity 324 may be positioned intermediate the second and fourth lines of discontinuity 308, 320 and may extend in a direction transverse to the second and fourth lines of discontinuity 308, 316. The sixth line of discontinuity 324 may have the same pitch and angle as discussed above with respect to the third and fourth lines of discontinuity 312, 316.

The discontinuous bond or aperture pattern 300 can include a seventh plurality of seventh discontinuous elements 326 forming a seventh discontinuous line 328. The seventh discontinuity 328 may have the same features as discussed above with respect to the third discontinuity 312 and the fourth discontinuity 316. The seventh discontinuity line 328 may be positioned intermediate the second discontinuity line 308 and the fourth discontinuity line 320 and may extend in a direction transverse to the second discontinuity line 308 and the fourth discontinuity line 316. The seventh discontinuity 328 may have the same pitch and angle as discussed above with respect to the third discontinuity 312 and the fourth discontinuity 316.

The sixth and seventh discontinuities 324, 328 may be symmetrical or substantially symmetrical (process tolerance) with the third and fourth discontinuities 312, 316 about the second discontinuity 308. In other words, the sixth discontinuity 324 and the seventh discontinuity 328 may be a mirror image or substantially a mirror image (process tolerance) of the third discontinuity 312 and the fourth discontinuity 316 with respect to the second discontinuity 308.

Many other lines besides the first, second, third, fourth, fifth, sixth and seventh discontinuous lines may be part of a discontinuous bond or hole pattern, as shown in fig. 27 and 28. For the sake of brevity, each additional line will not be discussed, but it should be understood that lines that appear similar in fig. 19, 27, and 28 may have the features discussed herein.

A discontinuous bond or pattern of holes may be positioned on the landing member. The landing member may be an outer cover nonwoven, a discrete nonwoven landing zone, or a non-extensible front belt comprising a nonwoven. The landing member may be configured to receive and retain a hook positioned on a tape tab of the fastener 46. In some cases, the landing member may be positioned in the back waist region, and the belt projection comprising a hook may be positioned in the front waist region if the absorbent article is fastened front to back. In other cases, the discontinuous bond or pattern of apertures may be located, for example, on other absorbent article nonwoven components, or on a nonwoven material.

Table 1: measurement results of the present disclosure

Table 1 reflects 5 samples for the outer cover nonwoven and discrete landing zone or discrete non-elasticized front belt of the present disclosure. The Sq value (texture) and Sk value (height) of these samples were measured according to the surface texture and height test herein. The Sq value (texture) data is also reflected in fig. 29, where the sample codes of the present disclosure (P1-P5) are graphically represented.

The outer cover nonwoven of the present disclosure may have a texture Sq value in the range of about 0.1mm to about 0.6mm, about 0.1mm to about 0.5mm, about 0.1mm to about 0.45mm, about 0.1mm to about 0.4mm, about 0.11mm to about 4mm, about 0.115mm to about 0.4mm, about 0.115mm to about 0.338mm, about 0.11mm to about 0.35mm, about 0.3mm, about 0.25mm, about 0.2mm, about 0.15mm, about 0.1mm, about 0.338mm, about 0.115mm, about 0.0965mm, about 0.219mm, or about 0.208mm, specifically listing the specified ranges and all 0.001mm increments formed therein or thereby. All Sq values are measured according to the surface texture and height test herein.

The outer cover nonwoven of the present disclosure may have a Sk value (height) in the range of about 0.2mm to about 1.5mm, about 0.2mm to about 1.4mm, about 0.3mm to about 1.2mm, about 0.3mm to about 1.15mm, about 0.35mm to about 1.2mm, about 0.38mm to about 1.2mm, about 0.382mm to about 1.197mm, about 0.484mm, about 0.382mm, about 0.875mm, or about 0.738mm, specifically listing the specified ranges and all 0.0001mm increments formed therein or therein. All Sk values are measured according to the surface texture and height test herein.

The discrete landing zone and/or discrete non-elasticized front belt of the present disclosure may have a texture Sq value in the range of about 0.05mm to about 0.4mm, about 0.08mm to about 0.3mm, about 0.9mm to about 0.3mm, about 0.1mm to about 0.2mm, about 0.1mm to about 0.15mm, about 0.115mm to about 0.338mm, about 0.137mm, about 0.136mm, about 0.115mm, about 0.105mm, about 0.137mm, specifically listing the specified ranges and all 0.0001mm increments formed therein or thereby. All Sq values are measured according to the surface texture and height test herein.

The discrete landing zone and/or discrete non-elasticized front belt of the present disclosure may have a Sk value (height) in the range of from about 0.2mm to about 1mm, from about 0.2mm to about 0.8mm, from about 0.2mm to about 0.7mm, from about 0.3mm to about 0.7mm, from about 0.4mm to about 0.6mm, from about 0.429mm to about 0.534mm, from about 0.524mm, from about 0.462mm, from about 0.428mm, or about 0.529mm, specifically listing the specified ranges and all 0.0001mm increments formed therein or thereby. All Sk values are measured according to the surface texture and height test herein.

Table 2: measurement results of related art

Table 2 reflects relevant art samples for the outer cover and discrete landing zone or discrete non-elasticized front belt of the present disclosure. The Sq values (texture) and Sk values (height) of these samples were measured. The Sq data is also reflected in fig. 29, in which the relevant field sample codes are graphically represented.

Repeat unit measurement results

For example, the various repeat units of the pattern may have certain characteristics, such as repeat unit area (the overall X-Y plane area of the repeat unit), repeat unit width, and repeat unit length. Absorbent articles comprising an outer cover nonwoven and discrete landing zones or discrete non-elasticized front belts comprising a repeating pattern of bonds or apertures having a plurality of repeating units may have certain characteristics of repeating units. These characteristics are discussed below. The repeating units may also be printed on the outer cover nonwoven and discrete landing zones or discrete non-elasticized front belts.

Repeat unit area-outer cover nonwoven

All or a majority of the individual repeat units in the repeating pattern of bonds or apertures on the outer cover nonwoven material of the absorbent article may have a caliper of about 25mm²To about 400mm²About 100mm²To about 300mm²About 125mm²To about 275mm²About 150mm²To about 250mm²About 175mm²To about 225mm²About 190mm²To about 215mm²About 195mm²To about 210mm²About 200mm²To about 210mm²About 25mm²To about 125mm²About 25mm²To about 100mm²About 50mm²To about 90mm²About 50mm²To about 80mm²About 55mm²To about 75mm²About 60mm²To about 70mm²About 64mm²About 65mm²Or about 66mm²Repeat unit area within the range, specifically all 0.1mm of the specified range and all ranges formed therein or therefrom are listed²And (4) increasing. The repeat unit area is measured according to the repeat unit measurement test herein.

Repeat unit area-discrete landing zone or discrete non-elasticized front belt

All or a majority of the individual repeat units in the repeating pattern of bonds or apertures on the discrete landing zone or discrete non-elasticized front belt of the absorbent article may have a caliper of about 25mm²To about 400mm²About 40mm²To about 300mm²About 50mm²To about 275mm²About 50mm²To about 250mm²About 50mm²To about 225mm²About 75mm²To about 200mm²About 75mm²To about 100mm²About 150mm²To about 225mm²About 175mm²To about 200mm²About 25mm²To about 125mm²About 25mm²To about 100mm²About 25mm²To about 75mm²About 35mm²To about 65mm²About 40mm²To about 60mm²About 45mm²To about 55mm²About 47mm²About 48mm²Or about 49mm²Repeat unit area within the range, specifically all 0.1mm of the specified range and all ranges formed therein or therefrom are listed²And (4) increasing. Repeat Unit area according to the textIs measured by the repeating unit measurement test of (a).

Repeat unit width-outer cover nonwoven

All or a majority of the individual repeat units in the repeating pattern of bonds or apertures on the outer cover nonwoven material of the absorbent article may have a repeat unit width in the range of from about 5mm to about 75mm, from about 5mm to about 50mm, from about 10mm to about 40mm, from about 10mm to about 30mm, from about 10mm to about 25mm, from about 12mm to about 22mm, from about 15mm to about 20mm, from about 16mm, from about 19mm, from about 8mm to about 20mm, from about 10mm to about 15mm, from about 12mm, about 13mm, or about 14mm, specifically listing all 0.1mm increments within the specified ranges and all ranges formed therein or thereby. Repeat cell widths are measured according to the repeat cell measurement test herein.

Repeat unit width-discrete landing zone or discrete non-elasticized front belt

All or a majority of the individual repeat units in the repeating pattern of bonds or apertures on the discrete landing zone or discrete non-elasticized front belt of the absorbent article may have a repeat unit width in the range of from about 5mm to about 75mm, from about 5mm to about 50mm, from about 8mm to about 40mm, from about 10mm to about 30mm, from about 10mm to about 25mm, from about 10mm to about 20mm, from about 10mm to about 18mm, from about 10mm to about 15mm, from about 15mm, about 11mm, about 12mm, or about 13mm, specifically listing the specified ranges and all 0.1mm increments formed therein or thereby. Repeat cell widths are measured according to the repeat cell measurement test herein.

Repeat unit length-outer cover nonwoven

All or a majority of the individual repeat units in the repeating pattern of bonds or apertures on the outer cover nonwoven material of the absorbent article may have a repeat unit length in the range of from about 2mm to about 75mm, from about 3mm to about 50mm, from about 3mm to about 40mm, from about 5mm to about 30mm, from about 5mm to about 25mm, from about 5mm to about 20mm, from about 8mm to about 20mm, from about 11mm, from about 18mm, from about 17mm, from about 3mm to about 15mm, from about 1mm to about 10mm, from about 1mm to about 8mm, from about 3mm to about 10mm, from about 3mm to about 8mm, from about 3mm to about 7mm, from about 4mm, from about 5mm, about 6mm, or about 7mm, specifically listing all 0.1mm increments therein and all ranges formed therein or thereby. Repeat unit lengths are measured according to the repeat unit measurement test herein.

Repeat unit length-discrete landing zone or discrete non-elasticized front belt

All or a majority of the individual repeat units in the repeating pattern of bonds or apertures on the discrete landing zone or discrete non-elasticized front belt of the absorbent article may have a repeat unit length of from about 2mm to about 75mm, from about 2mm to about 50mm, from about 3mm to about 40mm, from about 3mm to about 30mm, from about 3 to about 25mm, from about 3mm to about 20mm, from about 3mm to about 10mm, from about 10mm to about 20mm, from about 17mm, about 6mm, about 7mm, from about 1mm to about 10mm, from about 2mm to about 8mm, from about 2mm to about 6mm, from about 3mm to about 5mm, or about 4mm, specifically listing all 0.1mm increments therein or all ranges formed thereby. Repeat unit lengths are measured according to the repeat unit measurement test herein.

Fluff

There is an optimum repeat unit size on the components of the absorbent article. Discrete landing zones, discrete non-elasticized front belts, and/or outer cover nonwovens on absorbent articles that appear napped may not have a premium appearance. Fluff may be caused by too large a repeat unit. If the repeat units are too small, the nonwoven material may not appear to be of good quality. If the repeating units are too large, they may also appear to be poor because there are too few repeating units on the part. It may be desirable to have repeat units large enough to look good, but not so large that there are many unbonded open spaces that can create fuzz during consumer use. The smaller the repeat unit, the lower the likelihood of fuzzing in the unbonded open spaces. In the case of a discrete landing zone or a discrete non-elasticized front belt, it may be desirable to balance the premium appearance with the repeat unit size while still keeping the repeat unit size small enough to reduce fuzz and small enough to have fastening strength for engagement with hooks. Another aspect of the premium appearance may be the ability of the consumer to see the unbonded areas. These unbonded areas can be filled with bonds (to reduce fuzz), but this can detract from the quality appearance.

Material

The discrete landing zones or discrete non-elasticized front belt and outer cover nonwoven materials of the present disclosure may comprise suitable nonwoven materials and/or other materials. Some examples are carded nonwovens, air-laid nonwovens, wet-laid nonwovens, air-spun nonwovens, spunbond high-loft materials (e.g., spunbond high-loft materials having at least one layer of crimped fibers), and/or combinations thereof. The nonwoven material may include natural fibers, such as cotton and/or other bio-based materials or resins. The nonwoven material may be, for example, embossed, ultrasonically embossed, hydroentangled, and/or apertured. The nonwoven material can have, for example, bonds and three-dimensional features, apertures and three-dimensional features, bonds, apertures and three-dimensional features.

The discrete landing zone or discrete non-elasticized front belt and outer cover nonwoven fabrics of the present disclosure may comprise a PE/PP bicomponent fiber spunbond nonwoven web. Other suitable nonwoven webs may include spunbond webs comprising side-by-side crimped fibers (e.g., PE/PP or PP/PP) bonded via calender (thermal point) bonding or through-air bonding. Other suitable nonwoven webs may include carded, through-air bonded or resin bonded (high loft) nonwovens including PE/PP or PE/PET fibers. The nonwoven web may comprise nanofibers, optionally with other fibers. In some cases, a multi-layer web may be more desirable than a single-layer web (even at the same basis weight) due to increased uniformity/opacity and the ability to combine webs with different properties. For example, an extensible spunbond nonwoven carrier layer can be combined with a soft high loft nonwoven fabric (spunbond or carded) to create a nonwoven web that is both soft and strong. The layers may have the same or different surface energies. The layers may have different permeability/capillarity.

The fibers of the discrete landing zone or discrete non-elasticized front belt and outer cover nonwoven may comprise any suitable thermoplastic polymer. Exemplary thermoplastic polymers are polymers that crystallize or harden upon cooling after melting, but can be remelted upon further heating.

The thermoplastic polymer may be derived from any suitable material, including renewable resources (including bio-based and recycled materials), fossil minerals and oils, and/or biodegradable materials. Some suitable examples of thermoplastic polymers include polyolefins, polyesters, polyamides, copolymers thereof, and combinations thereof. Polypropylene and/or polypropylene copolymers, including atactic polypropylene; isotactic polypropylene, syndiotactic polypropylene, and combinations thereof may also be used.

The thermoplastic polymer part may be a single polymer substance or a blend of two or more thermoplastic polymers, such as two different polypropylene resins. For example, the fibers of the discrete landing zone or discrete non-elasticized front belt and the first nonwoven layer of the outer cover nonwoven may comprise a polymer such as polypropylene and blends of polypropylene and polyethylene, while the discrete landing zone or discrete non-elasticized front belt and the second nonwoven layer of the outer cover nonwoven may comprise fibers selected from polypropylene, polypropylene/polyethylene blends, and polyethylene/polyethylene terephthalate blends. In some forms, the second nonwoven layer may comprise fibers selected from the group consisting of cellulose rayon, cotton, other hydrophilic fibrous materials, or combinations thereof.

The fibers of the discrete landing zone or discrete non-elasticized front belt and outer cover nonwoven may comprise monocomponent, bicomponent, and/or biconstituent, round, or non-round fibers (e.g., capillary channel fibers) and may have a major cross-sectional dimension (e.g., diameter of round fibers) in the range of about 0.1 microns to about 500 microns. The fibers may also be a mixture of different fiber types that differ in characteristics such as chemical composition (e.g., polyethylene and polypropylene), composition (monocomponent and bicomponent), denier (microdenier and >2 denier), shape (i.e., capillary and circular), and the like. The fibers may range from about 0.1 denier to about 100 denier.

As used herein, the term "monocomponent fiber" refers to a fiber formed from one extruder using one or more polymers. This is not meant to exclude fibers formed from a polymer to which small amounts of additives have been added for reasons of coloration, antistatic properties, lubrication, hydrophilicity, etc.

As used herein, the term "bicomponent fiber" refers to a fiber formed from at least two different polymers extruded from separate extruders but spun together to form one fiber. Bicomponent fibers are also sometimes referred to as conjugate fibers or multicomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the bicomponent fibers and extend continuously along the length of the bicomponent fibers. For example, the configuration of such bicomponent fibers may be a sheath/core arrangement in which one polymer is surrounded by another; or may be in a side-by-side arrangement, a pie arrangement, or a "sea-island" arrangement. Some specific examples of fibers that may be used in the nonwoven layer include polyethylene/polypropylene side-by-side bicomponent fibers. Another example is a polypropylene/polyethylene bicomponent fiber, where the polyethylene is configured as a sheath and the polypropylene is configured as a core within the sheath. Another example is a polypropylene/polypropylene bicomponent fiber, where two different propylene polymers are configured in a side-by-side configuration. Additionally, forms are also contemplated in which the fibers of the nonwoven layer are crimped.

The bicomponent fibers may comprise two different resins, for example a first polypropylene resin and a second polypropylene resin. The resins may have different melt flow rates, molecular weights or molecular weight distributions.

As used herein, the term "biconstituent fibers" refers to fibers which have been formed from at least two polymers extruded from the same extruder as a blend. Biconstituent fibers do not have the various polymer components arranged in relatively constantly positioned distinct zones across the cross-sectional area of the fiber, and the various polymers are usually not continuous along the entire length of the fiber, but rather usually form fibrils which start and end at random. Biconstituent fibers are sometimes referred to as multiconstituent fibers. In other examples, the bicomponent fiber may comprise a multicomponent component.

As used herein, the term "non-round fibers" describes fibers having a non-round cross-section and includes "shaped fibers" and "capillary channel fibers". Such fibers may be solid or hollow, and they may be trilobal, delta-shaped, and may be fibers having capillary channels on their outer surfaces. The capillary channel can have various cross-sectional shapes, such as "U-shaped," H-shaped, "" C-shaped, "and" V-shaped. One practical capillary channel Fiber is T-401, designated 4DG Fiber, which is available from Fiber Innovation Technologies (Johnson City, TN). The T-401 fiber was poly (adipic acid terephthalate) (PET polyester).

Bio-based content of absorbent article components

The components of the absorbent articles described herein may be at least partially comprised of biobased content, as described in U.S. patent application 2007/0219521a 1. For example, the superabsorbent polymer component may be biobased via its derivation from biobased acrylic acid. Biobased acrylic acid and methods for its production are further described in U.S. patent application publication 2007/0219521 and U.S. patents 8,703,450, 9,630,901 and 9,822,197. Other components such as nonwoven webs and film components may comprise bio-based polyolefin materials. Biobased polyolefins are further discussed in U.S. patent application publications 2011/0139657, 2011/0139658, 2011/0152812 and 2016/0206774 and U.S. patent 9,169,366. Exemplary biobased polyolefins useful in the present disclosure include those available under the designation SHA7260^TM、SHE150^TMOr SGM9450F^TMThe obtained polymer (all available from Braskem s.a.).

The absorbent article component may comprise a biobased content value of from about 10% to about 100%, from about 25% to about 100%, from about 40% to about 100%, from about 50% to about 100%, from about 75% to about 100%, or from about 90% to about 100%, for example, as measured using ASTM D6866-10 method B.

The nonwoven web may comprise multicomponent fibers or bicomponent fibers, wherein at least one or more of the components is biobased. Examples include side-by-side, sheath/core, or islands-in-the-sea configurations, wherein one or more or all of the components are biobased.

Test method

Repeat cell measurement test

The absorbent article samples were glued to a rigid flat surface in a planar configuration with the test zone of the garment facing surface (such as the outer cover, landing zone or non-elasticized front belt) having a repeating pattern of upwardly facing bonds or apertures. The articles are glued in a way that avoids distortions of the repeating pattern of introduction apertures due to the extent to which the absorbent article extends longitudinally and laterally. Prior to testing, any absorbent articles to be tested were conditioned for 2 hours at 23 ℃ ± 2 ℃ and 50% ± 2% relative humidity. For the purposes of this method, all patterns and distances are considered based on the projection of the bond or hole pattern onto a two-dimensional plane.

A single repeating unit (hereinafter "SRU") (for subsequent dimensional measurements) within a test area having a repeating pattern of bonds, holes or printing that includes a plurality of repeating units is defined as follows. Any bonds, prints or holes are identified, hereinafter referred to as "selected points" (hereinafter referred to as "CP"). Any other bond, print, or aperture in the test area that is considered to be in an equivalent location based on the translational symmetry of the repeating unit is referred to as an "equivalent point" (hereinafter "EP"). An SRU is defined as a set of points that are closer (by euclidean distance) to the center of a CP than to the center of any other EP in the test area. The SRU identified for measurement cannot touch the edge of the test area. After all points within the SRU are found, if the SRU is found to touch the edge of the test area, the process is repeated with the replacement CP. This process is repeated until an SRU is identified that does not contact the edge of the test area.

One method of determining a point set for an SRU is based on identifying polygon boundaries. Referring to fig. 30, the boundaries of the SRU are convex polygons formed by the intersections of line segments immediately adjacent to the boundaries of the topsheet area containing the CP. The line segments are identified by lines drawn perpendicular to the midpoint of the line connecting the center of the CP to all adjacent EPs and the center near the EPs.

Referring to fig. 31, the SRU length (L) is defined as the feret diameter parallel to the longitudinal axis of the absorbent article and the SRU width (W) is defined as the feret diameter parallel to the lateral axis of the absorbent article. The Ferrett diameter is the distance between two parallel lines, both tangent to the boundary of the SRU, and recorded to 0.1mm accurately.

Record the internal area of the SRU to the nearest 0.1mm²。

Referring to fig. 32, the total lateral width of the absorbent article is measured along the central lateral axis (line X) and is accurately recorded to 0.1 mm. The total longitudinal length of the absorbent article is measured along the central longitudinal axis (line Y) and is accurately recorded to 0.1 mm. The total area of the absorbent article is calculated by multiplying the total absorbent article width by the total absorbent article length and is accurately recorded to 0.1mm²。

The number of SRUs per unit length of the absorbent article was calculated by dividing the total absorbent article longitudinal length by the SRU length and accurately recorded to 0.1 SRU. The number of SRUs per unit width of the absorbent article was calculated by dividing the total absorbent article lateral width by the SRU width and accurately recorded to 0.1 SRU. The number of SRUs per unit total area of the absorbent article was calculated by dividing the total absorbent article area (total absorbent article longitudinal length x total absorbent article lateral width) by the SRU area and accurately reported to 0.1 SRU.

This process was repeated for five separate substantially similar absorbent articles and each of the measurements was reported as the arithmetic average of five replicates to the accuracy described above.

Surface texture and height testing

In the "surface texture and height test", the joined backsheet film and outer cover nonwoven are removed from the absorbent article and the area surface topography of the nonwoven surface is measured using an optical profiling technique. The 3D surface data is then processed and analyzed to extract the micro-scale region surface roughness parameter Sq (root mean square height) and the surface height parameter Sk. All sample preparation and testing was performed in a conditioning chamber maintained at about 23 ± 2 ℃ and about 50 ± 2% relative humidity, and the samples were equilibrated in this environment for at least 24 hours prior to testing.

Sample preparation

To obtain the sample, the joined backsheet film and outer cover nonwoven were removed from the absorbent article. The sample was carefully removed so that its longitudinal and lateral extensions were retained to avoid distortion of the material. If necessary, a cryospray such as Cyto-Freeze, Control Company (Houston TX) or equivalent can be used to remove the sample from the underlying layer. Five replicates were prepared for testing.

3D surface image acquisition

The samples were adhered in a planar configuration to a rigid flat surface using double-sided adhesive tape so that the garment-facing surface of the sample was visible. A three-dimensional (3D) surface topography image of the sample was obtained using a DLP-based, structured light 3D surface topography measurement system (a suitable surface topography measurement system is the mikrococad Premium instrument or equivalent commercially available from LMI Technologies Inc. The system comprises the following main components: a) a Digital Light Processing (DLP) projector having a direct digitally controlled micro-mirror; b) a CCD camera having a resolution of at least 1600x1200 pixels; c) projection optics adapted to measure an area of at least 60mm x 45 mm; d) recording optics adapted to measure an area of 60mm x 45 mm; e) a table tripod based on small hard stone slabs; f) a blue LED light source; g) the measurement, control and evaluation computer runs surface texture analysis software (suitable software is MikroCAD software with mountain map technology or equivalent); and h) calibration plates for lateral (XY) and vertical (Z) calibration, purchased from suppliers.

The optical 3D surface topography measurement system uses digital micromirror pattern edge projection technology to measure the surface height of a sample. The nature of this pattern projection technique allows the surface topography of the sample to be interrogated through the transparent material. The measurements are 3D data sets of surface height (defined as the Z-axis) versus displacement in the horizontal (XY) plane. This 3D data set may also be considered an image where each pixel there of the image is associated with an XY displacement and the value of the pixel is the recorded Z-axis height value. The system has a 60 x 45mm field of view with an XY pixel resolution of about 37 microns and a height resolution of 0.5 microns with a total possible height range of 32 mm.

The instrument was calibrated according to the manufacturer's specifications using calibration plates for the lateral (XY plane) and vertical (Z axis) directions, purchased from the supplier.

The sample was laid flat on a table under the camera. The 3D surface topography image of the sample is collected by following the measurement procedure recommended by the instrument manufacturer, which may include focusing the measurement system and performing brightness adjustments. The pre-filtering option is not used. The collected height image file is saved to an evaluation computer running surface texture analysis software.

3D surface image analysis

The 3D surface topography image is opened in the surface texture analysis software. The following filtering process is then performed on each image: 1) removing invalid or non-measurement points; 2) a 5x5 pixel median filter to remove noise; 3) subtracting the least squares plane to level the surface; 4) using end effect correction, the surface was planarized by a Gaussian filter (according to ISO16610-61) with a nesting index (cut-off wavelength) of 15mm (25mm for patterns with repeating cells with lengths or widths greater than 15 mm); and 5) cut a 3mm wide border around the perimeter of the image.

This filtering procedure produces a surface from which the Sq values are calculated as described in ISO25178-2: 2012. The surface roughness value of Sq was recorded to the nearest 0.001 mm. This process was repeated for the remaining parallel samples. The 5 parallel Sq measurements were averaged together and reported to the nearest 0.001 mm.

The surface height measurement is based on the parameter core height values Sk as described in ISO 13565-2:1996 standard and ISO25178-2:2012 extrapolated to the surface. The parameter Sk is derived from an area-to-material ratio curve (Abbott-firstone), which is a cumulative curve of the surface height distribution histogram versus the range of surface heights. The core height value is the height difference between the material ratios Mr1 and Mr2 as read from the area material ratio curve. Mr1 set at 2% is the material ratio that distinguishes the protruding peaks from the core roughness. Mr2 set at 98% is the material ratio that distinguishes the deep valley from the core roughness. The surface height Sk value was recorded to the nearest 0.001 mm. The five parallel Sk values were averaged together and reported to 0.001mm accuracy.

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

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.