阅读说明：本技术 折叠的一次性吸收制品 (Folded disposable absorbent article ) 是由 S.L.哈迪 R.L.格拉斯迈耶 于 2019-04-11 设计创作，主要内容包括：本文公开了一次性吸收制品,其具有第一折叠线和第二折叠线。所述一次性吸收制品具有顶片、底片和设置在所述顶片和所述底片之间的吸收系统。所述吸收系统具有可以偏置方式构造的第一吸收芯和第二吸收芯。并且,所述吸收系统和/或所述第一折叠线和所述第二折叠线可相对于所述吸收制品被构造成在所述折叠制品中实现厚度变化。(Disclosed herein are disposable absorbent articles having a first fold line and a second fold line. The disposable absorbent article has a topsheet, a backsheet, and an absorbent system disposed between the topsheet and the backsheet. The absorbent system has a first absorbent core and a second absorbent core that can be configured in an offset manner. And, the absorbent system and/or the first and second fold lines may be configured relative to the absorbent article to effect a thickness change in the folded article.)

1. An array of disposable absorbent articles, each of the absorbent articles within the array comprising a front end portion, an opposing second end portion, and an intermediate portion disposed between the front end portion and the second end portion, the array further comprising:

a first plurality of absorbent articles and a second plurality of absorbent articles, each of the first and second plurality of absorbent articles comprising: a topsheet, a backsheet, and an absorbent system disposed between the topsheet and the backsheet, the absorbent system comprising a first absorbent core and a second absorbent core, wherein the first absorbent core and the second absorbent core are disposed offset from each other such that the front end portion comprises only one of the first absorbent core or the second absorbent core and the back end portion comprises only the other of the one of the first absorbent core or the second absorbent core, wherein a central portion is disposed between the front end portion and the back end portion;

wherein the absorbent system of the first plurality of absorbent articles comprises a central portion having a first length and the absorbent system of the second plurality of absorbent articles comprises a central portion having a second length, wherein the second length is greater than the first length, and wherein the first plurality of absorbent articles comprises a first folded thickness and the second plurality of absorbent articles comprises a second folded thickness, wherein the second thickness is greater than the first thickness.

2. The array of claim 1, wherein each of the first plurality of absorbent articles and the second plurality of absorbent articles comprises a pair of fold lines, wherein at least one of the fold lines is disposed in the central portion.

3. The array of claim 2, wherein the ratio of the first fold thickness to the second fold thickness may be about 2.0 to 1.0, more preferably about 1.8 to 1.0, or most preferably about 1.2 to 1.0.

4. A series according to any preceding claim, wherein both fold lines are provided in the central portion.

5. The array of claim 1, wherein each of the first and second plurality of absorbent articles comprises a pair of fold lines, wherein the fold lines are disposed outboard of the central portion.

6. The array of claim 5, wherein the ratio of the first fold thickness to the second fold thickness may be about 1.6 to 1.0, more preferably about 1.4 to 1.0, most preferably about 1.1 to 1.0.

7. The array of claim 1, wherein the first and second plurality of absorbent articles comprise a pair of fold lines, wherein the fold lines of the first plurality of absorbent articles are disposed outboard of the central portion, and wherein the fold lines of the second plurality of absorbent articles are disposed within the central portion.

8. The array of claim 7, wherein the ratio of the first fold thickness to the second fold thickness may be about 2.5 to 1.0, more preferably about 2.3 to 1.0, most preferably 1.6 to 1.0.

9. The array of claim 14, wherein the second plurality of articles has a higher capacity than the first plurality of articles.

10. The array of any of claims 7-9, wherein the front end portions of the first plurality of articles comprise a front end length and the back end portions comprise a back end length, wherein the front end length and the back end length are equal, and wherein a first fold line is disposed in the front end portions and a second fold line is disposed in the second end portions.

11. The array of any of claims 7-10, wherein the front end portions of the second plurality of absorbent articles comprise a front end length and the back end portions comprise a back end length, wherein the front end length and the back end length are equal, wherein a first fold line is disposed in the central portion and a second fold line is disposed in the central portion.

Technical Field

The present invention relates to folded disposable absorbent articles suitable for absorbing and containing body exudates.

Background

Consumers have relied on a variety of disposable absorbent articles to treat or manage body exudates. These consumers may include infants, toddlers, children, adolescents, adults, and the elderly. Thus, it will be apparent that the type of fluid or bodily exudates managed by such articles may also vary to include urine, feces, menses, and other excretions. Typically, in the case of adults, the articles take the form of sanitary napkins, adult incontinence pads and adult incontinence diapers or undergarments. One of the main desires of wearers for these products is to convince them: others will not perceive the occurrence of incontinence as they occur, and even more desirably the wearer will not perceive the occurrence of incontinence.

One way widely utilized by manufacturers to improve the performance and overall discreteness of disposable absorbent articles is to include superabsorbent polymers, which are capable of absorbing increased amounts of liquid and thus forming swollen hydrogel materials. The resulting hydrogel is used to retain fluids, such as discharged body fluids, within the structure. One such type of absorbent structure in which a hydrogel-forming material in particulate form is incorporated into a fibrous web is disclosed in Weisman and Goldman; U.S. Pat. nos. 4,610,678; it was published in 9 months and 9 days of 1986.

While disposable absorbent articles having these superabsorbent materials tend to be highly absorbent and less bulky, many users of these products have high Body Mass Indices (BMIs) and many expectations remain for these products. In particular, these users tend to experience excessive bunching of the absorbent article during wear, and thus may increase the chance of leakage occurring.

Accordingly, there is a need for a disposable absorbent article that is intended to provide enhanced leakage protection for consumers with high BMI, while maintaining a level of wearer balance during use. In addition, there is a need to provide disposable absorbent articles in an unobtrusive package, which typically occupies a small area.

Disclosure of Invention

Disposable absorbent articles according to the present disclosure are well suited for providing leakage protection to users experiencing relatively small to relatively large fluid discharges. In addition, the disposable absorbent articles of the present disclosure can be folded in a variety of ways to affect the resulting pad thickness.

An exemplary array of disposable absorbent articles, wherein each of the absorbent articles within the array comprises a front end portion, an opposing second end portion, and an intermediate portion disposed between the front end portion and the second end portion, the array further comprising: a first plurality of absorbent articles and a second plurality of absorbent articles, each of the first and second plurality of absorbent articles comprising: a topsheet, a backsheet, and an absorbent system disposed between the topsheet and the backsheet, the absorbent system comprising a first absorbent core and a second absorbent core, wherein the first absorbent core and the second absorbent core are disposed offset from each other such that the front end portion comprises only one of the first absorbent core or the second absorbent core and the back end portion comprises only the other of the first absorbent core or the second absorbent core, wherein a central portion is disposed between the front end portion and the back end portion; wherein the absorbent system of the first plurality of absorbent articles comprises a central portion having a first length and the absorbent system of the second plurality of absorbent articles comprises a central portion having a second length, wherein the second length is greater than the first length, and wherein the first plurality of absorbent articles comprises a first folded thickness and the second plurality of absorbent articles comprises a second folded thickness, wherein the second thickness is greater than the first thickness.

Drawings

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the following description which is taken in conjunction with the accompanying drawings in which like reference numerals identify substantially identical elements and in which:

FIG. 1 is a plan view showing an exemplary embodiment of a disposable absorbent article of the present invention, which is an incontinence pad;

fig. 2 is a cross-sectional view of the incontinence pad of fig. 1, taken along 2-2;

fig. 3 is a plan view of the pad of fig. 1 with the primary topsheet removed;

fig. 4A is a cross-sectional view of the absorbent system of the pad of fig. 3 taken along 3-3;

FIG. 4B is a cross-sectional view of another absorbent system that may be used in the absorbent articles of the present disclosure;

FIG. 5A is a cross-sectional view of the absorbent system of FIG. 4A showing a first fold line and a second fold line;

FIG. 5B is a cross-sectional view of the absorbent system of FIG. 5A in a tri-fold configuration;

FIG. 5C is a cross-sectional view of the absorbent system of FIG. 5A in another tri-fold configuration;

FIG. 6A is a cross-sectional view of the absorbent system of FIG. 4A in another configuration having a first fold line and a second fold line;

fig. 6B is a cross-sectional view of the absorbent system of fig. 6A in a tri-fold configuration.

Detailed Description

The disposable absorbent articles of the present disclosure may provide flexibility for improved and comfortable fit that is less prone to bunching during use. In particular, it is contemplated that the articles of the present disclosure exhibit increased structural resilience through the proposed configuration and orientation of the layers contained therein. For the purposes of this disclosure, reference will be made to an incontinence pad, a disposable absorbent article or an absorbent article. However, the present invention is applicable to a variety of absorbent articles including, but not limited to, sanitary napkins, pantiliners, catamenial pads, diapers, training pants, adult incontinence pants, and the like.

When designing disposable absorbent articles, such as incontinence pads, several factors need to be considered, particularly if improved fit and performance are desired. First, the stiffness of the pad is an important factor. Generally, thinner pads provide less stiffness than bulkier pads. Less stiffness may be desirable in some areas of the pad because the lower stiffness areas may allow the pad to conform to the contours of the wearer as desired; however, if not properly managed, the absorbent article may not provide structural resistance to bunching/compression during wear, which may result in leakage. In contrast, while bulkier pads may have a lower likelihood of collapsing when subjected to typical compression during wear, bulkier pads are less desirable because they may cause the incontinence pad to be noticeable during use. In addition, although resisting compressive forces during use, bulkier pads do not conform as easily as their thinner pad counterparts. This lack of conformability can similarly lead to leakage problems during use.

Second, the absorbent capacity of the absorbent article. Ideally, the pad is well suited to contain small or large loads of exudates. This containment means not only that any type of load is adequately stored, but that such loads are effectively and quickly wicked from the body-contacting surface of the pad so that the user experiences little to no wetness sensation upon release of the load. Under light load conditions, the wearer should be able to continue wearing the pad for a reasonable period of time after release, as it may not be feasible or desirable to immediately replace the pad.

In the past, the design of conventional incontinence pads has required a slight compromise in terms of these factors. In contrast, absorbent articles designed according to the present disclosure take these factors into account, and the resulting absorbent articles exhibit improved leakage protection, particularly for wearers above the average Body Mass Index (BMI). That is, the absorbent articles of the present disclosure provide good core flexibility, excellent wicking, distribution, and overall absorbency, and in certain forms, may include barrier cuffs that stand up during use and contact the wearer in place, included as part of the structure, for further preventing the possibility of leakage. For the purposes of this disclosure, reference will be made to an incontinence pad, disposable absorbent article, or absorbent article; however, the present disclosure is applicable to a variety of absorbent articles including, but not limited to, sanitary napkins, pantiliners, catamenial pads, diapers, training pants, adult incontinence pants, and the like.

Fig. 1 shows an absorbent article 10 of the present disclosure. The absorbent article 10 includes a longitudinal axis 80 and a lateral axis 90. The longitudinal axis 80 extends generally parallel to the longest dimension of the absorbent article 10. The lateral axis 90 extends generally perpendicular to the longitudinal axis 80 and is in the same plane as the absorbent article 10 in a flattened state on a flat surface. The lateral axis 90 bisects the length of the absorbent article 10, wherein the length is parallel to the longitudinal axis 80, and the longitudinal axis 80 bisects the width of the absorbent article 10, wherein the width is parallel to the lateral axis 90. Additionally, as shown, the MD direction may be generally parallel to the longitudinal axis 80 of the incontinence pad 10 and the CD direction may be generally parallel to the lateral axis 90.

The absorbent article 10 has a generally elongated oval shape. However, any suitable shape may be utilized. Some examples include an hourglass shape (peanut shape), an offset hourglass shape (one end wider than the opposite end with a narrowed middle portion between the ends), and the like. Incontinence pad 10 can be symmetrical about longitudinal axis 80 or asymmetrical about longitudinal axis 80. Similarly, the absorbent article 10 may be symmetric about the lateral axis 90 or asymmetric about the lateral axis 90.

The absorbent article 10 may also include a chassis 20 having a plurality of side edges 22 and 24 extending generally parallel to the longitudinal axis 80. A pair of end edges 26 and 28 join each of the side edges 22 and 24. One end edge 26 joins the side edges 22 and 24 in the first end region 40 of the absorbent article 10, while the other end edge 28 joins the side edges 22 and 24 in the second end region 48 of the absorbent article 10-the second end region 48 being opposite the first end region 40. The intermediate region 44 is disposed between the first end region 40 and the second end region 48.

The chassis 20 of fig. 1 is shown in cross-section in fig. 2. Wherein the chassis 20 comprises a primary topsheet 203. Such a primary topsheet has a body-facing surface 203A and a garment-facing surface 203B. This chassis 20 of the absorbent article 10 further comprises a backsheet 207 which also comprises its own body facing surface 207A and an opposite garment facing surface 207B. These two components hold the absorbent system 205. In other words, the absorbent system 205 is disposed between the topsheet 203 and the backsheet 207. All three components (i.e., topsheet 203, backsheet 207, and absorbent system 205) form chassis 20 of pad 10. Additional layers may very well be included in the chassis 20, in particular between the topsheet 203 and the backsheet 207, but it should be noted that these layers are separate and apart from the absorbent system. Suitable additional layers may include secondary topsheets, acquisition layers, additional distribution layers above the above discussed layers, as will be discussed below, and other useful layers. In the case of the secondary topsheet, it is disposed beneath the primary topsheet 203 and on the body-facing surface of the core. In certain embodiments, the secondary topsheet (also referred to as "STS") has a greater length and width than the absorbent core 205.

The chassis 20 also includes a wearer-facing surface 20A and a garment-facing surface 20B. The wearer-facing surface 20A may comprise a topsheet 203 and the garment-facing surface 20B may comprise a backsheet.

The absorbent system 205 is formed of multiple layers and involves rapid acquisition of body fluids or exudates and distribution of them along the length of the core. Fig. 3-4B illustrate an absorbent system 205 suitable for use with the absorbent articles of the present disclosure. Fig. 3 shows a plan view of the absorbent article 10 with the primary topsheet 203 removed to view the absorbent system 205 positioned above the backsheet 207. The absorbent system 205 comprises a first absorbent core 60 and a second absorbent core 70. As shown, in some forms, the first absorbent core 60 and/or the second absorbent core 70 may comprise a laminate structure comprising a plurality of layers-see fig. 4B. Alternatively, in some forms, the first absorbent core 60 and/or the second absorbent core 70 may comprise a single layer of absorbent material-see fig. 4A.

For those forms in which the first absorbent core 60 and/or the second absorbent core comprise a laminate structure, any suitable number of layers may be provided in each of these absorbent cores. In some forms, the first absorbent core 60 may include a first superabsorbent layer 61 disposed on a first distribution layer 62. The first absorbent core 60 has an upper surface 60A and a lower surface 60B opposite the upper surface. In addition, the first absorbent core 60 has a first end 66 and a second end 67 opposite the first end 66. The absorbent system 205 further comprises a second absorbent core 70 comprising a second superabsorbent layer 71 disposed on a second distribution layer 72. The second absorbent core 70 also has an upper surface 70A and a lower surface 70B, a first end 76, and a similar opposing second end 77. As shown, the first distribution layer 62 is joined to the second distribution layer 72 along the length of the core in an offset manner or configuration.

As used herein, "offset" or "offset manner" means that the layers or laminates of interest are staggered and that when the layers or laminates overlap one another, their respective first or second ends are not aligned in the z-direction (i.e., the first end of one layer or laminate is not contiguous with the second end of an adjacent underlying or overlying layer or laminate). This offset joining of the first distribution layer 62 and the second distribution layer 72 forms an overlap and joined area of the two laminates that forms the central portion 205C of the absorbent core 205. The core central portion 205C is thus defined on each side of the core front and rear end portions 205R. In other words, the front end portion 205F and the rear end portion 205R are disposed at opposite ends of the core 205, respectively. The front end portion 205F is formed by the first end 66 or the second end 67 of the first laminate 60, while the back end portion 205F of the core 205 is formed by the first end 76 or the second end 77 of the second laminate 70. In the form of fig. 3, the first end 66 of the first laminate and the first end 76 of the second laminate are opposite each other and form the front end portion 205F and the back end portion 205R, respectively, of the absorbent core 205. In an alternative embodiment, the second end 67 of the first laminate and the second end 77 of the second laminate may be opposite each other and form the front end portion 205F and the back end portion 205R of the absorbent core 205, respectively. In both cases, the first end 66 and the first end 76 are in the form of male connectors that originate from nested cuts of the first and second laminates. Similarly, the second ends 67 and 77 are in the form of female connectors that originate from nested cuts of the first and second laminates, respectively. The version of fig. 4A may be similarly configured as the absorbent system 205 of fig. 4B.

The front end portion 205F includes a front end length and the rear end portion 205R includes a rear end length. In some forms, the front end length may be equal to the back end length. Forms are envisaged in which the front end length and the rear end length are different. For example, the front end length may be greater than the back end length. As another example, the back end length may be greater than the front end length.

The length of the central portion 205C may vary depending on the size of the absorbent article 10. For example, for those absorbent articles sized for wearers of higher BMI, the length of the central portion 205C may be higher than the central portion 205C of absorbent articles sized for wearers of lower BMI. In addition, where the absorbent article is equipped with elasticized barrier leg cuffs, the central portion 205C may extend past the outermost anchor point of the elastomeric member of the barrier leg cuff. Extending the central portion 205C past the outermost anchor point may reduce the likelihood of the ends of the absorbent article folding during application of the absorbent article. Folding the ends during application of the absorbent article can be problematic, as described in U.S. patent application 2017/0049634. In some forms, the central portion 205C may have a length of at least 50mm, at least 75mm, at least 90mm, at least 100mm, at least 125mm, at least 150mm, at least 175mm, at least 200mm, at least 225mm, at least 250mm, 275mm, 300mm, 325mm, 350mm, or 375mm, and specifically includes all values within these ranges and any ranges formed thereby.

In some forms, the first absorbent core 60 and the second absorbent core 70 may be joined to each other in a slightly different configuration, with the first distribution layer 62 joining the second superabsorbent layer 71 and not the second distribution layer. In this case, the laminate is also joined to each other in an offset manner, except that the first distribution layer 62 joins the second superabsorbent layer 71 instead of the second distribution layer. The form of fig. 4A may be similarly constructed as the absorbent system of fig. 4B.

In other forms, the first absorbent core 60 is joined to the second absorbent core 70 by any of the other superabsorbent layers or distribution layers most suitable for the purpose of the resulting article. The engagement is also in an offset manner resulting in a longer core having a thicker central portion than the front and rear portions.

In some forms, the overlapping region or zone forming the central portion 205C of the core 205 has at least one of a greater capacity, a greater void volume, or a greater thickness than the front and back end portions 205F, 205F of the absorbent core 205. This embodiment is particularly useful for providing enhanced leakage protection in the central portion where female users of such pads will typically contact the pad and release fluid.

Folding line

Referring back to fig. 1, the absorbent article 10 may further include a first fold line 50 and a second fold line 55. The first fold line 50 may define a boundary between the first end region 40 and the intermediate region 44. The second fold line 55 may define a boundary between the second end region 48 and the intermediate region 44. The first end region 40 may be defined by the end edge 26, a first fold line 50, and a portion of the side edges 22 and 24 disposed between the end edge 26 and the first fold line 50. The intermediate region 44 may be defined by the first fold line 50, the second fold line 55, and a portion of the side edges 22 and 24 disposed between the first fold line 50 and the second fold line 55. The second end region 48 is defined by a second fold line 55, the end edge 28, and a portion of the side edges 22 and 24 disposed between the end edge 28 and the second fold line 55. Fold lines 50 and 55 can be parallel and can be collinear (on average) with the fold lines formed via the packaging process of incontinence pad 10.

In some forms, the first fold line 50 and the second fold line 55 may be configured such that the fold lines 50 and 55 divide the pad into three halves. In other forms, the first fold line 50 may be biased toward the end edge 28 and the second fold line 55 may be biased toward the end edge 28. In such forms, this enables the second end region 48 to be tucked between the intermediate region 44 and the first end region 40 when the pad is in a folded configuration.

The inventors have found that the placement of the fold lines can affect the absorbent article 10 in a variety of ways. For example, as described in U.S. patent application publication 2017/0049634, a fold placed too far inboard of an elastomeric anchor point can cause problems during application of the article to a user's undergarment. In addition, for the absorbent articles of the present disclosure, the placement of the fold can affect the thickness of the folded article. This thickness, in turn, can affect the unobtrusiveness of the folded article, as thicker articles can generally be perceived as being prominent or more prominent than their thinner counterparts. This is particularly the case where a light absorbent product is desired/utilized. However, some consumers may consider thinner, less noticeable articles to provide less protection than their thicker counterparts. This is particularly the case where higher absorbency products are desired/utilized.

This can be particularly problematic when different absorbency levels of the absorbent article have the same overall length and/or width. In such forms, different levels of absorbency can be achieved via higher basis weight superabsorbents, higher basis weight cellulose, and the like. Unfortunately, such variations may not be very noticeable to the wearer. For example, a superabsorbent basis weight increase of 10gsm or 20gsm (which may provide a significant increase in absorbency for the consumer) may result in only a small change in the thickness of the folded absorbent article. Thus, when the wearer compares the two articles, the wearer may feel any claims for increased absorbency inaccurate.

Referring to fig. 5A and 5B, a form is contemplated in which the first fold line 50 is created in the front end portion 205F of the absorbent system and the second fold line 55 is created in the back end portion 205R of the absorbent system. The first folded portion 550 including the first end portion 66 of the first absorbent core 60 is created via a first fold line 50. A second fold portion 555 comprising the second end portion 77 of the second absorbent core 70 is created via the second fold line 55. For such forms, a thinner overall thickness may be achieved after folding the article. For example, a folded article will have only three layers of the absorbent system 205 that make up its thickness in the first fold region 560. Similarly, where the second fold line 55 is disposed in the rear end portion 205R of the absorbent system, the folded article will have only three layers of absorbent systems 205 in the second fold region 570. For those forms in which the first absorbent core 60 and/or the second absorbent core 70 comprise a laminate structure, the above-described placement of the first fold line 50 and the second fold line 55 may also result in a folded absorbent article of a lesser thickness.

Table 1 below shows a hypothetical example of the thickness of a folded article. Thickness is evaluated based on the measured thickness of all components of the exemplary absorbent articles of the present disclosure (e.g., topsheet, secondary topsheet, first absorbent core, secondary absorbent core, and backsheet). Each of the first and second absorbent cores comprises a laminate structure as shown in figure 4B. In addition, the thickness is evaluated based on the varying basis weight of the distribution layer in each of the first and second absorbent cores 60, 70.

TABLE 1

As previously mentioned, in situations where a lighter absorbent product is desired, the wearer may prefer to use a less noticeable folded article. As shown in table 1, where the first folded portion 550 and the second folded portion 555 do not overlap, it is believed that a tri-folded article constructed according to the present disclosure may have a thickness of less than 11mm, or less than 10mm, specifically reciting all values within these ranges and any ranges resulting therefrom.

For those forms in which the first and second folded portions 550 and 555 overlap in a folded state (as shown in fig. 5C), the thickness of a tri-folded article constructed according to the present disclosure may still result in a relatively thin article. For example, it is believed that the thickness of a tri-folded article constructed according to the present disclosure may have a thickness of less than 15mm, less than 14mm, or less than 13mm, specifically including all values within these ranges and any ranges produced thereby.

Referring to fig. 6A and 6B, a form is contemplated in which the first fold line 50 and/or the second fold line 55 is created in the central portion 205C of the absorbent system. The first folded portion 650 including the first end portion 66 of the first absorbent core 60 is created via the first fold line 50. A second fold portion 655 comprising the second end 77 of the second absorbent core 70 is created via the second fold line 55. For such forms, a higher overall thickness may be achieved after folding the article. For example, a folded article will have four layers of the absorbent system 205 that make up its thickness in the first fold region 660. Similarly, where the second fold line 55 is disposed in the rear end portion 205C of the absorbent system, the folded article will have four layers of absorbent system 205 in the second fold region 670. For those forms in which the first absorbent core 60 and/or the second absorbent core 70 comprise a laminate structure, the above-described placement of the first fold line 50 and the second fold line 55 may also result in a higher thickness folded absorbent article.

Table 2 below shows a hypothetical example of the thickness of a folded article. The thickness is evaluated based on the measured thickness of the first and second absorbent cores. Each of the first and second absorbent cores comprises a laminate structure as shown in figure 4B. In addition, the thickness is evaluated based on the varying basis weight of the distribution layer in each of the first and second absorbent cores 60, 70.

TABLE 2

As previously mentioned, where a higher absorbency product is desired, a wearer may prefer to use a thicker thickness of the folded article. As shown in table 2, where the first folded portion 650 and the second folded portion 655 do not overlap, it is believed that the thickness of a tri-folded article constructed according to the present disclosure may be greater than 10mm, greater than 12mm, or greater than 13mm, specifically enumerating all values within these ranges and any ranges resulting therefrom.

With the fold line (or at least one of the fold lines) disposed in the central portion 205C of the absorbent system, the ratio of the highest absorbency to the lower absorbency of the folded article thickness (within the same category, i.e., pad to pad, liner to liner, but not pad to liner) may be about 2.0 to 1.0, about 1.8 to 1.0, about 1.5 to 1.0, about 1.4 to 1.0, or about 1.2 to 1.0, specifically reciting all values within these ranges and any ranges resulting therefrom.

Where the fold line is located outside the central portion 205C of the absorbent system, the ratio of the highest absorbency to the lower absorbency (within the same category, i.e., pad to pad, liner to liner, not pad to liner) for the thickness of the folded article may be from about 1.6 to 1, from about 1.4 to about 1.0, from about 1.2 to about 1.0, or from about 1.1 to about 1.0, specifically reciting all values within these ranges and any ranges resulting therefrom.

In addition, to accommodate the desires of a wide variety of consumers, the thickness ratio can be adjusted so that those users who wish to fold the article less conspicuous (e.g., lower thickness) are adequately satisfied relative to those users who wish to "see" a thicker article (e.g., higher thickness) for the sake of brevity. For example, the thickness ratio of the highest absorbency to the lower absorbency of the folded article thickness (within the same category, i.e., pad to pad) can be between about 2.5 to about 1.0, between about 2.3 to about 1.0, between about 2.0 to about 1.0, or between about 1.6 to about 1.0, specifically including all values within these ranges and any ranges resulting therefrom. Such configurations may be achieved by providing some absorbent articles with fold lines outside of the central portion 205C and some articles with fold lines within the central portion 205C. For example, a higher absorbency absorbent article may have a fold line within the central portion 205C, while a lower absorbency absorbent article may have a fold line outside of the central portion 205C.

The indication of the absorbent article of higher absorbency or lower absorbency is typically provided on the absorbent article package. For example, some packages may show/highlight 5 drops of liquid to provide their highest absorbency, while a lower absorbency provided may show/highlight 4 drops or less of liquid. Alternatively, some may utilize a numbering system where 5 is the highest absorbency provided and 1 is the lowest absorbency provided. When viewing the absorbent article package, it is contemplated that one of ordinary skill in the art will be able to determine the higher/highest absorbent article package from the lower/lowest absorbent article package.

For those versions in which the first folding portion 650 and the second folding portion 655 overlap in a folded state, the thickness of a tri-folded article constructed according to the present disclosure may still result in a relatively thin article. For example, it is believed that the thickness of a tri-folded article constructed according to the present disclosure may have a thickness greater than 15mm, greater than 16mm, greater than 17mm, or greater than 19mm, specifically including all values within these ranges and any ranges resulting therefrom.

A form is envisaged in which the first edge 66 of the first absorbent core 60 overlaps the second edge 77 of the second absorbent core 70. In such forms, the thickness of the folded absorbent article may be increased relative to the thickness of the configuration shown in fig. 6B. Forms are envisaged in which the first edge 66 of the first absorbent core overlaps the second edge 67. In such forms, the first edge 76 of the second absorbent core 70 and the second edge 77 of the second absorbent core 70 may similarly overlap. However, this need not be the case. In such forms, the first folded region 660 or the second folded region 670 may comprise five layers of the absorbent system 205. Additional forms are contemplated by such forms in which the first edge 76 overlaps the second edge 77 of the second absorbent core 70. In such forms, the first folded portion 660 or the second folded region may comprise six layers of the absorbent system 205. Of course, in case the first and second absorbent cores 60, 70 comprise a laminate structure, the first and/or second folded areas 660, 670 may comprise additional layers.

As previously mentioned, depending on the placement of the fold lines, the thickness of the folded article can be greatly affected. In addition to its folded thickness, the folded absorbent article also has a folded length and a folded width. For wearers with higher BMI, the length and width of the absorbent article generally increase, which in turn can affect its folded length and width. For example, the fold length (generally parallel to the longitudinal centerline of the article) may be in the range of from about 60mm to about 160mm, or from about 70mm to about 150mm, specifically including all values within these ranges and any ranges resulting therefrom. The endpoints of the above ranges are indicative of the smallest dimension and the largest dimension, and wherein intermediate dimensions include values within the ranges. For example, the intermediate dimension may include a fold length of about 90mm, 100mm, 120mm, 130mm, and/or 140 mm.

The fold width (generally parallel to the transverse centerline of the absorbent article) may range from about 70mm to about 140mm, or from about 80mm to about 120mm, specifically including all values within these ranges and any ranges resulting therefrom. The endpoints of the above ranges are indicative of the smallest dimension and the largest dimension, and wherein intermediate dimensions include values within the ranges. For example, the intermediate dimension may include a fold width of about 90mm, 100mm, 105mm, 110mm, and/or 120 mm.

Forms of the array in which the products are provided are envisaged. A first plurality of products within the array may have an overall first length and a second plurality of products within the array may have an overall second length. The first length and the second length may be equal. The second plurality of products may have a higher absorbent capacity than the first plurality of products. The higher absorbent capacity may be communicated by the package for the second plurality of absorbent articles.

The first plurality of products may have a first folded length and a first folded width, and the second plurality of products may have a second folded length and a second folded width. The first fold length may be within ± 10% of the second fold length. Similarly, the first fold width may be within ± 10% of the second fold width. The folded thickness of the second plurality of absorbent articles may be greater than the folded thickness of the first plurality of absorbent articles. For example, in some forms, the fold thickness may be greater than about 10%, greater than about 20%, greater than about 30%, greater than about 40%, greater than about 50%, specifically including any value within these ranges and any range formed thereby.

In some forms, each of the first plurality of absorbent articles and each of the second plurality of absorbent articles may comprise an absorbent system as described herein. In such forms, the central portion 205C (as shown in fig. 4A-4B) of each of the second plurality of absorbent articles may have a length that is greater than the length of the central portion 205C of the first plurality of absorbent articles.

In some forms, the array of absorbent articles may include a first plurality of absorbent articles, a second plurality of absorbent articles, and a third plurality of absorbent articles. Each of the first, second, and third pluralities of absorbent articles may comprise an absorbent system 205 as described herein. For example, each of the first, second, and third pluralities of absorbent articles may include first and second absorbent cores disposed in an offset manner with respect to one another. Each of the first, second, and third pluralities of absorbent articles may have a different length and a different level of absorbency. In addition, at least two of the first, second, and/or third plurality of absorbent articles may include a superabsorbent layer, a distribution layer, and/or an absorbent core of different basis weights. Each of the first, second, and third pluralities of absorbent articles may comprise a fold thickness, wherein the fold thickness increases with increasing absorbent capacity. In some forms, the first, second, and third pluralities of absorbent articles may comprise a fold length and a fold width. In some forms, the fold length and/or fold width may increase as the absorbent capacity increases. In some forms, the central portion 205C can include a length, wherein the length of the central portion 205C increases as the absorbent capacity increases.

Applicants will now provide a more detailed description of the various components of the disposable absorbent articles contemplated herein.

Main top sheet

Referring back to fig. 3-4, the primary topsheet 203 (also referred to herein as the "topsheet") of the chassis 20 is positioned adjacent the body-facing surface 203A of the absorbent system 205 and may be joined thereto and to the backsheet 207 by attachment methods (not shown), such as those well known in the art. Suitable attachment methods will be described with reference to joining the backsheet 207 to the absorbent system 205. The topsheet 203 and the backsheet 207 may be joined directly to each other in the incontinence pad periphery and may be joined together indirectly by joining them directly to the absorbent system 205 or may be joined together indirectly by additional optional layers within the chassis, such as a secondary topsheet spanning the entire area or a partial area of the article. Such indirect or direct engagement may be accomplished by attachment methods well known in the art.

The absorbent article may comprise any known or otherwise effective primary topsheet, such as one that is compliant, soft feeling, and non-irritating to the wearer's skin. Suitable primary topsheet materials include liquid pervious materials that are oriented toward and contact the body of the wearer, permitting bodily exudates to pass rapidly therethrough, without permitting fluid to pass back through the topsheet to the skin of the wearer. While the primary topsheet allows for rapid transfer of fluid therethrough, it also allows for transfer or migration of the lotion composition to the exterior or interior of the wearer's skin. Suitable topsheets can be made from a variety of materials, such as woven and nonwoven materials; apertured film materials including apertured formed thermoplastic films, apertured plastic films and fiber wound apertured films; a hydroformed thermoplastic film; a porous foam; reticulated foam; a reticulated thermoplastic film; a thermoplastic scrim; or a combination thereof. Some suitable examples of films that can be used as topsheets are described in U.S. Pat. nos. 3,929,135; 4,324,246; 4,342,314; 4,463,045; 5,006,394; 4,609,518; and 4,629,643.

Non-limiting examples of woven and nonwoven materials suitable for use as the topsheet include fibrous materials made from natural fibers, modified natural fibers, synthetic fibers, or combinations thereof. Other suitable examples are described in U.S. Pat. nos. 4,950,264; 4,988,344; 4,988,345, respectively; 3,978,185, respectively; 7,785,690, respectively; 7,838,099, respectively; 5,792,404, respectively; and 5,665,452.

In some forms, the topsheet may comprise tufts, such as those described in U.S. patent 8,728,049; 7,553,532; 7,172,801, respectively; 8,440,286, respectively; 7,648,752, respectively; and 7,410,683. The primary topsheet may have a pattern of discrete hair-like fibrils, as described in us patent 7,655,176 or 7,402,723. Additional examples of suitable topsheets include U.S. patent 8,614,365; 8,704,036, respectively; 6,025,535 and U.S. patent application publication 13743M.

Another suitable primary topsheet, or a primary topsheet combined with a secondary topsheet, may be formed from a three-dimensional substrate, as detailed in U.S. patent application publication 2017/0258647 a 1.

The primary topsheet can have one or more layers, such as U.S. patent application publication 2016/0167334 a 1; 2016/0166443A 1; 2017/0258651A 1. The topsheet can be apertured as disclosed in U.S. Pat. No. 5,628,097 to Benson et al, published 5/13 1997.

Secondary topsheet

As previously mentioned, the disposable absorbent articles of the present disclosure may include additional layers, one of which includes a secondary topsheet. As previously mentioned, the secondary topsheet may be separate and apart from the absorbent system. In addition, a secondary topsheet is disposed beneath the primary topsheet 203 and on the body-facing surface of the core. In some forms, the secondary topsheet can have a basis weight of from about 40gsm to about 100gsm, from about 45gsm to about 75gsm, or from about 50gsm to about 60gsm, specifically including all values within these ranges and any ranges resulting therefrom. In some forms, the secondary topsheet may comprise a homogeneous mixture of fibers.

Some exemplary secondary topsheets are described in U.S. patent application publications 2015/0351976 a1 and 2014/0343523a 1; and U.S. patent application serial No. 15/729704. Forms are envisaged in which the carrier web comprises a secondary topsheet.

Negative film

The backsheet 207 of the chassis 20 may be positioned adjacent to the garment-facing surface of the absorbent system 205 and may be joined thereto by an attachment method (not shown), such as those well known in the art. For example, the backsheet 207 may be secured to the absorbent system 205 by a uniform continuous layer of adhesive, a patterned layer of adhesive, or a series of separate lines, spirals, or spots of adhesive. Alternatively, the attachment method may include the use of thermal bonding, pressure bonding, ultrasonic bonding, dynamic mechanical bonding, or any other suitable attachment method or combination of these attachment methods as known in the art. Forms of the present disclosure are also contemplated in which the absorbent system 205 is not joined to the backsheet 207, the topsheet 203, or both.

The backsheet 207 may be impervious or substantially impervious to liquids (e.g., urine) and may be manufactured from a thin plastic film, although other liquid impervious flexible materials may also be used. As used herein, the term "flexible" refers to materials that are compliant and readily conform to the general shape and contours of the human body. The backsheet 207 may prevent or at least inhibit the exudates absorbed and contained in the absorbent system 205 from wetting a garment article, such as an undergarment, in contact with the incontinence pad 10. However, in some cases, the backsheet 207 may allow vapors to escape from the absorbent system 205 (i.e., breathable), while in other cases, the backsheet 207 may not allow vapors to escape (i.e., non-breathable). Accordingly, backsheet 205 may comprise a polymeric film, such as a thermoplastic polyethylene film or a polypropylene film. A suitable material for the backsheet 207 is a thermoplastic film having a thickness of, for example, about 0.012mm (0.5 mil) to about 0.051mm (2.0 mils). Any suitable backsheet known in the art may be used in the present invention.

Other suitable examples of backsheets are described in U.S. patent 5,885,265; 4,342,314; and 4,463,045. Suitable single layer breathable backsheets for use herein include those described in, for example, GB a 2184389, GB a 2184390, GB a 2184391, U.S. patent 4,591,523, U.S. patent 3989867, U.S. patent 3,156,242; WO 97/24097 and us patent 6,623,464; 6,664,439 and 6,436,508.

The backsheet may have two layers: a first layer comprising a breathable formed film layer and a second layer comprising a breathable microporous film layer, as described in U.S. patent 6,462,251. Suitable dual or multi-layer breathable backsheets for use herein include those exemplified in U.S. patent 3,881,489, U.S. patent 4,341,216, U.S. patent 4,713,068, U.S. patent 4,818,600, EP 203821, EP 710471, EP 710472, and EP 793952.

Absorption system

The absorbent system 205 of the present invention can comprise any suitable shape. As previously mentioned, the absorbent system 205 is typically the hardest portion of the absorbent article. Thus, shapes useful in articles of the present disclosure will generally include a reduced width intermediate region. For example, in some versions of the invention, the absorbent system 205 may have a contoured shape, e.g., narrower in the middle region than in the end regions. As another example, the absorbent system may have a tapered shape with a wider portion in one end region of the pad that tapers into a narrower middle region and end regions in the other end region of the pad. The absorbent system 205 may include varying stiffness in the MD and CD.

As detailed previously, the absorbent system 205 includes a first absorbent core and a second absorbent core. And as described herein, the first absorbent core and/or the second absorbent core may comprise a single layer or multiple layers. The two laminates are generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids such as urine and other certain body exudates, including menses.

The configuration and construction of the absorbent system 205 may vary (e.g., the absorbent system 205 may have varying caliper zones, a hydrophilic gradient, a superabsorbent gradient, or lower average density and lower average basis weight acquisition zones). In addition, the size and absorbent capacity of the absorbent system 205 can also be varied to accommodate a wide variety of wearers. However, the total absorbent capacity of the absorbent system 205 should be compatible with the design loading and intended use of the disposable absorbent article or incontinence pad 10.

In some forms of the present disclosure, the absorbent system 205 may include a plurality of multi-functional layers in addition to the first absorbent core and the second absorbent core. For example, the absorbent system 205 may include a core wrap (not shown) that may be used to enclose the first and second laminates, as well as other optional layers. The core wrap may be formed from two nonwoven materials, substrates, laminates, films, or other materials. In one form, the core wrap may comprise only a single material, substrate, laminate, or other material that is wrapped at least partially around itself.

The absorbent system 205 of the present disclosure may include one or more adhesives, for example, to help secure the SAP or other absorbent material within the first laminate and the second laminate.

Absorbent cores containing relatively high levels of SAP with various core designs are disclosed in U.S. patent nos. 5,599,335, EP 1,447,066 to Goldman et al; WO 95/11652; U.S. patent publication 2008/0312622a 1; and WO 2012/052172. These can be used to construct the superabsorbent layer.

The addition of the core of the present disclosure is contemplated. In particular, potential additions to current multi-layer laminate absorbent cores are described in U.S. Pat. nos. 4,610,678; 4,673,402; 4,888,231; 4,834,735; 5,234,423; and 5,147,345. These are useful if they do not counteract or conflict with the effects of the layers of the absorbent core of the present invention described below.

The first and second absorbent core layers and/or laminates of the absorbent system 205 have been previously detailed, but it is important to note that these layers or laminates may have the same or different lateral widths as one another. As previously discussed, for example, the first absorbent core layer or laminate may have a smaller lateral width or a larger lateral width than the second absorbent core layer or laminate. In some cases, the first and second absorbent core layers or laminates may have the same longitudinal length, while in other cases the first and second absorbent cores have different longitudinal lengths. In the latter case, the first absorbent core layer or laminate may have a smaller machine direction length than the second absorbent core layer or laminate, or conversely, the first absorbent core layer or laminate may have a larger machine direction length than the second absorbent core layer or laminate.

In some forms, the first and second absorbent core layers or laminates may further include an optional intermediate layer disposed between the respective superabsorbent layers and distribution layers. Generally, the optional intermediate layer may comprise the materials detailed herein with respect to the optional layer of the chassis.

In addition, in some forms, the absorbent article or incontinence pad may comprise, in addition to the first and second absorbent core layers or laminates, an optional additional absorbent core comprising a superabsorbent layer and/or a distribution layer. This optional additional core may take the form of a third, fourth, fifth, or even additional layer. The superabsorbent layer and the distribution layer may exhibit the same or different properties as previously detailed with respect to the first and second superabsorbent layers and the distribution layer. Any optional additional core may be disposed on the body facing surface of the first or second absorbent core, or on the garment facing surface of the first or second absorbent core.

As previously noted, in some forms the first absorbent core layer or laminate has end edges 66 that are complementary in shape to their respective end edges 67. More specifically, the end edge 66 of the first absorbent core layer or laminate may conform in shape to the end edge 67 of the first absorbent core layer or laminate. The same conformability may be applicable to the second absorbent core layer or laminate. This configuration results from the nested slits of the first and second absorbent core layers or laminates that provide matching or form fitting ends. Likewise, this feature may also be generally applicable to any optional absorbent core that may be incorporated into an absorbent system. This nested or nested cut feature of the absorbent core allows for reduced trim waste during manufacture. It has also been found that when the first and second layers are overlapped and joined to form an absorbent system with a central portion 205C having an overlap area, it is possible to construct the first and second absorbent cores or laminates in a manner that allows their respective convex edges to oppose each other.

Referring to fig. 3-4B, as previously described, the front end portion of the absorbent system 205F may be formed by the end edge 66 or the end edge 77 of the first or second absorbent core. The rear end portion of the absorbent system 205R is similarly formed by the end edge 66 or the end edge 77 of the other of the first or second absorbent cores. This configuration results in an absorbent system having mating (i.e., male connector) ends. In other forms, the front end portion of the absorbent system may be formed by the end edge 66 or 76 of the first or second absorbent core, whereas the back end portion of the absorbent system is formed by the end edge 67 or 77 of the other of the first or second absorbent core. In such forms, the second end is shaped as a female connector and therefore does not match the front end portion of the same core. In other forms, the front end portion of the absorbent system may be formed by the end edge 67 of the first absorbent core or the end edge 77 of the second absorbent core. The rear end portion of the absorbent system may similarly be formed by the end edge 67 of the remaining first absorbent core or the end edge 77 of the second absorbent core. This configuration results in an absorbent system having mating (i.e., female connectors) ends. However, it should be noted that the widths of the first and second absorbent cores may be the same or different, as described herein. The nested cut of the respective end edges of the first and second absorbent cores may have a shape selected from the group consisting of arcuate, semi-circular, semi-elliptical, V-shaped, rectangular, sinusoidal, saw-shaped, and combinations thereof.

In some forms, the first absorbent core or the second absorbent core may include one or more recessed regions that extend in the longitudinal or transverse direction. These recessed regions can coincide with a discontinuous pattern of one or more of the superabsorbent layer and the distribution layer, whether it be the first absorbent core, the second absorbent core, or both. These recessed areas may also be formed by embossing the first absorbent core or the second absorbent core only. These recessed areas may alternatively be formed by cutting, ring rolling, or otherwise providing mechanical deformation through the first and/or second absorbent cores. Each of the ways of forming the indented regions mentioned herein is intended to create an indented region that is capable of providing a preferential bending point for the entire article.

Additionally, for those forms in which the first absorbent core and/or the second absorbent core do not comprise a laminate structure, airlaid core materials may be utilized. Any suitable airlaid core may be utilized. The gas flow core material may be obtained from the manufacturer of such materials or may be prepared on-line via equipment known in the art. In the case of using airlaid cores, the need for separate superabsorbent and distribution layers can be reduced. In such forms, the absorbent core web 500 (shown in fig. 5) may comprise an airlaid web as described herein. Suitable airlaid absorbent core structures are disclosed in U.S. patent nos. 8,105,301 and 8,603,622 and U.S. patent application No. 2017/0348166.

Super absorbent layer

Referring to fig. 4B, the first and second superabsorbent layers 61, 71 of the first and second absorbent core laminates 760, 770 comprise superabsorbent polymers or Absorbent Gelling Materials (AGM). In some forms, the superabsorbent layers 61 and/or 71 can include a carrier web and a composition. In such forms, the superabsorbent may be deposited on a carrier web to form a superabsorbent layer. The superabsorbent layer may comprise AGM granules or AGM fibres. Generally, such AGMs utilize only their fluid absorption properties. These materials form hydrogels when contacted with a liquid (e.g., with urine, blood, etc.). A highly preferred type of hydrogel-forming absorbent gelling material is based on hydrolyzed polyacids, in particular neutralized polyacrylic acid. Hydrogel-forming polymeric materials of this type are those which, upon contact with fluids (i.e., liquids), such as water or body fluids, absorb such fluids and thereby form hydrogels. In this way, fluid discharged into the fluid absorbent structure herein may be collected and retained. These preferred superabsorbent polymers will generally comprise substantially water-insoluble, slightly crosslinked, partially neutralized, hydrogel-forming polymeric materials prepared from polymerizable, unsaturated, acid-containing monomers.

The size of the fluid-absorbent gelling material particles can vary within a wide range. For industrial hygiene reasons, an average particle size of less than about 30 microns is less desirable. Particles having a minimum dimension greater than about 2mm can also create a gritty feel in the absorbent article that is undesirable from a consumer aesthetic standpoint. In addition, the fluid absorption rate may be affected by particle size. Larger particles have a very reduced absorption rate. The fluid absorbent gelling material particles preferably have a particle size (substantially all particles) of about 30 microns to about 2 mm. As used herein, "particle size" refers to the weighted average of the smallest dimension of individual particles.

In some forms, the absorbent cores of the present disclosure, or portions thereof, may be substantially free of airfelt and, thus, differ from the intermixed layer, which may comprise airfelt. As used herein, "substantially free of airfelt" means less than 5%, 3%, 1%, or even 0.5% airfelt. In some forms, no measurable airfelt may be present in the superabsorbent layer. As far as the first superabsorbent layer is concerned, it is preferably discontinuously disposed on the first distribution layer. And as previously mentioned, the second superabsorbent layer may be bonded to the first superabsorbent layer or discontinuously disposed on the second distribution layer independently of the first superabsorbent layer. As used herein, "discontinuous" or "in a discontinuous pattern" means that the superabsorbent polymer is applied to the first distribution layer in a pattern that separates the shaped regions. These regions of superabsorbent polymer or regions free of superabsorbent polymer can include, but are not limited to, linear stripes, non-linear stripes, circles, rectangles, triangles, waves, meshes, and combinations thereof. However, like the second superabsorbent layer, the first superabsorbent layer may be disposed in a continuous pattern on its respective distribution layer. As used herein, "continuous pattern" or "continuous" means that the material is deposited and/or secured to the superabsorbent carrier material and/or adjacent distribution layer in an uninterrupted manner such that the superabsorbent polymer has a fairly complete coverage of the distribution layer.

In some forms, the first superabsorbent layer and the second superabsorbent layer may comprise the same superabsorbent polymer. In other embodiments, the first superabsorbent layer and the second superabsorbent layer can comprise superabsorbent polymers that are different from each other. This may be in addition to the different deposition patterns discussed above.

The superabsorbent layer is configured to have a thickness of 0.2mm, 0.3mm, 0.4mm, or 0.5mm to 1mm, 1.2mm, 1.4mm, 1.8mm, or 2 mm. The first superabsorbent layer and the second superabsorbent layer may have the same or different lateral widths when applied to their respective distribution layers. For example, the first and second superabsorbent layers can have a transverse width of 20mm, 25mm, 30mm, 35mm, or 40mm to 50mm, 60mm, 65mm, 70mm, 80mm, or 90 mm. Alternatively, in embodiments in which the lateral widths of the first and second superabsorbent layers are different from each other, the first superabsorbent layer may have a smaller lateral width than the second superabsorbent layer. In particular, the first superabsorbent layer may have a lateral width that is about 95%, 90%, 80%, 70%, or even 60% less than the width of the second superabsorbent layer.

In certain embodiments, one or both of the first and second superabsorbent layers span greater than about 50%, 60%, 70%, 80%, 90%, or even 95% of the transverse width of the superabsorbent carrier layer and/or the respective adjoining first or second distribution layer. Forms of the present disclosure are contemplated in which the absorbent core web 500 includes a superabsorbent layer that is processed to form the superabsorbent layer 61 and the superabsorbent layer 71.

Distribution layer

The first and second distribution layers may be used to wick body fluids away from the wearer's skin, thereby facilitating sustained wear comfort after release. In some forms, the support web may include a distribution layer. In some forms, the support web may be constructed similar to the carrier webs described herein. In some forms, the first and second distribution layers of the first and/or second laminates not only face each other, but are also joined in an offset manner to form a portion of the core. The distribution layer includes one or more of cellulose and compensated wood pulp. This may be in the form of an air-laid web. Airlaying can be chemical bonding or thermal bonding. In particular, the airlaid can be a multi-bond airlaid (MBAL). In this case, the distribution layer may also comprise a fibrous thermoplastic binder material that at least partially air-laid bonds to itself and to an adjacent distribution layer, superabsorbent layer or other additional (optional) layer. It should be noted that it is contemplated that the same materials that are suitable for use in the optional layers of the chassis are suitable for use in the distribution layer. The first and second distribution layers each have a basis weight ranging from 80gsm, 80gsm 100gsm, 110gsm, 120gsm, or 130gsm to 140gsm, 150gsm, 160gsm, 180gsm, 200gsm, 220gsm, or 240 gsm. The distribution layer of the first and second laminates each preferably has a basis weight of 135 gsm.

Barrier hoop

Referring back to fig. 2, the incontinence pad 10 may further include first and second barrier cuffs 230A, 230B and a fastening adhesive 211 disposed on the garment-facing surface 20B of the chassis 20. As shown, the fastening adhesive 211 may not extend laterally to the same extent as the absorbent system 205. Thus, a configuration in which pad curl is reduced would be advantageous.

The first barrier cuff 230A and the second barrier cuff 230B may be attached to the chassis 20 at any suitable location. For example, as shown, first barrier cuff 230A and second barrier cuff 230B may be attached to wearer-facing surface 20A of chassis 20. As shown, the first barrier cuff 230A and the second barrier cuff 230B are attached to the primary topsheet 203. In some forms, first barrier cuff 230A and second barrier cuff 230B may be attached to garment facing surface 20B of chassis 20. For example, first barrier cuff 230A and second barrier cuff 230B may be attached to the backsheet 207. Some examples of other suitable barrier cuffs are described in the following patents: U.S. Pat. nos. 4,695,278; us patent 4,704,115; U.S. Pat. nos. 4,795,454; U.S. Pat. nos. 4,909,803; U.S. patent application publication 2009/0312730.

As shown, in some forms, the first barrier cuff 230A comprises a first cover 231 and a first elastic member 233. The second barrier cuff 230B comprises a second cover 235 and a second elastic member 237. As shown, the first cover 231 may completely enclose the first elastic member 233. Similarly, the second cover 235 may completely enclose the second elastic member 237.

Although the first barrier cuff 230A and the second barrier cuff 230B are shown as discrete elements attached to the chassis 20, any suitable configuration may be employed. For example, the first cover 231 and/or the second cover 235 may comprise a portion of the primary topsheet 203 and/or a portion of the backsheet 207. In such forms, the first barrier cuff 230A and/or the second barrier cuff 230B may be integrally formed with the chassis 20. The form in which the first barrier cuff 230A and the second barrier cuff 230B are integrally formed with the chassis 20 is shown in figure 3 and described below.

The first elastic member 233 and the second elastic member 237 may be attached to the first cover 231 and the second cover 235, respectively, by any suitable means. In one example, the first elastic member may be adhered to the first cover 231. Similarly, the second elastic member 237 may be adhered to the second cover 235. For example, as shown, the first adhesive portions 251 and 253 may attach the elastic members 233 and 237 to their respective covers 231 and 235. Similarly, the second adhesive portions 255 and 257 may attach their respective covers 231 and 235 to the primary topsheet 203. As described below, the first and second elastic members 233 and 237 may be attached to only a portion of the first and second covers 231 and 235, respectively. Other forms are contemplated in which the first elastic member 233 and/or the second elastic member 237 are attached to the chassis 20 in conjunction with or separate from their respective covers 231 and 235.

Referring to fig. 3, the elastic members 233 and 237 may be disposed laterally inward of the side edges 205A and 205B of the absorbent system 205. In other forms, the elastic members 233 and 237 may be disposed laterally outboard of the side edges 205A and 205B of the absorbent system 205. In other forms, the elastic members 233 and 237 may be disposed laterally inboard of the side edges 205A and 205B of the absorbent system 205 in the first end region 40 and the second end region 48, but may be disposed laterally outboard of the side edges 205A and 205B of the absorbent system 205 in the intermediate region 44. Additional forms are contemplated in which the elastic members 233 and 237 are disposed laterally inboard of the side edges 205A and 205B of the absorbent system 205 in the first end region 40, but are disposed outboard of the side edges 205A and 205B of the absorbent system 205 in the intermediate region 44 and/or the second end region 48.

The elastic member comprised of the barrier cuff may be glued at various bond lengths using various glue and glue amounts and arrangements. Glue placement is another variable that should be considered particularly where core flexibility is a design concern. The adhesion of the elastic member to the cover may form an anchor point on the pad.

The cover of the barrier cuff of the present invention may be made of various types of nonwovens having different MD and CD flexibility. The cover member may be bonded to the topsheet of the absorbent article, for example by a slot-coated adhesive strip, a bead of glue, an ultrasonic seal, or other suitable adhesive. In some forms of the invention, the cover may be bonded to the backsheet at the side edges 22 and 24 (see fig. 1) of the pad, for example using a fold or other suitable adhesive such as an adhesive.

The elastic member may comprise any suitable elastic material. Some suitable examples include Spandex^TMOr other similar polyurethanes, natural or synthetic rubbers, styrene block copolymers, metallocene polyolefins, Lycra^TMOr any other suitable elastomeric material known in the art. Preferably, the elastic member is easy to process and durable during use of the article, and exhibits excellent elasticity (recovery after strain) even at strains up to 400%.

Additionally, the elastic members of the present disclosure may have any suitable dtex. In other forms, the elastic member may have a dtex of 680 or less. In some forms, the elastic member may have a decitex between 680 and 470, specifically including all values within these ranges and any ranges formed thereby.

The minimum spacing between the first barrier cuff 230A and the second barrier cuff 230B may be determined in large part by the female anatomy. However, adverse effects may occur when the barrier cuffs (and their respective elastic members) are placed too far outboard of the absorbent system 205 and too far proximal of the absorbent system 205. Accordingly, the spacing between the most distal elastic members of their respective barrier cuffs should be carefully selected. Starting from the narrowest width, the spacing between the most distal elastic members of the first barrier cuff 230A and the second barrier cuff 230B should be large enough to allow adequate ingress into the absorbent system 205 during use while also taking into account the forces that will be applied to the pad. If too narrow, access to a portion of the absorbent system 205 may be hindered, possibly resulting in leakage despite the presence of the barrier cuffs 230A and 230B. In some forms of the invention, the minimum spacing between the elastic member of the first barrier cuff 230A and the elastic member of the second barrier cuff 230B that are most distal to each other may be at least 20 mm. Any suitable spacing may be used. For example, in some forms of the invention, the spacing may be greater than or equal to about 20mm, greater than about 30mm, greater than about 33mm, greater than about 35mm, greater than about 40mm, greater than about 45mm, greater than about 50mm, greater than about 54mm, greater than about 60mm, greater than about 65mm, less than or equal to about 70mm, or less than about 65mm, or less than about 60mm, less than about 55mm, less than about 50mm, less than about 45mm, less than about 40mm, less than about 35mm, less than about 30mm, less than about 25mm, specifically including any value within these ranges or any range formed thereby.

Additional features

In some forms of the invention, the incontinence pad or sanitary napkin may include flaps. The wings may provide additional leakage protection for the incontinence pad and may help secure the pad to the user's undergarment. Any suitable flap configuration known in the art may be used.

Adhesives may be used to bond all of the components together, including hot melt adhesives known in the art. The adhesive may be Findlay H2128 UN or Savare PM 17 and may be applied using the Dynafiber HTW system.

According to fig. 2, the pad may be held in place during use by any support or connector suitable for such purpose. In some forms of the invention, the pad is placed over the user's undergarment or panty and secured thereto by fastening adhesive 211. The fastening adhesive 211 secures the pad in the crotch portion of the user's underwear. A portion or all of the garment-facing surface 20B of the chassis 20 is coated with the fastening adhesive 211. Any adhesive or glue suitable for such purposes may be used as the fastening adhesive 211 herein, such as with a pressure sensitive adhesive. Suitable binders include, for example, Century a-305-IV manufactured by Century adhesives Corporation (Columbus, Ohio); and Instant Lock 34-2823 manufactured by national starch and Chemical Company (Bridgewater, N.J.). Suitable adhesive fasteners are also described in U.S. Pat. No.4,917,697. Prior to use of the absorbent article, the pressure sensitive adhesive is typically covered by a removable release liner to prevent the adhesive from drying out or adhering to surfaces other than the crotch portion of the undergarment prior to use. Suitable release liners are also described in U.S. Pat. Nos. 4,917,697 and 4,556,146. Any commercially available release liner commonly used for such purposes may be utilized herein. Non-limiting examples of suitable release liners are BL30MG-A Silox E1/0 and BL30MG-A Silox 4P/O, both manufactured by Akrosil Corporation (Menasha, Wis.). The using method of the protective pad comprises the following steps: the release liner is removed and the absorbent article is then placed on the undergarment such that the adhesive contacts the undergarment. During use, the adhesive secures the absorbent article in place within the undergarment. The release liner may also be a wrap that is capable of individually wrapping the pad.

Furthermore, while most of the discussion herein is directed to incontinence pads and sanitary napkins, it is contemplated that the present invention can also be used with taped diapers, pull-on training pants, adult incontinence diapers and pants, and replaceable pads for incontinence and menstrual fluid collection that can be inserted into and removed after use with disposable or durable panties or underwear.

Test method

Linear distance

The linear distance may be measured by any suitable instrument which is calibrated and capable of making measurements to the nearest 0.1 mm. Area measurements were made using the projected area of the article, as indicated orthogonal to the plane of the longitudinal and transverse axes, to an accuracy of 0.1mm in square millimeters²。

Thickness of

The thickness of a material is measured as the distance between a reference platform on which the material is placed and a pressure foot that applies a specified amount of pressure to the material over a specified time. All measurements were performed in a laboratory maintained at 23 ℃ ± 2 ℃ and 50% ± 2% relative humidity, and the test samples were conditioned in this environment for at least 2 hours prior to testing.

The thickness is measured with a manually operated micrometer equipped with a pressure foot capable of exerting a steady pressure of 0.50kPa ± 0.01kPa on the test sample. The manually operated micrometer is a dead weight type instrument, which reads to the nearest 0.001 mm. A suitable instrument is Mitutoyo series 543 ID-C Digimatic, available from VWR International, or equivalent. The pressure foot is a flat ground circular active surface having a diameter smaller than the test specimen and capable of applying the required pressure. A suitable pressure foot has a diameter of 56mm, however, depending on the size of the sample being measured, smaller or larger feet may be used. The test specimen is supported by a horizontal, flat reference platform that is larger than and parallel to the surface of the pressure foot. The system was calibrated and operated according to the manufacturer's instructions.

The test sample is obtained by removing it from the absorbent article package. When the test sample is cut from the absorbent article package, care is taken not to impart any contamination or deformation to the test sample layer during said handling. The article is held in its folded state for making fold thickness measurements. The article is unfolded after the folded thickness measurement is completed and an unfolded thickness measurement is taken. The test specimen must be larger than the pressure foot.

To measure thickness, the micrometer is zeroed against a horizontal flat reference platform. The test specimen is placed on the platform with the test position centered under the pressure foot. The pressure foot was gently lowered at a rate of 3.0mm ± 1.0mm per second drop until the full pressure was applied to the test sample. Wait 5 seconds and then record the thickness of the test sample to the nearest 0.01 mm. In a similar manner, a total of five replicate test samples were replicated. The arithmetic mean of all thickness measurements was calculated and recorded as thickness to the nearest 0.01 mm.

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

Each document cited herein, including any cross referenced or related patent or patent application and any patent application or patent to which this application claims priority or its benefits, 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 any disclosure of the invention or the claims herein or that it alone, or in combination with any one or more of the references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

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