阅读说明：本技术 一次性吸收制品 (Disposable absorbent article ) 是由 S.L.哈迪 J.A.威廉姆斯 于 2019-04-11 设计创作，主要内容包括：本文描述了一种一次性吸收制品,所述一次性吸收制品具有纵向中心线和大致垂直于所述纵向中心线的侧向中心线。所述一次性吸收制品具有顶片；底片；以及设置在所述顶片与所述底片之间的吸收系统。所述吸收系统具有第一吸收芯和第二吸收芯,以及所述第一吸收芯和所述第二吸收芯的一对外侧距离,所述第一吸收芯和所述第二吸收芯被配置为使得所述第一吸收芯与所述第二吸收芯之间存在重叠。(Described herein is a disposable absorbent article having a longitudinal centerline and a lateral centerline generally perpendicular to the longitudinal centerline. The disposable absorbent article has a topsheet; a negative film; and an absorbent system disposed between the topsheet and the backsheet. The absorbent system has a first absorbent core and a second absorbent core configured such that there is an overlap between the first absorbent core and the second absorbent core, and a pair of outboard distances of the first absorbent core and the second absorbent core.)

1. A disposable absorbent article (10) having a longitudinal centerline (80) and a lateral centerline (90) generally perpendicular to the longitudinal centerline, the disposable absorbent article further comprising:

a topsheet (203);

a backsheet (207);

a first end region (40), an opposing second end region (48), and an intermediate region (44) disposed between the first and second end regions;

a first absorbent core (60) disposed between the topsheet and the backsheet, the first absorbent core having an intermediate zone first absorbent core width (164);

a second absorbent core disposed between the first absorbent core and the backsheet, wherein the second absorbent core has a middle region second absorbent core width (174), and wherein the middle region first absorbent core width is greater than the middle region second absorbent core width or the middle region second absorbent core width is greater than the middle region first absorbent core width by an intermediate outboard distance, wherein the first absorbent core and the second absorbent core overlap by an overlap distance, and wherein the first absorbent core and the second absorbent core are disposed in a longitudinally offset configuration.

2. The disposable absorbent article of claim 1, wherein the first absorbent core comprises a first zone first absorbent core width (160), and wherein the first zone first absorbent core width is greater than the intermediate zone first absorbent core width.

3. The disposable absorbent article of any of the preceding claims, wherein the second absorbent core comprises a first region second absorbent core width (170), and wherein the first region second absorbent core width is greater than the intermediate region second absorbent core width.

4. The disposable absorbent article of any of the preceding claims, wherein the first region second absorbent core width is greater than the first region first absorbent core width.

5. The disposable absorbent article of any of the preceding claims, wherein the second absorbent core in the first end region extends a first end region outboard distance outboard of the first absorbent core in the first end region.

6. The disposable absorbent article of any of the preceding claims, wherein the intermediate region first absorbent core width is less than the intermediate region second absorbent core width.

7. The disposable absorbent article of claim 6, wherein the first end region outer distance is less than the middle region outer distance.

8. The disposable absorbent article of claims 6 and 7, wherein the intermediate zone outer distance is between about 5mm and about 20mm, more preferably from about 7mm to 18mm, and most preferably from about 8mm to about 15 mm.

9. The disposable absorbent article of any of the preceding claims, wherein the first absorbent core comprises a first portion (61), a second portion (63), and a spacing (251) disposed between the first portion and the second portion, wherein the first portion, second portion, and spacing extend generally parallel to the longitudinal centerline.

10. The disposable absorbent article of claim 9, wherein the spacing is less than 2 times the thickness of the first and/or second portion, or more preferably less than 1.5 times the thickness of the first and/or second portion.

11. The disposable absorbent article of any of the preceding claims, wherein the first absorbent core comprises a second region first absorbent core width (168) and the second absorbent core comprises a second region second absorbent core width (178), wherein the second region first absorbent core width is less than the second region second absorbent core width.

12. The disposable absorbent article of any of the preceding claims, wherein the second absorbent core in the second end region extends a second end region outboard distance outboard of the first absorbent core in the second end region, and wherein the second end region outboard distance is greater than the first end region outboard distance.

13. The disposable absorbent article of any of the preceding claims, wherein the first absorbent core comprises a first portion, a second portion, a third portion (65) spaced apart from and disposed between each of the first portion and the second portion, wherein the first portion, the second portion, and the third portion extend generally parallel to the longitudinal centerline.

14. The disposable absorbent article according to any of the preceding claims, wherein the first absorbent core and/or the second absorbent core comprises a laminate comprising a distribution layer and a superabsorbent layer.

15. The disposable absorbent article of any of the preceding claims, wherein the first absorbent core first end edge is disposed closer to the first end region than the second absorbent core first end edge.

16. The disposable absorbent article of any of the preceding claims, wherein the second absorbent core second end edge is closer to the second end region than the first absorbent core second end edge.

Technical Field

The present invention relates to disposable absorbent articles adapted to absorb and contain 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. Absorbent structures of this type in which hydrogel-forming material in particulate form is incorporated into a fibrous web are disclosed in Weisman and Goldman, U.S. patent No. 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.

Disclosure of Invention

Described herein are disposable absorbent articles that can provide improved leakage protection for consumers with multiple BMIs. Additionally, the methods disclosed herein may facilitate the manufacture of such articles.

An exemplary absorbent article includes: a longitudinal centerline and a lateral centerline substantially perpendicular to the longitudinal centerline, the disposable absorbent article further comprising: a topsheet; a negative film; a first end region and an opposing second end region, and an intermediate region disposed between the first end region and the second end region; a first absorbent core disposed between the topsheet and the backsheet, the first absorbent core having a central region first absorbent core width; a second absorbent core disposed between the first absorbent core and the backsheet, wherein the second absorbent core has a central zone second absorbent core width, and wherein the central zone first absorbent core width is greater than the central zone second absorbent core width, or the central zone second absorbent core width is greater than the central zone first absorbent core width by an intermediate outboard distance, wherein the first absorbent core and the second absorbent core overlap by an overlap distance, and wherein the first absorbent core and the second absorbent core are disposed in a longitudinally offset configuration.

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. 1A is an illustration of an absorbent article (excluding a topsheet and any optional intervening layers) constructed according to the present disclosure;

FIG. 1B is a representation of FIG. 1A showing various widths along the length of a second absorbent core of the article;

FIG. 1C is a representation of FIG. 1A showing various widths along the length of a first absorbent core of the article;

FIG. 1D is a representation of FIG. 1A highlighting various cross-sections along the length of the article;

FIG. 1E is an illustration of a cross-section of the article of FIG. 1A in a first end region along line 1E-1E;

FIG. 1F is a representation of a cross-section of the article of FIG. 1A in the intermediate region along line 1F-1F;

fig. 1G is an illustration of a cross-section of the article of fig. 1A in the second end region along line 1G-1G;

fig. 1H illustrates an alternative configuration of an absorbent system that may be used in the absorbent articles of the present disclosure;

FIG. 1I illustrates an alternative configuration of an absorbent system that may be used in the absorbent articles of the present disclosure;

FIG. 2A is an illustration of another configuration of an absorbent article constructed according to the present disclosure (excluding the topsheet and any optional intervening layers);

FIG. 2B is a representation of a cross-section of the article of FIG. 2A along line 2A-2A;

FIG. 3 is an illustration of a cross-section of an article constructed according to the present disclosure;

FIG. 4 is an illustration of an absorbent system suitable for use with the absorbent articles of the present disclosure;

FIG. 5 is a schematic view of a process that may be used to manufacture an absorbent system according to the present disclosure;

FIG. 6 is a representation of an absorbent core web showing various slit lines;

FIG. 7 is a representation of another absorbent system suitable for use in the absorbent articles of the present disclosure;

FIG. 8A is a representation of another absorbent core web having various slit lines and edges;

FIG. 8B is an illustration of a cross-section of an absorbent article constructed according to the present disclosure;

FIG. 9A is a representation of another absorbent core web having a single slit line;

FIG. 9B is an illustration of another absorbent article constructed according to the present disclosure; and is

Fig. 10 is an illustration of another absorbent article constructed according to the present disclosure.

Fig. 11 is an illustration of another absorbent system suitable for use in the absorbent articles of the present disclosure.

Detailed Description

The following explanations of terms may aid in understanding the present disclosure:

the disposable absorbent article of the present invention, particularly an incontinence pad or pant, may provide flexibility to allow for an 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 various 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.

"elastic," "elastomeric" or "elastomeric" means that a material exhibits elastic properties, and includes any material that is capable of being stretched or elongated to an elongated length greater than 10% of its original length upon application of a force to its relaxed, original length, and will substantially recover to about its original length upon release of the applied force.

As used herein, the term "joined" includes configurations in which an element is directly secured to another element by affixing the element directly to the other element, and configurations in which the element is indirectly secured to the other element by affixing the element to an intermediate member (which in turn is affixed to the other element).

"longitudinal" refers to a direction running substantially perpendicular from a waist edge of an absorbent article to a longitudinally opposing waist edge, or in a bi-folded article from a waist edge to the bottom of the crotch (i.e., the fold line), when the article is in a flat, uncontracted state. Directions within 45 degrees of the longitudinal direction are considered to be "longitudinal". "lateral" refers to a direction running from a longitudinally extending side edge of the article to a laterally opposing longitudinally extending side edge and generally at right angles to the longitudinal direction. Directions within 45 degrees of lateral are considered "lateral".

The term "nonwoven" refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. The nonwoven does not have a woven filament or woven filament pattern.

The term "machine direction" (MD) refers herein to the direction of material flow during processing. Further, the relative placement and movement of materials may also be described as passing through the process from upstream of the process to downstream of the process in the machine direction.

The term "cross direction" (CD) refers herein to a direction that is generally perpendicular to the machine direction.

The disposable absorbent articles of the present disclosure, particularly incontinence pads or pants, can provide flexibility to allow for an 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 various layers contained therein, while also allowing for conformability of the article.

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. Lower 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 managed properly, the absorbent article may not provide structural resistance to bunching/compression during wear, which may lead to leakage. In contrast, while bulkier pads may be less likely to yield to the compression typical during wear, bulkier pads are less desirable because they may cause the incontinence pad to be noticeable and uncomfortable to the wearer during use. Furthermore, although bulkier pads resist compressive forces during use, they do not conform as easily as their corresponding thinner pads. This lack of conformability can also 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, conventional incontinence pad designs have required a compromise in some respect to 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 those 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 construction to further prevent 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. 1A shows an absorbent article 10 according to the present disclosure. The absorbent article 10 may include a longitudinal centerline 80 and a lateral centerline 90. The longitudinal centerline 80 extends generally parallel to the longest dimension of the absorbent article 10. The lateral centerline 90 extends generally perpendicular to the longitudinal centerline 80 and lies in the same plane as the absorbent article 10 in a flattened state on a flat surface. The lateral centerline 90 bisects the length of the absorbent article 10, wherein the length is parallel to the longitudinal centerline 80, and the longitudinal centerline 80 bisects the width of the absorbent article 10, wherein the width is parallel to the lateral centerline 90. Further, as shown, the MD direction (machine direction) may be generally parallel to the longitudinal centerline 80 of the absorbent article 10, and the CD direction (cross-machine direction) may be generally parallel to the lateral centerline 90.

The absorbent article 10 also includes a chassis 20 having an absorbent system 205 that, in some forms, includes a first absorbent core 60 and a second absorbent core 70. As shown, the absorbent article 10 may have a generally hourglass shape. However, any suitable shape may be utilized. Some examples include an offset hourglass shape (one end wider than the opposite end and a middle portion between the ends narrower), a bicycle seat cushion shape (one end and the middle portion narrower than the second end), and the like. The side edges 22 and 24 may follow the general contour of the first absorbent core 60 and/or the second absorbent core 70. Thus, in case the first absorbent core 60 and/or the second absorbent core 70 have an hourglass shape, the side edges 22, 24 may also be arranged in an hourglass shape. However, forms are contemplated in which the side edges 22 and 24 are generally straight or slightly curved such that they do not follow the contours of the first absorbent core 60 and/or the second absorbent core 70. Additional details are discussed below. The absorbent article 10 may be symmetric about the longitudinal centerline 80 or asymmetric about the longitudinal centerline 80. Similarly, the absorbent article 10 may be symmetric about the lateral centerline 90 or asymmetric about the lateral centerline 90.

As shown, the first absorbent core 60 may be positioned closer to the wearer-facing surface in the absorbent article than the second absorbent core 70. However, a form is contemplated in which the second absorbent core 70 is positioned in a position closer to the wearer-facing surface in the absorbent article than the first absorbent core 60.

The plurality of side edges 22 and 24 extend generally parallel to the longitudinal centerline 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, wherein the second end region 48 is 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 intermediate region 44 generally corresponds to the region of the article where fluid ingress is expected. For a catamenial pad, the expected area of fluid entry may be a location on the catamenial pad corresponding to the vaginal opening. For adult incontinence articles, the intended area of fluid entry may be the location of the incontinence article corresponding to the urethra or vulvar region, as labial tissue may cover the pathway from the urethra to the absorbent article. Also, in general, the intermediate region 44 may correspond to a portion of the absorbent article 10 that is positioned between the thighs of the wearer during use. In some forms, the intermediate region 44 may include a lateral centerline 90. In some forms, the intermediate region 44 may be disposed asymmetrically about the lateral centerline 90, e.g., on one side of the lateral centerline 90 or more on one side of the lateral centerline 90 than on the other side of the lateral centerline 90. A method for determining the extent of the intermediate region 44 is described herein.

In one particular example, the intermediate zone 44 extends in the longitudinal direction from the intended point of ingress a distance equal to 15% of the total length of the article. In some forms, the intermediate region 44 can comprise about 20% of the total article length, about 30% of the total article length, about 40% of the total article length, or about 50% of the total article length, specifically including all values within these ranges and any ranges resulting therefrom. The first end region 40 and/or the second end region 48 may comprise about 45% of the total length of the absorbent article, about 30% of the length of the absorbent article, about 20% of the length of the absorbent article, about 15% of the length of the absorbent article, any combination thereof, and specifically all values within these ranges and any ranges resulting therefrom.

The intermediate region 44 may be designed to accommodate wearers of different BMIs. For example, the overall length of the intermediate region 44 may be greater than about 25mm, greater than about 30mm, greater than about 40mm, greater than about 50mm, greater than about 60mm, greater than about 70mm, greater than about 80mm, greater than about 90mm, or greater than about 100mm, specifically including all values within these ranges and any ranges produced thereby. A longer length of the intermediate region 44 may accommodate wearers with greater BMI.

As shown, in some forms, the first end region 40 may have a first end region width 140 representing the widest portion of the first end region. Similarly, second end region 48 may have a second end region width 148 that represents the widest portion of second end region 48. The intermediate region 44 may have an intermediate region width 144 representing the narrowest portion of the intermediate region 44. In some forms, the first end region width 140 may be greater than the middle region width 144. In some forms, the second end region width 148 may be greater than the middle region width 144. In some forms, the first end region width 140 may be greater than the second end region width 148, and vice versa.

The smaller width intermediate region 44 accommodates wearers of various BMIs. For example, the articles of the present disclosure may be positioned in the underwear of a user and at least partially between the thighs of the wearer. Regardless of the BMI of the wearer, the narrowest spacing to be achieved by an absorbent article is generally between the thighs of the wearer. Conventional absorbent articles may tend to bunch up in this area due to the narrow spacing. However, because the width of the intermediate region is narrower, the absorbent articles of the present disclosure can more easily accommodate this spacing by aligning the intermediate region 44 with the spaces between the wearer's thighs. Furthermore, as BMI increases, the length of the narrow space between the thighs may increase. Thus, in some forms, the length of the intermediate zone 44 for a higher BMI wearer may be longer than the length of the intermediate zone 44 for a lower BMI wearer.

As previously mentioned, forms are contemplated in which the side edges 22 and 24 do not follow the contours of the first absorbent core 60 and/or the second absorbent core 70. In such forms, the middle region width 144 may be equal to the first end region width 140 and/or the second region width 148. However, in such forms, the first absorbent core 60 and/or the second absorbent core 70 may be contoured such that their respective widths in the intermediate region 44 are narrower than their respective first end widths and/or second end widths. Such a form may still accommodate narrow spacing between the thighs of the wearer. For example, as previously mentioned, the absorbent core material of an absorbent article may often be the hardest part of the absorbent article. As discussed below, the absorbent system 205 of the absorbent article of the present disclosure is contoured. Thus, it is believed that the materials of the absorbent article 10 outside of the contoured absorbent system 205 can be readily conformed due to their low stiffness, even without contouring the side edges 22 and 24.

Referring now to fig. 1A-1C, the first absorbent layer 60 may include side edges 62 and 64 and a pair of end edges 66 and 68 joining the side edges 62 and 64 in the first end region 40 and the second end region 48, respectively, of the incontinence pad 10. Similarly, the second absorbent layer 70 may include side edges 72 and 74 and a pair of end edges 76 and 78 joining the side edges 72 and 74 in the first end region 40 and the second end region 48 of the incontinence pad 10, respectively.

Further, as shown, the end edges 66 and 68 of the first absorbent layer 60 may be substantially flat. The end edges 76 and 78 of the second absorbent layer 70 may be similarly configured. Additionally, as shown, in some forms, the end edge 66 of the first absorbent layer 60 may be joined to the end edge 76 of the second absorbent layer 70. In some forms, the first absorbent layer 60 and the second absorbent layer 70 may be positioned within the absorbent article 10 such that the first absorbent layer 60 is offset from the second absorbent layer 70. This configuration is explained in more detail below.

As shown, the side edges 62 and 64 may be contoured such that the intermediate zone first absorbent layer width 164 is less than the first zone first absorbent layer width 160 and/or less than the second zone first absorbent layer width 168. Similarly, the side edges 72 and 74 may be contoured such that the intermediate region second absorbent layer width 174 is less than the first region second absorbent layer width 170 and/or less than the second region second absorbent layer width 178.

In some forms, the first region first absorbent layer width 160 may be less than the first region second absorbent layer width 170. In some forms, the second region first absorbent layer width 168 may be less than the second region second absorbent layer width 178. In some forms, the intermediate zone first absorbent layer width 164 may be less than the intermediate zone second absorbent layer width 174. In some forms, one or more of the foregoing widths of the first absorbent core 60 may be the same, larger, smaller, or have any combination of these relationships, as compared to one or more of the foregoing widths of the second absorbent core 70.

In addition to contouring the absorbent system 205 described above, it is believed that the smaller width of the first absorbent core 60 also contributes to the conformability of the absorbent article. As previously mentioned, the hardest material of the absorbent article 10 is in the absorbent system 205. Thus, there is a higher level of stiffness for those areas where the first and second absorbent cores 60, 70 overlap each other, as opposed to those areas where the second absorbent core 70 extends outside the first absorbent core 60. For those regions of the absorbent article where the second absorbent core 70 extends outside the first absorbent core 60, the stiffness is much less than for those regions where the first absorbent core 60 and the second absorbent core 70 overlap.

In some forms, the amount of the second absorbent core 70 that is outboard of the first absorbent core 60 can be constant along the length of the first absorbent core 60. In such forms, it is believed that the smallest portion of the second absorbent core 70 outside the first absorbent core 60 is greater than 5 mm. It is believed that this minimum distance may be beneficial to allow the absorbent article to have sufficient conformability. However, a form is contemplated in which the portion of the second absorbent core 70 outside the first absorbent core 60 may vary depending on the location. Examples relating to this aspect of the absorbent article of the present disclosure are provided below.

Referring now to fig. 1D-1E, cross-sectional views of the absorbent article 10 in the first end region 40 are shown. As previously mentioned, the first absorbent core side edges 62 and 64 may be laterally inboard of the second absorbent core side edges 72 and 74. The distance between side edge 62 and side edge 72 is a first outboard distance 152 and the distance between side edge 64 and side edge 74 is a second outboard distance 154. And the area between first outside distance 152 and second outside distance 154 is overlap distance 150. As noted above, it is believed that sufficient conformability may be achieved with the first and second outboard distances 152, 154 being greater than 5mm, particularly in the intermediate region 44. However, where the first end region 40 corresponds to the front of the article, the first end region 40 is generally positioned in front of the vaginal opening and in front of the urethral opening. In this region of the body, the body contour is generally flat over a wide range of wearer BMIs. As the body surface is flatter, the conformability of the absorbent article in the first end region 40 may not be as critical as in other regions. Accordingly, the first and second lateral distances 152, 154 in the first end region 40 may be less than 10 mm. In some forms, the outboard distances 152 and 154 may be between 0mm and 7mm, more preferably between 1mm and 5mm, and most preferably between 2mm and 4mm, specifically including all values within these ranges and any ranges resulting therefrom. In some forms, the first and/or second outboard distances 152, 154 may be 0 mm.

The overlap distance 150 may be any desired value for the comfort of the wearer and may be adapted to the expected load of the wearer. In some forms, the overlap distance 150 may be between about 10mm to about 30mm, more preferably from about 20mm to about 40mm, most preferably from about 25mm to about 50mm, or greater than about 60mm, specifically including all values within these ranges and any ranges resulting therefrom.

The outboard distances 152 and 154 may gradually increase from the first end region 40 to the intermediate region 44. As previously mentioned, the intermediate region 44 is generally the portion of the absorbent article 10 that is positioned between the thighs of the wearer during use. Due to the limited spacing between the wearer's thighs, the excess material of the absorbent article may tend to compress/bunch if not carefully controlled. Such compression/bunching may increase the likelihood of leakage. Thus, in the intermediate region 44, the conformability of the absorbent article 10 is critical to reducing the likelihood of leakage.

Referring now to fig. 1D and 1F, in the intermediate region 44, the outboard distances 152 and 154 may be greater than 5 mm. In some forms, the outboard distance 152 and/or 154 may be greater than 5mm, at least 7mm, at least 8mm, at least 10mm, at least 15mm, or at least 20mm, specifically including all values within these ranges and any ranges resulting therefrom. In the intermediate region 44, the outboard distance may be between about 5mm to about 20mm, more preferably from about 7mm to about 18mm, or most preferably from about 8mm to about 15 mm. However, where the outboard distance 152 and/or 154 is greater than 20mm, the absorbent article 10 may be too conformable. Unfortunately, in the event the absorbent article is too conformable, this may result in the absorbent article 10 compressing/bunching, thereby increasing the likelihood of leakage. In contrast, where the outboard distances 152 and 154 are less than or equal to 5mm, increased force may be required to drive the conformability of the absorbent article 10. Such increased forces may cause discomfort to the wearer during use.

Further, the overlap distance 150 in the intermediate region 44 may be at least 10mm, at least 20mm, or at least 30mm, specifically including all values within these ranges and any ranges resulting therefrom. For wearers of higher BMI (e.g., 30 or greater), the overlap distance 150 may be less than 50mm, less than 40mm, less than 30mm, or about 20mm, specifically including all values within these ranges and any ranges resulting therefrom. For those wearers having a lower BMI (e.g., 30 or less), the overlap distance 150 can be greater than about 20mm, greater than about 30mm, greater than about 40mm, greater than about 50mm, greater than about 60mm, specifically including all values within these ranges and any ranges resulting therefrom.

Further, forms are contemplated in which the lateral distances 152 and 154 in the intermediate region 44 are achieved via the first absorbent core 60 being located outside the second absorbent core 70. Such configurations may be beneficial for higher BMI (e.g., 30 or greater) wearers. For these higher BMI wearers, the available space (width) adjacent to the vaginal or urethral opening may be greater than the available space (width) between the thighs. Therefore, a wider first absorbent core 60 closer to the wearer than a second absorbent core 70 may be beneficial.

In view of the above, a product family can be created that can accommodate a variety of BMIs. For example, for a lower BMI, the lateral distance and the overlap distance may be configured in a first plurality of products for wearers of lower BMI and in a second plurality of products for wearers of higher BMI.

Referring now to fig. 1D and 1G, much like first end region 40, lateral distances 152 and 154 in second end region 48 may be any suitable value. Generally, the second end region 48 of the absorbent article 10 is disposed rearward of the vaginal opening and is generally positioned adjacent to the gluteal groove (the gluteal groove is generally referred to as a fold of the buttocks or a gluteal fold of the horizontal gluteal fold). Similar to the first end region 40, the second end region 48 of the absorbent article 10 generally does not experience the same degree of bunching/compression as the intermediate region 44. Further, for those forms of the absorbent article 10, including catamenial pads or adult incontinence pads, the area of fluid insult generally corresponds to the intermediate region 44 and/or the first end region 40. Therefore, for such absorbent article forms, the absorbent capacity in the second end region 48 may not be as critical as for the first end region 40 and/or the intermediate region 44. Accordingly, the outboard distances 152 and 154 in the second end region 48 may be any suitable value. Similarly, the overlap distance 150 may be any suitable value. Notably, the absorbent capacity in the second end region 48 may provide some confidence to the wearer. Thus, even if primarily decorative, the absorbent capacity in the second end region 48 may be a good choice, particularly where the second end region 48 is adjacent the intermediate region 44.

Referring now to fig. 1H and 1I, examples of variable outboard distances 152 and 154 are shown. Further, the outside edges of the absorbent cores 60 and 70 are shown as being variable. With respect to fig. 1H, a form is contemplated in which the edges 62 and 64 of the first absorbent core 60 are disposed outboard of the edges 72 and 74 of the second absorbent core 70 in the first end region 40, the second end region 48, and/or the intermediate region 44. With respect to FIG. 1I, in some forms, the outboard distances 152 and 154 may vary within particular regions of the article. For example, the outboard distances 152 and 154 may vary within the intermediate region 44. In some forms, at least a portion of the outboard distance 152 and/or 154 in the intermediate region 44 may be equal to or less than 5mm as previously described. In such forms, it may be beneficial to configure the lower outboard distances 152 and 154 (i.e., equal to or less than 5mm) toward the ends of the intermediate region 44. Thus, for such forms, a lower outboard distance would be provided adjacent the first end region 40 and the second end region 48.

Referring now to fig. 2A, in some forms the end edges 66 and/or 68 of the first absorbent layer 60 may be contoured. For example, the end edge 66 of the first absorbent core 60 may have a convex (convex) configuration while the end edge 68 may have a concave (concave) configuration. In contrast, the end edge 76 of the second absorbent core 70 may have a concave (concave) configuration while the end edge 78 of the second absorbent core 70 has a convex (convex) configuration. The convex/concave configuration of the first absorbent core 60 and/or the second absorbent core 70 can minimize the amount of waste material generated during the manufacture of the absorbent articles of the present disclosure. Additional arrangements of absorbent core layers and processing of the absorbent articles of the present disclosure will be described in more detail below.

Referring now to fig. 2A and 2B, in some forms, the first absorbent core 60 can include a first portion 61 and a second portion 63. The first portion 61 and the second portion 63 can be discrete portions of the first absorbent core 60. For example, the spacing 251 between the first portion 61 and the second portion 63 may coincide with the longitudinal centerline 80. In some forms, the spacing 251 between the first portion 61 and the second portion 63 may be at least partially offset from the longitudinal centerline 80. First portion 61 may include a first trimmed edge 110 and second portion 63 may include a second trimmed edge 120. In some forms, first trimmed edge 110 and second trimmed edge 120 may abut each other such that a spacing 251 between first trimmed edge 110 and second trimmed edge 120 is minimized. In other forms, the spacing 251 may be larger. For example, in some forms, the spacing 251 may be greater than about 0.5mm, greater than about 1.0mm, greater than about 1.5mm, greater than about 2.0mm, greater than about 3.0mm, greater than about 4.0mm, up to about 5.0mm, including specifically all values within these ranges and any ranges resulting therefrom.

Notably, the spacing 251 between the first portion 61 and the second portion 63 may facilitate folding of the absorbent article 10 in the area of the spacing 251. As discussed previously, since the stiffness of the absorbent article 10 is reduced in the region of the spacing 251, folding of the article in this region during use can be facilitated. However, if the gap is too large, the absorbent article 10 may gather more easily, which may increase the likelihood of leakage. To reduce the likelihood of leakage, the spacing 251 is preferably less than or equal to 2 times the thickness of the first portion 61 and/or the second portion 63. In some forms, spacing 251 may be less than or equal to 1.5 times the thickness of first portion 61 and/or second portion 63. In some forms, spacing 251 may be less than or equal to about 1 times the thickness of first portion 61 and/or second portion 63.

The outboard distances 152 and 154 discussed herein are equally applicable to the form shown in fig. 2A-2B. Similarly, the overlap distance 150 (shown in fig. 1E-1G) may be equally applicable to the forms in fig. 2A-2B.

Referring now to fig. 1A-3, the chassis 20 of the exemplary absorbent article is shown in cross-section in fig. 3, the cross-section being taken along the lateral centerline 90. 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 pad 10 also includes a backsheet 207 that also includes 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 well be included in the chassis 20, particularly 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 some forms, the secondary topsheet (also referred to as "STS") has a greater length and width than the absorbent system 205. In some forms, the chassis may also include barrier cuffs 230A and 230B. Barrier cuffs are discussed in additional detail below.

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 207.

Referring now to fig. 4, a cross-section of an exemplary absorbent system 205 taken along a longitudinal centerline is shown. As previously mentioned, the absorbent system 205 may comprise a first absorbent core and a second absorbent core 70. As shown, the first absorbent core 60 has an upper surface 60A and a lower surface 60B opposite the upper surface. Similarly, the second absorbent core 70 has an upper surface 70A and a lower surface 70B. Further, in some forms, the first absorbent core 60 and/or the second absorbent core 70 may comprise a laminate structure having a plurality of layers. Such forms are discussed in additional detail below.

As shown, in some forms, the first absorbent core 60 may be joined to the second absorbent core 70 along the length of the absorbent system 205 in an offset manner or configuration. As used herein, "offset" or "offset manner" means that the layers of interest are staggered and their respective end edges are not aligned in the z-direction when the layers or laminate structures overlap one another (i.e., the end edge of one layer or laminate structure is not connected to an adjacent underlying or overlying layer or laminate structure end edge). This offset engagement of the first absorbent core 60 and the second absorbent core 70 results in an overlap and an area of engagement of the two layers that forms the central portion 205C of the absorbent system 205. The central portion 205C of the absorbent system 205 is thus bounded on each side by both the front end portion 205F and the back end portion 205R of the absorbent system 205. In other words, the front end portion 205F and the rear end portion 205R are disposed at opposite ends of the absorbent system 205, respectively. As shown in some forms, the distance between end edge 66 and end edge 76 may define the length of front end portion 205F. Similarly, the distance between end edge 78 and end edge 68 may define the length of rear end portion 205R. In some forms, end edge 76 may be the leading edge of absorbent system 205 (closer to first region 40 of pad 10) and end edge 68 may be the trailing edge of absorbent system 205 (closer to second region 48 of pad 10).

The length of the central portion 205C may vary depending on the size of the absorbent article 10. For example, the central portion 205C of those absorbent articles sized for wearers of higher BMI may be longer in length than the central portion 205C of absorbent articles sized for wearers of lower BMI. Further, where the absorbent article is equipped with elasticized barrier leg cuffs, the central portion 205C may extend beyond the outermost anchor point of the elastomeric member of the barrier leg cuff. Extending the central portion 205C beyond these outermost anchor points may reduce the likelihood of end portions of the absorbent article folding during application of the absorbent article. As described in U.S. patent application No. 2017/0049634, end folding can be problematic during application of absorbent articles. In some forms, the central portion 205C may have the following length: 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, specifically including all values within these ranges and any ranges produced thereby.

Methods according to the present disclosure may facilitate such forms of processing. As shown in fig. 2-6, the absorbent core web 500 may be purchased from a supplier or may be manufactured by an absorbent article manufacturer. Additional details of the absorbent core web 500 will be provided in greater detail below. As shown, the absorbent core web 500 can be conveyed in the machine direction to a cutter 510. Guillotines are well known in the art.

In some forms, absorbent core web 500 may be cut along slit lines 562 and 564, which may be offset from longitudinal centerline 580 of absorbent core web 500. As shown, after slitting, three separate webs may be formed, namely, a first absorbent core first portion web 561, a first absorbent core second portion web 563, and a second absorbent core web 570. Cutting the absorbent core web 500 can reduce the yield of waste material generated by processing the web. For example, the trimmed edges 510 and 520 of the web may be used as the first trimmed edge 110 and the second trimmed edge 120 in the first portion 61 and the second portion 63, respectively, of the first absorbent core 60. Further, the edges of the first portion web 561 formed by the slit lines 562 may serve as the side edges 62 in the first portion 61 of the first absorbent core 60 and as the side edges 72 for the second absorbent core 70. Similarly, the edges formed by the slit lines 564 may be used as the side edges 64 by the second portion 63 of the first absorbent core 60 and as the side edges 74 for the second absorbent core 70.

In some forms, the first absorbent core first portion web 561 and the first absorbent core second portion web 563 may then be provided to a cutting device 520A to cut discrete first portions 561A and discrete second portions 563A, respectively, from these absorbent core webs. Similarly, the second absorbent core web 570 may be provided to a cutting device 520B to cut discrete second absorbent core layers 570A from the second absorbent core web 570. Exemplary cutting devices are known in the art. Also, a cutting device for producing a male/female end edge is disclosed in U.S. patent application publication No. 2018/0154533.

In some forms, the cutting of the first absorbent core first portion web 561 and the first absorbent core second portion web 563 may be facilitated via the introduction of the first carrier web upstream of the cutting device 520A. In such forms, the first absorbent core first portion web 561 and the first absorbent core second portion web 563 may be bonded to a first carrier web. The first absorbent core first portion web 561 and the first absorbent core second portion web 563 may be positioned on the first carrier web in their proper orientation, e.g., providing a spacing 251 between the first portion and the second portion as described herein. The first absorbent core portion and the carrier web can then be simultaneously provided to a cutting device. A plurality of discrete first absorbent cores may be provided from the cutting device.

Still referring to fig. 2-6, as shown, the cutting device 520A can provide the first absorbent core 60 (both the first and second portions) with a convex (convex) end edge 66, while the second cutting device 520B can provide the second absorbent core layer 70 with a concave (concave) end edge 76. However, forms are envisaged in which both end edges 66 and 76 are convex (convex). A form is envisaged in which both end edges 66 and 76 are concave (concave). Forms are envisaged in which the end edge 66 is concave (concave) and the end edge 76 is convex (convex). Additional forms are contemplated wherein at least one end edge of the first absorbent core 60 (first portion and/or second portion) and/or the second absorbent core layer 70 is neither convex nor concave, e.g., is substantially flat, wavy, etc. The end edges of the first and second end portions of each 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.

A plurality of discrete first absorbent core first portions 561A are provided from the cutting device 520A to a cut and slide or cut and place operation 530A. Similarly, the first absorbent core second portion 563A may be provided to the same cut and slide or cut and place operation 530A as the first absorbent core first portion layer 561A. Or in some forms, the first absorbent core second part layer 563A may be provided for a separate cut and slide or cut and place operation. As described above, where the first absorbent core first portion web 561 and the first absorbent core second portion web 563 are provided to a first carrier web, then a plurality of discrete first absorbent cores may be provided to a single cut and slide or cut and place operation.

The cut and slide or cut and place operation 530A can position one of the plurality of first absorbent core first portions 561A and/or first absorbent core second portions 563A onto the carrier web. For those forms in which the first carrier web is introduced prior to the cutting device 520A, the discrete first absorbent core portions may be placed onto the second carrier web via a cut and slide or cut and place operation 530A. Whenever a carrier web is introduced into the process, the first absorbent core first portion 561A and the first absorbent core second portion 563A placed onto the first carrier web and/or the second carrier web may be oriented such that the convex (convex) end edge is the leading edge in the machine direction or the concave (concave) end edge is the leading edge. The first absorbent core first portion 561A and the first absorbent core second portion 563A are placed onto a carrier web after the cut and slide or cut and place operation 530A to form an absorbent core precursor web 580.

Similarly, a plurality of discrete second absorbent cores 570A are provided from the cutting device 520B to a cut and slide or cut and place operation 530B. The cut and slide or cut and place operation 530B can position one of the plurality of discrete second absorbent cores 570A onto the absorbent core precursor web 580. In such forms, the second absorbent core layer 70 may be disposed in an offset manner such that its upper surface 70A is attached to the lower surface 60B of the first absorbent core layer 60. The second absorbent core layer 70 and the first absorbent core layer 60 may be attached in any suitable manner (e.g., adhesive).

It is noted that in the case where the first absorbent core layer 60 and the second absorbent core layer 70 are positioned in an offset manner and adhesively attached, the manner in which the adhesive is applied should be noted. Referring now to fig. 4 and 5, the adhesive applied to the lower surface 60B should be strategically positioned to reduce the likelihood of equipment contamination. For example, as shown, the adhesive applied in the front end portion 205F may contaminate the device because the second absorbent core layer 70 does not cover the adhesive in this region. An adhesive is required in the central portion 205C. In addition, an adhesive should be provided in the rear end portion 205R. In such forms, an adhesive is applied to the carrier web to ensure that the second absorbent core layer 70 is completely released from the cut and slip or cut and place operation 540B. In other forms in which the end edges 76 form the front end portion 205F, adhesive should be applied to the carrier web in the front end portion 205F and the central portion 205C to ensure that the end edges 76 are released from the cut and slide or cut and place operation 540B. Cutting and sliding and cutting and placement devices are well known in the art.

Referring back to fig. 2A-6, a laminate structure web 590 comprising a carrier web, a first absorbent core 60 (comprising a first portion and a second portion), and a second absorbent core 70 is provided from a second cut and slide or cut and place operation 530B. From here on, a backsheet web, a topsheet web and/or additional layers may be provided on the lower surface 70B of the second absorbent layer 70. The backsheet web may cover the laminate structure web 590 with or without additional optional layers. The backsheet web and the first or second carrier web may then be joined to enclose the first absorbent core layer 60 and the second absorbent core layer 70 to form an absorbent article web. The absorbent article web may then be provided to a cutting device that cuts the absorbent article web into individual absorbent articles.

In some forms, the first absorbent core 60 (including the first portion and the second portion) and/or the second absorbent core 70 may comprise a plurality of webs and layers themselves. Referring now to fig. 7, for example, the first absorbent core 60 (shown in fig. 2 and 4) may include a first superabsorbent layer 61, i.e., a first absorbent core laminate 760, disposed on a first distribution layer 62. Also, the second absorbent core 70 (shown in fig. 3 and 4) may include a second superabsorbent layer 71, i.e., a second absorbent core laminate 770, disposed on the second distribution layer 72. In some forms, the first distribution layer 62 is joined to the second distribution layer 72 in an offset manner or configuration along the length of the core. This offset joining of the first distribution layer 62 and the second distribution layer 72 results in overlapping and joined areas of the two laminates that form the central portion 205C of the absorbent system 205. As shown, the front end portion 205F is formed by the end edge 66 of the first absorbent core laminate 760, while the back end portion 205R of the core 205 is formed by the end edge 78 of the second absorbent core laminate 770. For those forms in which the first distribution layer 62 is joined to the second distribution layer 72, the second absorbent core web 570 may be inverted prior to entering the cutting apparatus 520B.

For the version of fig. 7, the end edges 66 and 78 of the first and second absorbent core laminates oppose each other and form the front end portion 205F and the back end portion 205R, respectively, of the absorbent system 205, and vice versa. In other forms, the end edges 68 and 76 of the first and second absorbent core laminates may oppose each other and form the front end portion 205F and the back end portion 205R, respectively, of the absorbent system 205, and vice versa. In both cases, the end edge 66 and the end edge 78 may be in the form of male connections originating from nested cuts of the first and second absorbent cores. Similarly, end edge 68 and end edge 76 may be in the form of female connections originating from nested cuts of the first and second laminates, respectively.

In an alternative form, the first absorbent core laminate 760 may be joined to the superabsorbent layer 71 instead of the second distribution layer 72. In such forms, the laminates may also be joined to each other in an offset manner, except that the first distribution layer 62 is joined to the second superabsorbent layer 71 instead of the second distribution layer 72.

In some forms, the overlap region or area forming the central portion 205C of the core 205 has at least one characteristic of greater capacity, greater void volume, or greater thickness than the front and back end portions 205F, 205F of the absorbent system 205. These forms are 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.

Whether the absorbent system 205 utilizes the first absorbent core 60, the second absorbent core 70, the first absorbent core laminate 760, the second absorbent core laminate 770, or some combination thereof, the processing of the absorbent articles of the present disclosure may proceed generally as described herein. For example, the first absorbent core laminate 760 and the second absorbent core laminate 770 may be derived from an absorbent core laminate web (including a superabsorbent layer and a distribution layer) cut according to the description with respect to fig. 2A-6. And, the web formed therefrom can then be cut as described herein and placed onto a carrier web, a topsheet web, or a secondary topsheet web.

Additional forms are contemplated that can provide preferential folding of the absorbent article. Referring now to fig. 8A-8B, a form is contemplated in which an absorbent core web 500 may be cut into four separate web streams. In such forms, a first absorbent core third portion web 565 can be created in addition to the first absorbent core first portion web 561, first absorbent core second portion web 563, second absorbent core web 570. The first absorbent core third portion web 565 can have edges 510 and 512. As shown, the first absorbent core third portion web 565 can include edges 510 and 512, wherein edge 512 is the outer edge of the absorbent core web 500 and edge 510 is the edge formed via slitting.

The first absorbent core third portion web 565 can be placed on the first carrier web along with the first absorbent core first portion web 561 and the first absorbent core second portion web 563 via the processes described herein. All three webs plus the first carrier web may then be cut by a cutting device to produce a plurality of discrete first absorbent cores. Each of the plurality of discrete first absorbent cores may comprise a first portion 61, a second portion 63, and a third portion 65 disposed between the first portion 61 and the second portion 63. This form of lateral distances 152 and 154 may be in the first end region, the intermediate region, and the second end region as previously described. Further, the intervals 851 and 852 between the first portion 61 and the third portion 65 and between the second portion 63 and the third portion 65, respectively, may be as described with respect to the interval 251 shown in fig. 2B. Due to the spacings 851 and 852, the absorbent article 10 may have a preferential curvature in two specific regions over the entire width of the absorbent article 10. This may promote conformability while still maintaining the desired structural rigidity, making the absorbent article less conformable. Notably, the outboard distances 152, 154 disclosed herein are not required to be symmetrically distributed about the longitudinal centerline.

The conformable first and second absorbent cores may be aligned such that the wider portion of the first absorbent core may coincide with the wider portion of the second absorbent core. However, this is not essential. Forms are envisaged in which the widest part of the first and/or second portion of the first absorbent core is not coincident with the widest part of the second absorbent core. It is worth noting that the width of the absorbent article together with its relative stiffness in the intermediate region should be configured according to the present description. This may allow the disposable absorbent article to compress in a preconfigured manner, thereby reducing the likelihood of leakage during use.

Although the preceding discussion of the first portion 61, the second portion 63, and/or the third portion 65 is in the context of the first absorbent core 60, these portions may similarly be used to construct the second absorbent core 70. Further, multiple sections may be utilized in both the first absorbent core 60 and the second absorbent core 70.

Additional configurations of the absorbent system 205 are shown in fig. 9A-11. With respect to fig. 9A-9B, in some forms, the absorbent system 205 can include a first absorbent core 960 and a second absorbent core 970. As shown, the first absorbent core 960 and the second absorbent core 970 may be formed via an absorbent core web 500. The absorbent core web 500 may be cut along line 963 to form a first absorbent core web 860 and a second absorbent core web 870. Cutting the absorbent core web 500 as shown can reduce the yield of waste material generated by processing the web. For example, the finished edges 510 and 520 of the web may be used as edges in the first absorbent core 960 and the second absorbent core 970. Further, the contoured edges 962 and 964 of the first absorbent core 960 and the second absorbent core 970 may be created via slit lines 963. As shown, the first absorbent core 960 and the second absorbent core 970 may have an overlap distance 150 as described herein.

The areas of the first absorbent core 960 and the second absorbent core 970 outside the overlap distance 150 constitute the outboard distances 152 and 154. For versions configured according to fig. 9A-9B, outboard distances 152 and 154 may be configured as described herein.

Another configuration of an absorbent system 205 that may be used with the absorbent articles of the present disclosure is shown in fig. 10. As shown, the absorbent system 205 can comprise a first absorbent core 1060 and a second absorbent core 1070. In such forms, the second absorbent core 70 may not be present in the first end region 40. And similarly, the first absorbent core 60 may not be present in the second end region 48. Forms are contemplated in which the area of the first absorbent core 60 compared to the area of the second absorbent core 70 in the first region 40 may be a ratio of about 5:1, 4:1, 3:1, 2:1, or about 1.5:1 (specifically reciting all values within these ranges and any ranges resulting therefrom). As previously mentioned, while the absence or at least reduced presence of the second absorbent core 70 in the first end region 40 may allow for much greater flexibility in the first end region 40, such conformability may not adversely affect the performance of the article due to body contours positioned anteriorly from the vaginal opening/urethra.

Forms are contemplated in which the area of the second absorbent core 70 in the second end region 48 may be a ratio of about 5:1, 4:1, 3:1, 2:1, or about 1.5:1 (specifically reciting all values within these ranges and any ranges resulting therefrom) as compared to the area of the first absorbent core 60. Similar to the configuration in the first end region 40, the absence or at least reduced presence of the first absorbent core 60 in the second end region 48 may allow for much greater flexibility in the second end region 48. However, due to the contours of the body positioned anteriorly from the vaginal orifice/urethra, this conformity may not adversely affect the performance of the article.

The intermediate region 44 of the absorbent system 205 can be configured as previously described. That is, in the intermediate region 44, the overlap distance between the first absorbent core 1060 and the second absorbent core 1070 may be configured as described herein with respect to the overlap distance 150 (shown in fig. 1E-1G) in the same region. Similarly, the length of the intermediate region 44 of the absorbent system 205 of fig. 10 can be configured as described herein.

One can remember to prepare the absorbent system 205 of fig. 10 to have minimal or zero waste. For example, as shown, the first absorbent core 1060 may include a first portion 1061 and a second portion 1063. The first portion 1061 and the second portion 1063 may be discrete and include a finished edge that coincides with the longitudinal centerline 80 of the absorbent system 205. In some forms, the trimmed edges of the first and second portions 1061, 1063 may abut one another such that there is minimal separation between the first and second portions 1061, 1063. However, a form is envisaged in which a space (configured similarly to the space 251 shown in fig. 2B) is provided between the first part 1061 and the second part 1063.

Referring now to fig. 11, an absorbent core web 1500 may be purchased from a supplier or may be manufactured by an absorbent article manufacturer. Similar to the method described with respect to fig. 6, the absorbent core web 1500 can be provided to a slitter. Guillotines are well known in the art. As shown, the absorbent core web 1500 may be cut along slit lines 1162 and 1164, which may be offset from the longitudinal centerline 1190 of the absorbent core web 1500.

Referring now to fig. 2-5 and 11, after slitting, three separate webs may be formed, namely a first absorbent core first portion web 1161, a first absorbent core second portion web 1163, and a second absorbent core web 1170. Cutting the absorbent core web 1500 can reduce the yield of waste material generated by processing the web. For example, the trimmed edges of the webs 1110 and 1120 may be used as the first trimmed edge 110 and the second trimmed edge 120 in the first portion 61 and the second portion 63, respectively, of the first absorbent core 60. Further, the edges of the first portion web 561 formed by the slit lines 562 may serve as the side edges 62 in the first portion 61 of the first absorbent core 60 and as the side edges 72 for the second absorbent core 70. Similarly, the edges formed by the slit lines 1164 may be used as the side edges 64 by the second portion 63 of the first absorbent core 60 and as the side edges 74 for the second absorbent core 70.

In some forms, the first absorbent core first portion web 1161 and the first absorbent core second portion web 1163 may then be provided to a cutting device 520A to cut discrete first portions and discrete second portions from these absorbent core webs, respectively. Similarly, the second absorbent core web 1170 can be provided to a cutting device 520B to cut discrete second absorbent core layers from the second absorbent core web 1170. Exemplary cutting devices are known in the art. Also, a cutting device for producing a male/female end edge is disclosed in U.S. patent application publication No. 2018/0154533.

In some forms, the cutting of the first absorbent core first portion web 561 and the first absorbent core second portion web 563 may be facilitated via the introduction of the first carrier web upstream of the cutting device 520A. In such forms, the first absorbent core first portion web 1161 and the first absorbent core second portion web 1163 may be combined with a first carrier web. The first absorbent core first portion web 1161 and the first absorbent core second portion web 1163 may be positioned on the first carrier web in their proper orientations, e.g., providing a space 251 between the first portion and the second portion as described herein. The first absorbent core portion and the carrier web can then be simultaneously provided to a cutting device. A plurality of discrete first absorbent cores may be provided from the cutting device.

A plurality of discrete first absorbent core first portions are provided from the cutting device 520A to a cut and slide or cut and place operation 530A. Similarly, the first absorbent core second portion can be provided to the same cutting and sliding or cutting and placing operation 530A as the first absorbent core first portion layer. Or in some forms the first absorbent core second portion web may be provided to a separate cut and slip or cut and place operation. As described above, where the first absorbent core first portion web 1161 and the first absorbent core second portion web 1163 are provided to a first carrier web, then a plurality of discrete first absorbent cores may be provided to a single cut and slide or cut and place operation.

It is noted that in the case where the first absorbent core layer 60 and the second absorbent core layer 70 are positioned in an offset manner and adhesively attached, the manner in which the adhesive is applied should be noted. Referring now to fig. 4 and 5, the adhesive applied to the lower surface 60B should be strategically positioned to reduce the likelihood of equipment contamination. For example, as shown, the adhesive applied in the front end portion 205F may contaminate the device because the second absorbent core layer 70 does not cover the adhesive in this region. An adhesive is required in the central portion 205C. In addition, an adhesive should be provided in the rear end portion 205R. In such forms, an adhesive is applied to the carrier web to ensure that the second absorbent core layer 70 is completely released from the cut and slip or cut and place operation 540B. In other forms in which the end edges 76 form the front end portion 205F, adhesive should be applied to the carrier web in the front end portion 205F and the central portion 205C to ensure that the end edges 76 are released from the cut and slide or cut and place operation 540B. Cutting and sliding and cutting and placement devices are well known in the art.

The absorbent core web 1500 may be processed as described with respect to fig. 2-6. Further, the absorbent core web 1500 can be processed such that the web has the configurations described with respect to the absorbent cores and/or absorbent systems described herein.

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 along the periphery of the incontinence pad 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 parts of the 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. Some suitable examples are described in U.S. Pat. nos. 4,950,264, 4,988,344, 4,988,345, 3,978,185, 7,785,690, 7,838,099, 5,792,404, and 5,665,452.

In some forms, the topsheet can include tufts, as described in U.S. patent nos. 8,728,049, 7,553,532, 7,172,801, 8,440,286, 7,648,752, and 7,410,683. The primary topsheet may have a pattern of discrete hair-like fibrils as described in U.S. patent 7,655,176 or 7,402,723. Additional examples of suitable topsheets include those described in U.S. patent nos. 8,614,365, 8,704,036, 6,025,535 and U.S. patent application publication No. 13743M.

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

The primary topsheet can have one or more layers as described in U.S. patent application publication nos. 2016/0167334 a1, 2016/0166443 a1, 2017/0258651 a 1. The topsheet may be apertured as disclosed in U.S. patent 5,628,097 to Benson et al, 5/13 in 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 can 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 may 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 formed 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 publication 2018/0098893. Where the carrier web comprises a secondary topsheet, various forms are contemplated.

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 an array 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.

Some suitable examples of backsheets are described in U.S. Pat. Nos. 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 No. 3,156,242, WO 97/24097, and U.S. patents 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 have any suitable shape. As previously mentioned, the absorbent system 205 is generally 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 and tapering to a narrower middle and end region in the other end region of the pad. The absorbent system 205 may have a stiffness that varies in the MD and CD.

As previously mentioned, 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 No. 5,599,335, EP 1,447,066, WO 95/11652, U.S. patent publication No. 2008/0312622a1, and WO 2012/052172 to Goldman et al. 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 as long as they do not counteract or conflict with the action 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 described in detail above, but it is important to note that these layers or laminates may have the same or different cross-directional widths as one another. As previously noted, for example, the first absorbent core layer or laminate may have a smaller lateral width than the second absorbent core layer or laminate or a larger lateral width than the second absorbent core layer or laminate. In some cases, the first absorbent core layer or laminate and the second absorbent core layer or laminate may have the same longitudinal length, while in other cases, the first absorbent core and the second absorbent core 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. The 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 cores 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 68. More specifically, the end edge 66 of the first absorbent core layer or laminate may conform in shape to its end edge 68. The same conformability may be applicable to the second absorbent core layer or laminate. This conformability results from the nested cuts of the first and second absorbent core layers or laminates providing mating 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 nesting or nested cut feature of the absorbent core allows for reduced scrap waste during manufacture. It has also been found that it is possible to configure the first and second absorbent core layers or laminates in such a way that: that is, when the first and second layers are overlapped and joined to form an absorbent system having a central portion 205C that includes an overlap region, their respective convex edges are allowed to oppose each other.

Referring to fig. 4 and 7, as previously described, the front end portion of the absorbent system 205F may be formed by the end edge 66 of the first absorbent core or the end edge 78 of the second absorbent core. The rear end portion of the absorbent system 205R is similarly formed by the end edge 66 or the end edge 78 of the other of the first or second absorbent cores. This configuration results in an absorbent system having mating (i.e., male connection) 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, while the back end portion of the absorbent system is formed by the end edge 68 or 78 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 leading end portion of the same core. In other forms, the front end portion of the absorbent system may be formed by the end edge 68 of the first absorbent core or the end edge 78 of the second absorbent core. The rear end portion of the absorbent system may similarly be formed by the end edge 68 of the remaining first absorbent core or the end edge 78 of the second absorbent core. This configuration results in an absorbent system having mating (i.e., female connection) 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 end edges of each 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 extending 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 regions may also be formed by embossing of 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. Airlaid core materials are available from manufacturers of such materials, or can be prepared in-line via equipment known in the art. In the case of airlaid cores, the need for separate superabsorbent and distribution layers may be reduced. In such forms, the absorbent core web 500 (shown in fig. 5) may comprise an air-laid 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. 7, the first and second superabsorbent layers 61, 71 of the first and second absorbent core laminates 760, 770 include superabsorbent polymers or Absorbent Gelling Materials (AGM). In some forms, the superabsorbent layers 61 and/or 71 may include a carrier web and a component. 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 (for substantially all particles) of from 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, there may be no measurable airfelt 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.

Carrier web/optional layer

Recall that the carrier web can comprise a primary topsheet and/or a secondary topsheet. Also, as with the optional layers that may be included in the chassis, the absorbent system may also include similar optional layers. The following description and attributes of the optional layers also apply to the carrier web. For convenience, the term "web" shall encompass the optional layer as well as the carrier web. The optional layer and/or carrier web can be a web selected from the group consisting of fibrous structures, air-laid webs, wet-laid webs, high loft nonwovens, needle punched webs, hydroentangled webs, fiber tows, woven webs, knitted webs, flocked webs, spunbond webs, layered spunbond/meltblown webs, carded webs, coform webs of cellulosic fibers and meltblown fibers, coform webs of staple fibers and meltblown fibers, and layered webs that are layered combinations thereof.

These optional layers and/or carrier webs may include materials such as creped cellulose wadding, fluffed cellulose fibers, airfelt, and textile fibers. The material of the web may also be fibers such as, for example, synthetic fibers, thermoplastic particles or fibers, tricomponent fibers, and bicomponent fibers such as, for example, sheath/core fibers having the following polymer combinations: polyethylene/polypropylene, polyethylvinyl acetate/polypropylene, polyethylene/polyester, polypropylene/polyester, copolyester/polyester, and the like. An optional layer can be any combination of the above-listed materials and/or a plurality of the above-listed materials, alone or in combination.

The materials of the fibrous web may be hydrophobic or hydrophilic depending on their location within the chassis.

The material of the web may include constituent fibers comprising polymers such as polyethylene, polypropylene, polyester, and blends thereof. The fibers may be spunbond fibers. The fibers may be meltblown fibers. The fibers may comprise cellulose, rayon, cotton, or other natural materials or blends of polymers and natural materials. The fibers may also include superabsorbent materials such as polyacrylates or any combination of suitable materials. The fibers may be monocomponent, bicomponent and/or biconstituent, non-round (e.g., capillary channel fibers), and may have a major cross-sectional dimension (e.g., diameter of round fibers) in the range of 0.1 to 500 microns. The constituent fibers of the nonwoven precursor web can also be a mixture of different fiber types that differ in characteristics such as chemistry (e.g., polyethylene and polypropylene), composition (mono-and bi-), denier (micro-and >20 denier), shape (i.e., capillary and circular), and the like. The constituent fibers may range from about 0.1 denier to about 100 denier.

The web may comprise thermoplastic particles or fibers. The material, particularly the thermoplastic fibers, can be made from a variety of thermoplastic polymers including polyolefins such as polyethylene (e.g., PULPEX)^TM) Polypropylene, polyester, copolyester, and copolymers of any of the foregoing.

Depending on the desired characteristics, suitable thermoplastic materials include hydrophobic fibers made hydrophilic, such as surfactant-treated or silica-treated thermoplastic fibers derived from, for example, polyolefins such as polyethylene or polypropylene, polyacrylates, polyamides, polystyrenes, and the like. Surfactants which can be used on the surface of the hydrophobic thermoplastic fibersSuch as a nonionic or anionic surfactant, to become hydrophilic, for example by spraying the fiber with the surfactant, by dipping the fiber into the surfactant, or by including the surfactant as part of the polymer melt in the production of thermoplastic fibers. Upon melting and resolidification, the surfactant will tend to remain at the surface of the thermoplastic fibers. Suitable surfactants include nonionic surfactants such as Brij 76 manufactured by ICI America, Inc. (Wilmington, Del.) and Pegosperse under the trademark^TMVarious surfactants are sold by Glyco Chemical, Inc. In addition to nonionic surfactants, anionic surfactants may also be used. These surfactants may be, for example, from about 0.2 to about 1g/cm²The amount of thermoplastic fiber is applied to the thermoplastic fiber.

Suitable thermoplastic fibers can be made from a single polymer (monocomponent fibers) or can be made from more than one polymer (e.g., bicomponent fibers). The polymer comprising the sheath often melts at a different (usually lower) temperature than the polymer comprising the core. Thus, these bicomponent fibers provide thermal bonding due to the melting of the sheath polymer while maintaining the desired strength characteristics of the core polymer.

Suitable bicomponent fibers for the webs of the present disclosure may include sheath/core fibers having the following polymer combinations: polyethylene/polypropylene, polyethylvinyl acetate/polypropylene, polyethylene/polyester, polypropylene/polyester, copolyester/polyester, and the like. Particularly suitable bicomponent thermoplastic fibers for use herein are those having a polypropylene or polyester core and a copolyester, polyethylvinyl acetate or polyethylene sheath having a lower melting temperature (e.g., DANAKLON)^TM、CELBOND^TMOr CHISSO^TMBicomponent fibers). These bicomponent fibers may be concentric or eccentric. As used herein, the terms "concentric" and "eccentric" refer to whether the sheath has a uniform or non-uniform thickness across the cross-sectional area of the bicomponent fiber. Eccentric bicomponent fibers are desirable when providing greater compressive strength at lower fiber thickness. Suitable bicomponent fibers for use herein can be uncrimped (i.e., not crimped) orCurled (i.e., bent). Bicomponent fibers can be crimped by typical textile methods such as the stuffer box method or the gear crimping method to obtain a predominantly two-dimensional or "flat" crimp.

The length of the bicomponent fibers may vary depending on the particular characteristics desired for the fibers and the web forming process. Typically, in an airlaid web, the thermoplastic fibers are from about 2mm to about 12mm long, such as from about 2.5mm to about 7.5mm long, or from about 3.0mm to about 6.0mm long. The nonwoven fibers may be between 5mm and 75mm long, such as 10mm long, 15mm long, 20mm long, 25mm long, 30mm long, 35mm long, 40mm long, 45mm long, 50mm long, 55mm long, 60mm long, 65mm long, or 70mm long. The properties of these thermoplastic fibers can also be adjusted by varying the diameter (thickness) of the fibers. The diameter of these thermoplastic fibers is generally defined in terms of denier (grams/9000 meters) or dtex (grams/10000 meters). Suitable bicomponent thermoplastic fibers for use in the airlaid machine can have a dtex in the range of from about 1.0 to about 20, such as from about 1.4 to about 10 dtex, or from about 1.7 to about 7 dtex.

The compressive modulus of these thermoplastic materials, particularly the compressive modulus of the thermoplastic fibers, may also be important. The compressive modulus of thermoplastic fibers is affected not only by their length and diameter, but also by the composition and characteristics of the polymer or polymers from which they are made, the shape and configuration of the fibers (e.g., concentric or eccentric, crimped or uncrimped), and the like. The difference in compression modulus of these thermoplastic fibers can be used to modify the properties, particularly the density characteristics, of the corresponding thermally bonded fibrous matrix.

The web may also include synthetic fibers that are not normally used as binder fibers but which modify the mechanical properties of the web. Synthetic fibers include cellulose acetate, polyvinyl fluoride, polyvinylidene 1, 1-dichloride, acrylics (such as orlon), polyvinyl acetate, insoluble polyvinyl alcohol, polyethylene, polypropylene, polyamides (such as nylon), polyesters, bicomponent fibers, tricomponent fibers, mixtures thereof, and the like. These may include, for example, polyester fibers such as polyethylene terephthalate (e.g., DACRON)^TMAnd KODEL^TM) High melting crimped polyester fibers (e.g., KODEL made by Eastman Chemical Co., Ltd.)^TM431) Hydrophilic nylon (HYDROFLIL)^TM) And so on. Suitable fibers may also hydrophilize hydrophobic fibers, such as surfactant-treated or silica-treated thermoplastic fibers derived from, for example, polyolefins such as polyethylene or polypropylene, polyacrylics, polyamides, polystyrenes, polyurethanes, and the like. In the case of non-binding thermoplastic fibers, their length may vary depending on the particular properties desired for the fibers. Typically, they are about 0.3cm to 7.5cm in length, such as about 0.9cm to about 1.5 cm. Suitable non-binding thermoplastic fibers can have a dtex in the range of from about 1.5 to about 35, such as from about 14 to about 20 dtex.

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 configured similar to the carrier web 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. A form of a laminate structure is contemplated in which the absorbent core web 500 (shown in fig. 5) includes a superabsorbent layer and a distribution layer.

Barrier hoop

Referring back to fig. 3, 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. No. 4,695,278, U.S. Pat. No. 4,704,115, U.S. Pat. No. 4,795,454, U.S. Pat. No. 4,909,803, U.S. patent application publication No. 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 discussed 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 still 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 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, such as with 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, a compromise may occur when the barrier cuffs (and their respective elastic members) are disposed too far outboard of the absorbent system 205 and too far inboard 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 sufficient access to the absorbent system 205 during use while also taking into account the forces that will be applied to the pad. If too narrow, a portion of the access to the absorbent system 205 may be impeded despite the presence of the barrier cuffs 230A and 230B, which may result in leakage. 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.

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 viewed from a direction orthogonal to the plane of the longitudinal and transverse axes) to an accuracy of 0.1mm in square millimeters²。

Thickness of

The thickness or 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 for a specified amount of 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 was measured with a manually operated micrometer equipped with a pressure foot capable of applying a steady pressure of 0.50kPa ± 0.01kPa to 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 543ID-C Digimatic, available from VWR International, or equivalent. The pressure foot is a flat circular movable face of smaller diameter than the test specimen and capable of applying the required pressure. A suitable pressure foot has a diameter of 56mm, but smaller or larger pressure feet may be used depending on the size of the sample being measured. 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.

If necessary, the test sample is obtained by taking it out of the absorbent article. When the test sample is cut from the absorbent article, care is taken not to cause any contamination or deformation to the test sample layer during this process. The test samples were taken from areas without creases or wrinkles and had to be larger than the pressure foot.

To measure the thickness, the micrometer is first zeroed relative to 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 specimen 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 reported as "thickness" to the nearest 0.01 mm.

Middle area test method

The middle zone test method is used to determine a middle zone length index value and a lateral width of the forming core at a plurality of feature points.

A two-dimensional shape defined by the projection of a planar core perpendicular to its longitudinal and transverse axes is captured and is referred to hereinafter as the core projection. The core projection maintains the same longitudinal and transverse axes of the core itself. The centroid of the core projection is calculated and the position of the centroid along the longitudinal axis of the core projection is defined as the core centroid point. A line extending through the core centroid point and parallel to the transverse axis serves to divide the core projection into two sub-shapes, a first core projection and a second core projection. Centroids of the first and second core projections are calculated and defined as first and second centroids, respectively. The position of the first centroid along the longitudinal axis of the core projection is defined as the first core centroid point. The position of the second centroid along the longitudinal axis of the core projection is defined as the second core centroid point.

Lines extending parallel to the transverse axis of the core projection through the first and second centroid points delineate the front and rear boundaries of the intermediate zone. The length of the intermediate zone along the longitudinal axis is calculated and reported to the nearest 0.1 mm.

The middle zone length index value is calculated by dividing the length of the middle zone by the total length of the core projection along the longitudinal axis and is a dimensionless ratio reported to be accurate to 0.01.

The lateral widths of the core projections were measured at the anterior and posterior centroid points and reported to the nearest 0.1mm each. The lateral width of the core projection was measured at the narrowest point within the middle zone and reported to be accurate to 0.1 mm.

All measurements were performed on five substantially similar absorbent cores and reported as the arithmetic mean of the five values.

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.