JP2017526447A - Absorbent article having ΔE * - Google Patents

Abstract

The absorbent article includes a liquid permeable three-dimensional material, a liquid impermeable backsheet, and an absorbent core disposed at least partially between the liquid impermeable backsheet and the three dimensional material. . The absorbent core includes an absorbent material having one or more channels defined therein. The absorbent article may include other layers at least partially disposed between the absorbent core and the liquid permeable three-dimensional material, which may also include one or more channels. Any layer of the absorbent article can include an indicator and / or color. Absorbent articles may have a ΔE * greater than 1 according to the ΔE * test herein.

Description

The present disclosure, according to Delta] E ^* test shown herein, relates to an absorbent article having a specific Delta] E ^*.

  Absorbent articles are used to absorb and contain body discharges (eg, urine, menstruation, stool). Absorbent articles are often configured, for example, as diapers, pants, adult incontinence articles, sanitary napkins. Some market consumers want a three-dimensional material (such as a topsheet) on the surface facing the wearer of the absorbent article. These three-dimensional materials create depth in the absorbent article, thereby giving the consumer the impression of better absorbency and reduced skin exposure to body discharges. Three-dimensional materials also provide improved softness or an impression of improved softness compared to flat materials. However, the attributes consumers want are not only better absorbency, reduced skin exposure to body excretion, and a soft impression. Also, consumers not only have the absorbent article properly contain body discharge, reduce skin exposure to body discharge and have improved softness, but the absorbent article also absorbs body discharge. We want the impression that it is evenly distributed over the length of the active article and at least prevents the crotch portion from sagging. In addition, consumers have the impression that they are visually attractive and that the absorbent article contains body discharge, reduces skin exposure to body discharge, and provides an impression of depth and improved softness. I want an absorbent article to strengthen. What is needed is an impression of depth and improved softness, which reduces skin exposure to body exudates, while providing an impression of uniform fluid distribution over the length of the absorbent article It is an absorbent article. Further, what is needed is an absorbent article with a display and / or color that provides consumers with a desirable absorbent article that is aesthetically pleasing and provides the desired impression as described above.

  The absorbent article of the present disclosure not only provides an impression of depth, improved softness, and reduced exposure to body excretion, but also provides an impression of uniform fluid distribution over the length of the absorbent article. By providing, it solves the problems associated with absorbent articles in the related fields. The absorbent article of the present disclosure provides all of these advantages by providing a three-dimensional material combined with channels in various layers between the wearer and the garment facing surface of the absorbent article. provide. For example, the channel may be present in the absorbent core and / or in one or more layers of material disposed between the absorbent core and the topsheet. In some examples, the three-dimensional material can create an impression of the channel using one or more designs or one or more elongated designs that are visible from the wearer-facing surface of the absorbent article. . The one or more designs or elongate designs can be arranged to at least partially overlap, fully overlap, or have no overlap (over the entire Z direction) with other channels of the absorbent article. One or more designs or elongated designs can be formed in the 3D material through the use of non-3D regions (different 3D regions compared to the rest of the 3D region), or Can be formed in a flat topsheet or capture material using, for example, embossing, printing, and / or graphics.

The impression of depth, improved softness, absorbency, and reduced exposure to body excretion can also be absorbed by providing displays and / or colors on various layers of the absorbent article or part thereof. It can be strengthened in the property article. Within the various layers of the present disclosure, the display and / or color can be used in combination with a three-dimensional material and / or channel to achieve all of the attributes of the absorbent article desired by the consumer. This display and / or color can be described in terms of ΔE ^* , as shown in more detail by the ΔE ^* test herein.

  In addition to providing the advantages identified above, consumers want an absorbent article that is packaged in a convenient sized package while having the appropriate amount of absorbent article. This package should be a compression pack, which allows convenient storage of the package of absorbent articles. In addition, compression packaging of absorbent articles has the advantage of distribution costs, and this cost savings ultimately leads to consumer benefits.

  In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable nonwoven material that includes a first surface and a second surface. The nonwoven material includes a plurality of fibers. The nonwoven material includes a plurality of separations including a generally flat first region, a protrusion extending outwardly from the first surface of the nonwoven material, and a deformation forming an opening in the second surface of the nonwoven material. And the integrated second region. The protrusion part is formed from the fiber. A base portion proximate to the first surface of the nonwoven material, an opposing distal end extending outwardly from the base portion in the Z direction, and a base portion and a distal end of the protrusion portion; And a cap including at least a portion of the sidewall and distal end of the protrusion. The sidewall has an internal surface. A plurality of fibers extend from the base of the protrusion to the distal end of the protrusion and contribute to forming the side of the protrusion and a portion of the cap. The fiber at least substantially surrounds the sides of the protrusion. The absorbent article includes a liquid impermeable material and an absorbent core disposed at least partially between the nonwoven material and the liquid impermeable material. The absorbent core includes an absorbent material having one or more channels defined therein. The absorbent article includes a material disposed at least partially between the nonwoven material and the absorbent core. One or more channels are defined in the material.

  In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable nonwoven material that includes a first surface and a second surface. The nonwoven material includes a plurality of fibers. The nonwoven material includes a plurality of separations including a generally flat first region, a protrusion extending outwardly from the first surface of the nonwoven material, and a deformation forming an opening in the second surface of the nonwoven material. And the integrated second region. The protrusion part is formed from the fiber. A base portion proximate to the first surface of the nonwoven material, an opposing distal end extending outwardly from the base portion in the Z direction, and a base portion and a distal end of the protrusion portion; And a cap including at least a portion of the sidewall and distal end of the protrusion. The sidewall has an internal surface. A plurality of fibers extend from the base of the protrusion to the distal end of the protrusion and contribute to forming the side of the protrusion and a portion of the cap. The fiber at least substantially surrounds the sides of the protrusion. The absorbent article includes a liquid impermeable material and an absorbent core disposed at least partially between the nonwoven material and the liquid impermeable material. The absorbent core includes an absorbent material. The first channel is defined in the absorbent material. The absorbent article includes a material disposed at least partially between the nonwoven material and the absorbent core. A second channel is defined in the material. The absorbent article includes a display that is visible from the surface facing the wearer on the nonwoven material or on another layer between the nonwoven material and the absorbent core.

  In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable nonwoven material that includes a first surface and a second surface. The nonwoven material includes a plurality of fibers. The nonwoven material includes a plurality of separations including a generally flat first region, a protrusion extending outwardly from the first surface of the nonwoven material, and a deformation forming an opening in the second surface of the nonwoven material. And the integrated second region. The protrusion part is formed from the fiber. A base portion proximate to the first surface of the nonwoven material, an opposing distal end extending outwardly from the base portion in the Z direction, and a base portion and a distal end of the protrusion portion; And a cap including at least a portion of the sidewall and distal end of the protrusion. The sidewall has an internal surface. A plurality of fibers extend from the base of the protrusion to the distal end of the protrusion and contribute to forming the side of the protrusion and a portion of the cap. The fiber at least substantially surrounds the sides of the protrusion. The nonwoven material includes an elongated viewable design. The absorbent article includes a liquid impermeable material and an absorbent core disposed between the nonwoven material and the liquid impermeable material. The absorbent core includes an absorbent material. The first channel is defined in the absorbent material. The absorbent article includes a material disposed at least partially between the nonwoven material and the absorbent core. A second channel is defined in the material. The elongated viewable design, the first channel, and the second channel all overlap at least partially in the Z direction.

  In one form, the present disclosure is directed, in part, to a package that includes a plurality of absorbent articles. At least a majority of the absorbent article includes a liquid permeable nonwoven material that includes a first surface and a second surface. The nonwoven material includes a plurality of fibers. The nonwoven material includes a plurality of separations including a generally flat first region, a protrusion extending outwardly from the first surface of the nonwoven material, and a deformation forming an opening in the second surface of the nonwoven material. And the integrated second region. The protrusion part is formed from the fiber. A base portion proximate to the first surface of the nonwoven material, an opposing distal end extending outwardly from the base portion in the Z direction, and a base portion and a distal end of the protrusion portion; And a cap including at least a portion of the sidewall and distal end of the protrusion. The sidewall has an internal surface. A plurality of fibers extend from the base of the protrusion to the distal end of the protrusion and contribute to forming the side of the protrusion and a portion of the cap. The fiber at least substantially surrounds the sides of the protrusion. The absorbent article includes a liquid impermeable material and an absorbent core disposed between the nonwoven material and the liquid impermeable material. The absorbent core includes an absorbent material. The first channel is defined in the absorbent material. The absorbent article includes a material disposed at least partially between the nonwoven material and the absorbent core. A second channel is defined in the material. The first channel at least partially overlaps the second channel in the Z direction. The package has an in-bag stack height in the range of about 70 mm to about 100 mm according to the in-bag stack height test herein.

  In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable topsheet and a capture material. The liquid permeable topsheet or capture material includes a first surface, a second surface, a generally flat first region, a protrusion extending outwardly from the second surface of the three-dimensional material, and the three-dimensional material. A three-dimensional material is formed that includes a plurality of separate integral second regions including a deformation that forms an opening in the first surface. At least a portion of each of the protrusions is between a base proximate the first surface, an opposing distal end extending outwardly from the base in the Z direction, and between the base and distal ends of the protrusion A side wall and a cap including at least a portion of the side wall and distal end of the protrusion. The sidewall has an internal surface. The inner surface of the sidewall defines a base opening at the base of the protrusion. The cap has a portion with a maximum inner width. The base opening has a width measured in the same direction as the maximum inner width. The maximum inner width of the cap of the protrusion is larger than the width of the base opening. The absorbent article includes a liquid impermeable backsheet and an absorbent core disposed at least partially between the three-dimensional material and the liquid impermeable backsheet. The absorbent core includes an absorbent material that is at least partially surrounded by a core bag. The absorbent article has one or more indicators on either the topsheet, the capture material, the core bag, or an additional layer disposed at least partially between the topsheet and the core bag. including. The display has a different color than the topsheet, capture material, core bag, or additional layer on which the display is disposed. The display unit is visible when viewing the surface facing the wearer of the absorbent article.

  In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable topsheet and a capture material. The liquid permeable topsheet or capture material includes a first surface, a second surface, a generally flat first region, a bulbous protrusion extending outwardly from the second surface of the three-dimensional material, and a three-dimensional A three-dimensional material is formed that includes a plurality of separate integral second regions including a deformation that forms an opening in the first surface of the material. The absorbent article includes a liquid impermeable backsheet and an absorbent core disposed at least partially between the three-dimensional material and the liquid impermeable backsheet. The absorbent core includes an absorbent material that is at least partially surrounded by a nonwoven core bag. The absorbent article has one or more indicators on either the topsheet, the capture material, the core bag, or an additional layer disposed at least partially between the topsheet and the core bag. including. The display has a different color than the topsheet, capture material, core bag, or additional layer on which the display is disposed. The display unit is visible when viewing the surface facing the wearer of the absorbent article.

  In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable topsheet and a capture material. The liquid permeable topsheet or capture material includes a first surface, a second surface, a generally flat first region, a protrusion extending outwardly from the second surface of the three-dimensional material, and the three-dimensional material. A three-dimensional material is formed that includes a plurality of separate integral second regions including a deformation that forms an opening in the first surface. At least a portion of each of the protrusions is between a base proximate the first surface, an opposing distal end extending outwardly from the base in the Z direction, and between the base and distal ends of the protrusion A side wall and a cap including at least a portion of the side wall and distal end of the protrusion. The sidewall has an internal surface. The inner surface of the sidewall defines a base opening at the base of the protrusion. The cap has a portion with a maximum inner width. The base opening has a width measured in the same direction as the maximum inner width. The maximum inner width of the cap of the protrusion is larger than the width of the base opening. The absorbent article includes a liquid impermeable backsheet and an absorbent core disposed at least partially between the three-dimensional material and the liquid impermeable backsheet. The absorbent core includes an absorbent material that is at least partially surrounded by a core bag. One of the topsheet portion, the capture material portion, the core bag portion, or the additional layer portion at least partially disposed between the topsheet and the core bag is the topsheet portion, the capture material. A different color from the other part of the core, part of the core bag, or part of the additional layer.

  In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable topsheet and a capture material. The liquid permeable topsheet or capture material includes a first surface, a second surface, a generally flat first region, a bulbous protrusion extending outwardly from the second surface, and an opening in the first surface. A three-dimensional material is formed that includes a plurality of separate integral second regions, including deformations that form a portion. The absorbent article includes a liquid impermeable backsheet and an absorbent core disposed at least partially between the three-dimensional material and the liquid impermeable backsheet. The absorbent core includes an absorbent material that is at least partially surrounded by a nonwoven core bag. One of the topsheet portion, the capture material portion, the core bag portion, or the additional layer portion at least partially disposed between the topsheet and the core bag is the topsheet portion, the capture material. A color different from another of a portion of the core bag, a portion of the core bag, and a portion of the additional layer.

In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable three-dimensional material that includes a first surface and a second surface. This three-dimensional material includes a plurality of fibers. The three-dimensional material includes a deformation that forms a generally flat first region, a protrusion extending outwardly from the first surface of the three-dimensional material, and an opening in the second surface of the three-dimensional material. A plurality of separate integral second regions. At least a portion of the protrusion may have a bulbous shape or include a bulbous shape. The protrusion part is formed from the fiber. A base portion proximate to the first surface of the three-dimensional material, an opposing distal end extending outwardly from the base portion in the Z direction, and a base portion and a distal end of the protrusion portion; And a cap including at least a portion of the sidewall and distal end of the protrusion. The sidewall has an internal surface. A plurality of fibers extend from the base of the protrusion to the distal end of the protrusion, and contribute to forming a side of the protrusion and a portion of the cap. The fiber at least substantially surrounds the sides of the protrusion. The absorbent article includes a liquid impermeable backsheet and an absorbent core disposed at least partially between the three-dimensional material and the liquid impermeable backsheet. The absorbent core includes an absorbent material that is at least partially surrounded by a core bag. The absorbent article by Delta] E ^* Test herein, has a more than 1 Delta] E ^*, or from about 1 to about 20 range of Delta] E ^*.

In one form, the present disclosure is directed, in part, to an absorbent article that includes a liquid permeable topsheet and a capture material. The liquid permeable topsheet or capture material forms a three-dimensional material. The three-dimensional material includes a first surface, a second surface, a generally flat first region, a protrusion extending outward from the second surface of the three-dimensional material, and a first surface of the three-dimensional material. And a plurality of separate integral second regions, including deformations that form the openings. The absorbent article includes a liquid impermeable backsheet and an absorbent core disposed at least partially between the three-dimensional material and the liquid impermeable material. The absorbent core includes an absorbent material that is at least partially surrounded by a core bag. The absorbent article by Delta] E ^* Test herein, has a more than 2 Delta] E ^*, or from about 1 to about 15 range Delta] E ^*.

The above and other features and advantages of the present disclosure, as well as the manner in which they are realized, will become more apparent from the following description of non-limiting forms of the disclosure, taken in conjunction with the accompanying drawings, and A deeper understanding of the disclosure itself will be gained.
It is a microscope picture which shows the end elevation of the prior art tuft. 1 is a schematic end view of a prior art tuft after being subjected to compression. FIG. 2 is a photomicrograph of the edge of a prior art nonwoven web showing a plurality of collapsed tufts. 1 is a schematic side view of a prior art conical structure before being exposed to compression and after being exposed to compression. FIG. 2 is a planar photomicrograph showing one surface of a nonwoven material having a three-dimensional deformation formed therein with an upward protrusion according to the present disclosure. FIG. 6 is a planar micrograph showing another surface of a nonwoven material similar to that shown in FIG. 5 with an upward opening in the nonwoven according to the present disclosure. 2 is a micro CT scan image showing a perspective view of a protrusion of a single layer nonwoven material according to the present disclosure. 4 is a micro CT scan image showing the side of a protrusion of a single layer nonwoven material according to the present disclosure. FIG. 6 is a micro CT scan image showing a perspective view of a deformation of a single layer nonwoven material according to the present disclosure with an opening upward. FIG. 6 is a perspective view of a deformation of a two-layer nonwoven material with an opening upwardly according to the present disclosure. 1 is a photomicrograph of a cross-section taken along the transverse axis of deformation showing an example of a multilayer nonwoven material with an upward opening according to the present disclosure, the multilayer nonwoven material projecting on one side of the material In the form of a three-dimensional deformation, which provides a wide opening on the other side of the material. FIG. 12 is a schematic view of the protrusion shown in FIG. 11 in accordance with the present disclosure. 2 is a planar photomicrograph from the protrusion side of the material after being subjected to compression, showing a high density fiber region around the periphery of the protrusion according to the present disclosure. 4 is a photomicrograph of a cross-section of a protrusion taken along the transverse axis of the protrusion, showing the protrusion after being subjected to compression, in accordance with the present disclosure. FIG. 3 is a cross-sectional view taken along the transverse axis of a variation of one form of a multilayer nonwoven web, shown with an upward base opening, in accordance with the present disclosure. FIG. 6 is a cross-sectional view taken along the transverse axis of another form of deformation of a multilayer nonwoven web shown with an upward base opening, in accordance with the present disclosure. FIG. 6 is a cross-sectional view taken along the transverse axis of another form of deformation of a multilayer nonwoven web shown with an upward base opening, in accordance with the present disclosure. FIG. 6 is a cross-sectional view taken along the transverse axis of another form of deformation of a multilayer nonwoven web shown with an upward base opening, in accordance with the present disclosure. FIG. 6 is a cross-sectional view taken along the transverse axis of another form of deformation of a multilayer nonwoven web shown with an upward base opening, in accordance with the present disclosure. FIG. 6 is a cross-sectional view taken along the transverse axis of another form of deformation of a multilayer nonwoven web shown with an upward base opening, in accordance with the present disclosure. 1 is a planar photomicrograph of a nonwoven web with upward protrusions showing the density of a single layer of fiber with a two layer structure according to the present disclosure. FIG. 17 is a perspective photomicrograph showing reduced fiber density in a sidewall of a protrusion in a layer similar to that shown in FIG. 16, in accordance with the present disclosure. 2 is a planar photomicrograph of a nonwoven web with upward protrusions showing reduced fiber density in the cap of the protrusions in the other layer of the two-layer structure according to the present disclosure. FIG. 19 is a perspective photomicrograph showing increased fiber density in a sidewall of a protrusion in a layer similar to that shown in FIG. 18 in accordance with the present disclosure. In accordance with the present disclosure, a multilayer nonwoven material on the surface of a forming roll that exhibits “hanging perforations” that can be formed in one of the layers when some nonwoven precursor web material is used. It is a perspective microscope photograph of one layer. 1 is a perspective view of an example of an apparatus for forming a nonwoven material described herein in accordance with the present disclosure. FIG. FIG. 22 is an enlarged perspective view of a portion of the male roll shown in FIG. 21 in accordance with the present disclosure. FIG. 22 is an enlarged perspective view showing a nip between the rolls shown in FIG. 21 according to the present disclosure. 1 is a schematic perspective view of one form of a method for producing a nonwoven material having deformation therein, where two precursor materials are used, one of the two precursor materials being a continuous web; FIG. The other is in the form of separate fragments. An absorbent article in the form of a diaper comprising an example topsheet / capture layer composite structure according to the present disclosure, wherein the length of the capture layer is shorter than the length of the topsheet and some layers are partially Has been removed. FIG. 26 is a cross-sectional view of one of the diapers of FIG. 25 taken along line 26-26, in accordance with the present disclosure. FIG. 26 is another cross-sectional view of the diaper of FIG. 25 in accordance with the present disclosure. 1 is a plan view of an example absorbent article according to the present disclosure, with the wearer facing surface facing the viewer and some layers partially removed. FIG. FIG. 29 is a cross-sectional view of an absorbent article taken along line 29-29 of FIG. 28 in accordance with the present disclosure. FIG. 29 is a cross-sectional view of an absorbent article taken along line 29-29 of FIG. 28 according to the present disclosure, wherein the absorbent article is filled with fluid. FIG. 4 is a plan view of another absorbent article according to the present disclosure, with the wearer facing surface facing the viewer and some layers partially removed. FIG. 32 is a cross-sectional view of an absorbent article taken along line 32-32 of FIG. 31 in accordance with the present disclosure. FIG. 32 is a plan view of the absorbent core of the example absorbent article of FIG. 31 according to the present disclosure, with some layers partially removed. FIG. 34 is a cross-sectional view of an absorbent core taken along line 34-34 of FIG. 33 in accordance with the present disclosure. FIG. 34 is a cross-sectional view of an absorbent core taken along line 35-35 of FIG. 33 in accordance with the present disclosure. A diaper comprising an example multilayer nonwoven web, wherein the length of the acquisition layer is shorter than the length of the topsheet, comprises channels in the absorbent core, and some layers are partially removed according to the present disclosure It is an absorbent article of an example of a form. FIG. 37 is a cross-sectional view of the example absorbent article of FIG. 36 taken along line 37-37, with the absorbent core having channels, in accordance with the present disclosure. FIG. 37 is a cross-sectional view of the example absorbent article of FIG. 36 taken along line 37-37 with the absorbent core at least partially filled with fluid in accordance with the present disclosure. 1 is a cross-sectional view of an example of an absorbent article according to the present disclosure, where both the absorbent core and the material between the absorbent core and the multilayer nonwoven web have channels. FIG. 40 is a cross-sectional view of the example absorbent article of FIG. 39 with the absorbent core at least partially filled with fluid in accordance with the present disclosure. 1 is a cross-sectional view of an example of an absorbent article according to the present disclosure, where the absorbent core and the two materials between the absorbent core and the multilayer nonwoven web all have channels. FIG. 4 is a cross-sectional view of an example absorbent article comprising an absorbent core, a generally flat topsheet, a three-dimensional acquisition layer, and two materials between the absorbent core and the three-dimensional acquisition layer according to the present disclosure. Yes, where one of the absorbent core and the material between the absorbent core and the three-dimensional acquisition layer has a channel. Sectional view of an example absorbent article comprising a three-dimensional topsheet, an absorbent core, a generally flat acquisition layer, and two materials between the absorbent core and the generally flat acquisition layer according to the present disclosure. Where the channel is within the absorbent core and within one of the materials between the absorbent core and the generally flat acquisition layer. 1 is a cross-sectional view of an example of an absorbent article according to the present disclosure, where both the absorbent core and the material between the absorbent core and the multilayer nonwoven web have channels. 1 is a plan view of an absorbent article having channels and a multilayer nonwoven web having a design according to the present disclosure. FIG. FIG. 46 is a cross-sectional view of the example absorbent article of FIG. 45 taken along line 46-46 in accordance with the present disclosure. FIG. 47 is a cross-sectional view of the absorbent article of FIG. 46 with the absorbent core at least partially filled with fluid in accordance with the present disclosure. 1 is a cross-sectional view of an example absorbent article having a channel and a multilayer nonwoven web having a design according to the present disclosure. FIG. 1 is a plan view of an example of a portion of a nonwoven facing web of an absorbent article according to the present disclosure, the nonwoven web comprising a design. FIG. 1 is a plan view of an example of a portion of a nonwoven facing web of an absorbent article according to the present disclosure, wherein the nonwoven material includes a design. FIG. 1 is a cross-sectional view of an example of an absorbent article with an absorbent core and two materials between the absorbent core and a multilayer nonwoven web according to the present disclosure; One of the materials between the webs both has channels and the channels do not overlap each other in the Z direction. 1 is a cross-sectional view of an example of an absorbent article with an absorbent core and two materials between the absorbent core and a multilayer nonwoven web according to the present disclosure; Both materials between the webs have channels and the channels do not overlap each other in the Z direction. 2 is a plan view of an example of a cellulosic three-dimensional material for use as at least part of a carrier layer and / or distribution material according to the present disclosure. FIG. FIG. 54 is a cross-sectional view of an example of a cellulosic three-dimensional layer taken along line 54-54 of FIG. 53 in accordance with the present disclosure. 2 shows some example patterns of a three-dimensional nonwoven web according to the present disclosure. FIG. 6 shows some example displays that can be placed under any of the example three-dimensional nonwoven webs having the patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 according to the present disclosure. . FIG. 56 shows an overlay of the pattern of the three-dimensional web of FIG. 55 and the display of FIG. 56 according to the present disclosure. 2 shows some example patterns of a three-dimensional nonwoven web according to the present disclosure. FIG. 6 shows some example displays that can be placed under any of the example three-dimensional nonwoven webs having the patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 according to the present disclosure. . 2 shows some example patterns of a three-dimensional nonwoven web according to the present disclosure. FIG. 6 shows some example displays that can be placed under any of the example three-dimensional nonwoven webs having the patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 according to the present disclosure. . FIG. 63 shows an overlay of the 3D web pattern of FIG. 60 and the display of FIG. 61 according to the present disclosure. FIG. 2 shows some example patterns of a three-dimensional nonwoven web according to the present disclosure. FIG. 6 shows some example displays that can be placed under any of the example three-dimensional nonwoven webs having the patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 according to the present disclosure. . 2 shows some example patterns of a three-dimensional nonwoven web according to the present disclosure. FIG. 6 shows some example displays that can be placed under any of the example three-dimensional nonwoven webs having the patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 according to the present disclosure. . FIG. 66 shows an overlay of the 3D web pattern of FIG. 65 and the display of FIG. 66 in accordance with the present disclosure. 2 shows some example patterns of a three-dimensional nonwoven web according to the present disclosure. FIG. 6 shows some example displays that can be placed under any of the example three-dimensional nonwoven webs having the patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 according to the present disclosure. . 2 shows some example patterns of a three-dimensional nonwoven web according to the present disclosure. FIG. 6 shows some example displays that can be placed under any of the example three-dimensional nonwoven webs having the patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 according to the present disclosure. . 2 shows some example patterns of a three-dimensional nonwoven web according to the present disclosure. FIG. 6 shows some example displays that can be placed under any of the example three-dimensional nonwoven webs having the patterns of FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 according to the present disclosure. . FIG. 6 is a plan view of another example absorbent article according to the present disclosure, which is a sanitary napkin, the wearer facing surface facing the viewer, and some layers being cut away; The nonwoven web of the present disclosure may be present in the absorbent article structure of this example. FIG. 2 is a side view of an absorbent article package showing the package width according to the present disclosure, with the outer surface shown as transparent for clarity.

Various non-limiting forms of the present disclosure are described below to provide a general understanding of the principles of structure, function, manufacture, and use of absorbent articles having delta E ^* as disclosed herein. To do. One or more examples of these non-limiting forms are shown in the accompanying drawings. Those skilled in the art will appreciate that the absorbent articles having Delta E ^* described herein and illustrated in the accompanying drawings are non-limiting exemplary forms, and the scope of various non-limiting forms of the present disclosure is claimed. It will be understood that it is defined only by terms. Features illustrated or described with respect to one non-limiting form may be combined with features of other non-limiting forms. Such modifications and variations are intended to be included within the scope of the present disclosure.

Definitions The term “absorbent article” as used herein refers to sanitary napkins, panty liners, tampons, interlabial devices, wound dressings, diapers (tape or pants), adult incontinence articles, wipes, etc. Including disposable items. At least some of such absorbent articles are intended for absorption of body fluids such as menstruation or blood, vaginal secretions, urine, and stool. The wipe may be used to absorb bodily fluids or may be used for other purposes such as cleaning the surface. The various absorbent articles described above typically include a liquid permeable topsheet, a liquid impermeable backsheet bonded to the topsheet, and an absorbent core between the topsheet and the backsheet. . Nonwoven materials, nonwoven webs, and / or three dimensional materials or webs described herein are at least one of other articles such as polishing pads, wet or dry mop pads (eg, SWIFFER® pads). Part.

  The term “hole” as used herein is a regular or substantially regular shape that is intentionally formed and extends completely through a web or structure (ie, a through hole). Point to the hole. The holes may be cleanly drilled through the web (“two-dimensional” holes) so that the material around the holes is coplanar with the web prior to the formation of the holes, or at least of the material around the openings A hole may be formed such that a portion is extruded from the plane of the web. In the latter case, the hole may resemble a recess with a hole in it and may be referred to herein as a “three-dimensional” hole, which is a subset of the hole.

  As used herein, the term “channel” refers to a region in a material layer having a basis weight that is substantially less than the surrounding material of the material layer (eg, less than 50%, less than 70%, less than 90%) or It is a zone. A channel may be a region in a material layer that is substantially free of material (eg, 90% free of material, 95% free of material, or 99% free of material, or fully Does not contain any material). The channel may extend through one or more material layers. The channel generally has a lower flexural modulus than the surrounding area of the material layer, so that the material layer can be bent more easily and / or more in the channel than the surrounding area of the material layer. May contain body discharge. Thus, the channel is not just a depression, compression, or embossment in the material layer that does not reduce the basis weight of the material layer in the area of the channel.

  As used herein, the term “component” of an absorbent article refers to a topsheet, acquisition layer, acquisition layer, distribution material, absorbent core or layer of absorbent core, backsheet, and barrier layers and barriers. It refers to individual components of absorbent articles such as cuffs and other barriers.

  As used herein, the term “cross-machine direction” or “CD” means a path perpendicular to the machine direction in the plane of the web.

  As used herein, the term “deformable material” is a material that can change its shape or density in response to applied stress or strain.

  As used herein, the term “separated” means different or not connected. When the term “separate” is used for a forming element on a forming member, the distal (or radially outermost) end of the forming element is different or connected in all directions, including machine and cross machine direction. (For example, the base of the forming element can be formed in the same surface of the roll).

  As used herein, the term “disposable” describes absorbent articles and other products that are not intended to be washed or otherwise restored or reused as absorbent articles or products. (Ie they are intended to be discarded after use, preferably recycled, composted or otherwise disposed of in an environmentally compatible manner).

  As used herein, the term “forming element” refers to any element on the surface of the forming member that is capable of deforming the web.

  As used herein to describe a protrusion, as “integral extension”, the term “integral” as used herein means that the fibers of the protrusion are derived from the fibers of the precursor web. Refers to being. Thus, as used herein, “monolithic” is distinguished from fibers that are introduced or added to a separate precursor web for the purpose of creating protrusions.

  As used herein, the terms “joined”, “joined”, “joined to”, “attached”, “attached”, “attached to”, “adhesion”, “ “Adhered” and “adhered to” means that an element is directly attached to another element by attaching the element directly to another element, and an element is attached to the intermediate member. And by attaching it to another element, the element is indirectly fixed to another element, and one element is integral with another element, i.e. one element is essentially And configurations that are part of other elements. These terms refer to a configuration in which an element is fixed to another element in a selected position in addition to a configuration in which the element is completely fixed to another element over one face of the element. Include. These terms include any known method by which an element can be secured, including but not limited to mechanical entanglement.

  As used herein, the term “machine direction” or “MD” means the path that a material, such as a web, travels through the manufacturing process.

  As used herein, the term “macroscopic” means that a person with 20/20 visual acuity is easy if the vertical distance between the viewer's eyes and the web is about 30 cm (12 inches). Refers to a structural feature or element that can be seen and clearly identified. Conversely, the term “microscopic” refers to such a feature that is not readily visible under such conditions and cannot be clearly identified.

  As used herein, the term “mechanically deforming” refers to a process in which a mechanical force is exerted on a material to permanently deform the material.

  As used herein, the term “permanently deformed” refers to a state of a deformable material whose shape or density has been changed permanently in response to applied stress or strain.

  As used herein, the term “SELF” or “SELF processing” refers to Procter & Gamble technology, and SELF is an abbreviation for Structural Elastic Like Film. Although the process was originally developed to deform polymer films to have beneficial structural properties, it has been found that the SELF processing process can be used to create beneficial structures in other materials. It was done. The processes, equipment, and patterns created by SELF are described in US Pat. Nos. 5,518,801, 5,691,035, 5,723,087, 5,891,544, No. 5,916,663, 6,027,483, and 7,527,615 (B2).

  As used herein, the term “tuft” refers to a particular type of feature that may be formed from fibers in a nonwoven web. The tufts may have a tunnel-like configuration, which may be open at one or both of their ends.

  The term “web” is used herein to refer to a material whose first dimension is XY, ie, along its length (or longitudinal direction) and width (or transverse direction). . It should be understood that the term “web” is not necessarily limited to a single layer or sheet of material. Thus, the web can include a laminate or combination of several sheets of the required type of material.

  As used herein, the term “Z dimension” or “Z direction” refers to a dimension that is orthogonal to the length and width of the web or article. The Z dimension usually corresponds to the thickness of the web or material. As used herein, the term “XY dimension” refers to a plane perpendicular to the thickness of the web or material. The XY dimensions typically correspond to each of the length and width of the web or material.

Non-woven Material This disclosure is directed, in part, to a bulky non-woven material having a separate three-dimensional deformation that provides a protrusion on one side of the non-woven material and opens on the other side of the non-woven material. Provide department. A method of making a nonwoven material is also disclosed. Nonwoven materials can be used in absorbent articles and other articles, as described in more detail below.

  As used herein, the term “nonwoven” or “nonwoven material” refers to a woven or knitted fabric (randomly oriented or substantially in the case of a knitted fabric), although the individual fibers or yarns are intricate. Refers to a web or material having a structure that is not intricate in a repetitive pattern as in (typically does not have randomly oriented fibers). The nonwoven web or material has a machine direction (MD) and a cross machine direction (CD), as is generally known in the art of web manufacture. “Substantially randomly oriented” means that a greater amount of fibers can be oriented in MD than in CD or vice versa due to the process conditions of the precursor web. For example, in the spunbond and meltblown processes, continuous strands of fibers are deposited on a support that moves to the MD. Even trying to truly “randomize” the fiber orientation of a spunbond or meltblown nonwoven web, usually a slightly higher percentage of fibers are oriented in the MD rather than the CD.

  The nonwoven web of the present disclosure is described first, followed by the channels in the various layers of the absorbent article of the present disclosure. Next, various color patterns and display unit patterns are described.

  Nonwoven webs and materials are often incorporated into products such as absorbent articles in high speed product manufacturing lines. In such a manufacturing process, compressive and shear forces can be applied to the nonwoven web, which can damage certain types of three-dimensional features intentionally formed in such webs. . In addition, if the nonwoven material is incorporated into a product that is manufactured or packaged under compression (eg, disposable diapers), after the material has been exposed to such compressive forces, any previous type of three-dimensional It becomes difficult to maintain the three-dimensional characteristics of features.

  For example, FIGS. 1 and 2 show a prior art nonwoven material 10 with a tuft structure. The nonwoven material includes a tuft 12 formed from looped fibers 14, which forms a tunnel-like structure having two ends 16. The tuft 12 extends outward in the Z direction from the surface of the nonwoven material. This tunnel-like structure has a width that is substantially the same from one end of the tuft to the other. Often, such tuft structures have holes or openings 18 at both ends and an opening 20 at each base. Typically, the openings 18 at both ends of the tuft are at the machine direction (MD) end of the tuft. The opening 18 at the end of the tuft can be the result of the process used to form the tuft. If the tuft 12 is formed by forming an element in the form of a tooth with a relatively small tip and a vertical leading and trailing edge that forms a sharp tip, these leading edges The portion and / or the trailing edge may puncture the nonwoven web at least at one of the ends of the tuft. As a result, the opening 18 can be formed at one end or both ends of the tuft 12.

  Such a nonwoven material 10 provides a clear tuft 12, but the opening 20 at the base of the tuft structure is relatively narrow and can be difficult to see with the naked eye. In addition, as shown in FIG. 2, the material of the tuft 12 surrounding this narrow base opening 20 may tend to form a hinge 22 or pivot point when force is applied to the tuft. When the nonwoven material 10 is compressed (eg, in the Z direction), in many cases the tuft 12 can be crushed to one side and the opening 20 can be blocked. Typically, the majority of tufts in such a tuft material collapse and block the opening 20. FIG. 2 schematically shows an example of the tuft 12 after being crushed. In FIG. 2, the tuft 12 is folded to the left. FIG. 3 is a photograph showing a nonwoven material with several upward tufts, with all tufts folded on one side. However, not all tufts 12 are crushed and folded on the same side. Often, some tufts 12 fold on one side and some tufts fold on the other side. As a result of the crushing of the tuft 12, the opening 20 at the base of the tuft closes, becomes a slit, and substantially disappears.

  Prior art nonwoven materials with certain other types of three-dimensional deformations (eg, conical structures) can also be subjected to crushing when compressed. As shown in FIG. 4, when exposed to compressive force F, the conical structure 24 does not necessarily fold like a particular tuft structure. However, the conical structure 24 is crushed by the relatively wide base opening 26 and the smaller tip 28 so that the conical structure is pushed back toward the surface of the nonwoven material, for example, into the shape shown at 24A. You may be exposed to

  The nonwoven material of at least some forms of the present disclosure described herein is intended to better retain the structure of the separated three-dimensional features of the nonwoven material after compression.

  5-14 show an example of a nonwoven material 30 with a three-dimensional deformation that includes a protrusion 32 therein. The nonwoven material 30 has a first surface 34, a second surface 36, and a thickness T (thickness shown in FIG. 12) between them. FIG. 5 shows a first surface 34 of the nonwoven material 30 with a protrusion 32 that extends outwardly from the first surface 34 of the upward nonwoven material. FIG. 6 shows a second surface 36 of a nonwoven material 30 such as that shown in FIG. 5, which has a three-dimensional deformation formed therein, with a downward protrusion and an upward base opening 44. Is provided. FIG. 7 is a micro CT scan image showing a perspective view of the protrusion 32. FIG. 8 is a micro CT scan image showing a side view of the protrusion 32 (a side surface on the longitudinal side of the protrusion). FIG. 9 is a micro CT scan image showing a modified perspective view with an upward opening 44. The nonwoven material 30 includes a plurality of fibers 38 (shown in FIGS. 7-11 and 14). As shown in FIGS. 7 and 9, the nonwoven material 30 may have a plurality of bonds 46 therein to hold the fibers 38 together. Any such bonds are typically present in the precursor material.

  The protrusion 32 may in some cases be formed from loop-like fibers (which may be continuous) 38, which are pushed outwardly to outwardly in the Z direction from the surface of the nonwoven web. Extend. The protrusion 32 typically includes a plurality of looped fibers. In some cases, the protrusions 32 may be formed from looped fibers and at least some broken fibers. In addition, for some types of nonwoven materials (eg, card material made of shorter fibers), the protrusions 32 can be formed from a loop that includes a plurality of discontinuous fibers. A plurality of discontinuous fibers in the form of a loop are shown as layer 30A in FIGS. The looped fibers may be aligned within the protrusion 32 (ie, may be oriented in substantially the same direction) or may not be aligned within the protrusion 32. Typically, when the male / female male forming element is used to form the protrusion and the female forming element substantially surrounds the male forming element, as well as the orientation in the precursor web from which the nonwoven material 30 is formed. , The fibers of the protrusions 32 may remain in a substantially random orientation (not aligned).

  The nonwoven material 30 can include a generally flat first region 40 and the three-dimensional deformation can include a plurality of separate integral second regions 42. The term “generally flat” does not imply any particular flatness, smoothness or dimensionality. Thus, the first region 40 may include other features that provide the first region 40 with topography. Such other features include, but are not limited to, small protrusions, raised mesh areas around the base opening 44, and other types of features. Therefore, the first region 40 is generally flat when considered in comparison with the second region 42.

  As used herein, the term “deformation” includes both a protrusion 32 formed on one side of the nonwoven material and a base opening 44 formed on the opposite side of the material. The base opening 44 is most often not in the form of a hole or a through hole. Rather, the base opening 44 may exhibit a concave appearance. The base opening 44 may be similar to the bag opening. The bag typically has an opening that does not completely penetrate the bag. In the case of the nonwoven fabric material 30 of this example, the base opening 44 is open toward the inside of the protrusion 32 as shown in FIG.

  FIG. 11 shows an example of a multi-layer nonwoven material 30 that has a three-dimensional deformation in the form of a protrusion 32 on one side of the material and provides a wide base opening 44 on the other side of the material. The dimensions of the “wide” base opening are described in more detail below. In this case, the base opening 44 is upward in the figure. If there are multiple nonwoven layers, the individual layers may be labeled as 30A, 30B, etc. Each of the individual layers 30A and 30B has a first and second surface, respectively, which are similarly labeled for the first and second surfaces 34 and 36 of the nonwoven material (eg, for the first layer 30A). The first and second surfaces are 34A and 36A, and the first and second surfaces of the second layer 30B are 34B and 36B).

As shown in FIGS. 11 and 12, the protrusions 32 have a base 50 adjacent to the first surface 34 of the nonwoven material and an opposing blistered distal or cap portion that extends to the distal end 54, or “ A “cap” 52, a sidewall (or “side”) 56, an interior 58, and a pair of ends 60 (this is shown in FIG. 5). The “base” 50 of the protrusion 32 includes the narrowest part of the protrusion when viewed from one end of the protrusion. The term “cap” does not imply any particular shape, but simply includes a wider portion of the protrusion 32, including and adjacent to the distal end 54 of the protrusion 32. The sidewall 56 has an inner surface 56A and an outer surface 56B. As shown in FIGS. 11 and 12, the side wall 56 may transition to the cap 52 and include a portion thereof. Thus, it is not necessary to precisely define where the side wall 56 ends and the cap 52 begins. Cap 52, between the inner surface 56A of the opposed side walls 56, having a maximum inner width _{W I.} Cap 52 also has a maximum outer width W between outer surfaces 56B of opposing side walls 56. The end 60 of the protrusion 32 is the portion of the protrusion that is furthest away along the longitudinal axis L of the protrusion.

As shown in FIGS. 11 and 12, the narrowest portion of the protrusion 32 defines a base opening 44. The base opening 44 has a width _{W O.} The base opening 44 may be located (in the Z direction) between the surface defined by the second surface 36 of material and the distal end 54 of the protrusion. As shown in FIGS. 11 and 12, the nonwoven material 30 has an opening (“second surface opening” 64) in the second surface 36 that transitions into (or transitions from) the base opening 44. This may be the same size as the base opening 44 or larger than the base opening 44. However, the base opening 44 is generally discussed more frequently herein. This is because if the nonwoven material 30 is placed in an article with a base opening 44 that is visible to the consumer, in this configuration the size of the base opening is often more visually apparent to the consumer. Because. In certain configurations, for example, in a configuration in which the base opening 44 faces outward (eg, in an absorbent article, away from the absorbent core toward the consumer), the base opening 44 is covered by another web. It will be appreciated that it may be desirable to be unbroken and / or unblocked.

As shown in FIG. 12, the protrusion 32 has a depth D measured from the second surface 36 of the nonwoven web to the inside of the protrusion at the distal end 54 of the protrusion. The protrusion 32 has a height H measured from the second surface 36 of the nonwoven web to the distal end 54 of the protrusion. In many cases, the height H of the protrusion 32 is larger than the thickness T of the first region 40. The relationship between the various parts of this deformation may be as shown in FIG. 11, when viewed from the end, the maximum inner width W _I of the cap 52 of the protrusion is the width W of the base opening 44. _Wider than _O.

  The protrusion 32 can be any suitable shape. Since the protrusion 32 has a three-dimensional shape, the description of the shape depends on the viewing angle. When viewed from the top as shown in FIG. 5 (i.e., perpendicular to the plane of the web, or a plan view), preferred shapes are circular, diamond-shaped, rounded diamond-shaped, American football-shaped, egg-shaped , Clover shape, triangle shape, teardrop shape, and oval shape. (The base opening 44 typically has a similar shape to the plan view shape of the protrusion 32.) In other cases, the protrusion 32 (and the base opening 44) may be non-circular. The protrusions 32 may have similar plan view dimensions in all directions, or the protrusions may have one dimension longer than the other. That is, the protrusion 32 may have different length and width dimensions. When the length and width of the protrusion 32 are different, the longer dimension is referred to as the length of the protrusion. Thus, the protrusion 32 can have a length to width ratio, ie, an aspect ratio. The aspect ratio can range from about 1: 1 to 10: 1.

  As shown in FIG. 5, the protrusion 32 may have a width W, which varies from one end 60 to the opposite end 60 when the protrusion is viewed in plan view. The width W may vary, and the central part of the protrusion is the widest part of the protrusion, and the width of the protrusion is reduced at the end 60 of the protrusion. In other cases, the protrusion 32 may be wider at one or both ends 60 than the central portion of the protrusion. In still other cases, the protrusion 32 can be formed to have substantially the same width from one end of the protrusion to the other end. When the width of the protrusion 32 varies along the length of the protrusion, the portion with the largest width of the protrusion is used to determine the aspect ratio of the protrusion.

  When the protrusion 32 has a length L that is longer than the width W, the length of the protrusion may be in any suitable direction relative to the nonwoven material 30. For example, the length of the protrusion 32 (ie, the longitudinal axis LA of the protrusion) may be in the machine direction, the cross machine direction, or any desired orientation between the machine direction and the cross machine direction. The protrusion 32 also has a transverse axis TA that is generally perpendicular to the longitudinal axis LA of the MD-CD surface. In the configuration shown in FIGS. 5 and 6, the longitudinal axis LA is parallel to the MD. In some forms, all spaced protrusions 32 can have generally parallel longitudinal axes LA.

  The protrusion 32 may have any suitable shape when viewed from the side. Suitable shapes include those having a distal portion or “cap” with an inflated dimension and a narrower portion of the base when viewed from at least one side. The term “cap” is similar to the bulk of a mushroom. (The cap need not resemble the bulk of any particular type of mushroom. In addition, the protrusion 32 may have a shaft portion, such as a mushroom, but need not.) In some cases, the protrusions 32 may be referred to as having a bulbous shape when viewed from the end 60, as shown in FIG. The term “bulb-like” as used herein is an increased dimension when viewed from at least one side of the protrusion 32 (particularly when viewed from one of the shorter ends 60). Is intended to refer to the configuration of the protrusion 32 having a cap 52 with a narrower portion at the base. The term “bulb shape” is not limited to protrusions having a circular or round plan view configuration joined to a columnar portion. The bulbous shape of the illustrated form (the longitudinal axis LA of the deformation 32 is oriented in the machine direction) is most when taken in a cross-section along the transverse axis TA of the deformation (ie the cross machine direction). It can be obvious. The bulbous shape may not be very obvious when looking at deformation along the length of deformation (or longitudinal axis LA), as shown in FIG.

  The protrusion 32 may include fibers 38 that at least substantially surround the sides of the protrusion. This is because there are a plurality of fibers extending from the base 50 of the protrusion 32 to the distal end 54 of the protrusion 32 (eg, in the Z direction), which form part of the protrusion side 56 and the cap 52. It means that it contributes to. The expression “substantially surround” does not require that each individual fiber substantially or completely surrounds the sides of the protrusion in the XY plane. If the fiber 38 is arranged completely surrounding the side of the protrusion, this means that the fiber is arranged 360 ° around the protrusion. For example, as shown in FIG. 1, the protruding portion 32 may not have a large opening at the end portion 60, such as the opening 18 at the front edge portion and the rear edge portion of the tuft. The protrusion 32 may also be different from the embossed structure, as shown in FIG. The embossed structure typically has a distal portion spaced vertically (ie, in the Z direction) from the base, which is the wider portion adjacent to the base, as in the case of the cap 52 of the protrusion 32 in this example. I don't have it.

  The protrusion 32 may have certain additional characteristics. As shown in FIGS. 11 and 12, the protrusion 32 can be substantially hollow. As used herein, the term “substantially hollow” refers to a structure in which the protrusion 32 is substantially free of fibers within the protrusion. However, the term “substantially hollow” does not have to be such that no fibers are contained within the protrusion. Therefore, there may be some fibers inside the protruding portion. “Substantially hollow” protrusions, such as those produced by fiber laydown, such as those produced by airlaying or carding a fiber into a forming structure with a recess therein, A distinction is made from filled three-dimensional structures.

  The side wall 56 of the protrusion 32 may have any suitable configuration. The configuration of the side wall 56 may be a straight line or a curved line when viewed from the end of the protruding portion as shown in FIG. 11, or the side wall may be formed by a combination of a linear part and a curved part. The curved portion can be concave, convex, or a combination of both. For example, the side wall 56 of the form shown in FIG. 11 includes a concave portion bent inward near the base of the protrusion and a portion convex outward near the cap of the protrusion. The area around the side wall 56 of the protrusion and the base opening 44 of the protrusion is 20 times lower than that of the non-woven part in the first region 40 that is not formed. Clearly has a lower fiber density (this may be evidence of lower basis weight or lower opacity). The protrusion 32 may also have fibers that are narrowed in the sidewall 56. This thinning of the fiber, if present, becomes apparent in the form of a cervical region in the fiber 38, as seen in a scanning electron microscope (SEM) image taken at 200x magnification. Thus, the fibers may have a first cross-sectional area when in a non-deformed nonwoven precursor web and a second cross-sectional area in the sidewall 56 of the deformed nonwoven web protrusion 32, the first cross-sectional area. One cross-sectional area is larger than the second cross-sectional area. Side wall 56 may also include a number of broken fibers.

  In some forms, the distal end 54 of the protrusion 32 may be composed of native basis weight, non-thinned and unbroken fibers. When the base opening 44 is facing down, the distal end 54 becomes the bottom of the recess formed by the protrusion. The distal end 54 has no holes formed completely through the distal end. Thus, the nonwoven material can be non-porous. The term “pore” as used herein refers to a hole formed in a nonwoven after formation of the nonwoven and does not include pores typically present in the nonwoven. The term “hole” also refers to irregular ruptures in a nonwoven material (such as shown in FIGS. 15D-15F and FIG. 20) caused by local tearing of the material during the process of forming deformation in the nonwoven material. (Or such breaks may be due to non-uniformities in the precursor material). The distal end 54 may have a relatively high fiber density or density compared to the rest of the structure forming the protrusion. However, as will be described in detail below, when the nonwoven web is composed of multiple layers, the density of the fibers in different portions of the protrusions can vary between the different layers.

  The protrusion 32 can be any suitable size. The size of the protrusion 32 can be described in terms of the length, width, thickness, height, depth, cap size, and opening size of the protrusion. (Unless otherwise stated, the protrusion length L and width W are the length and width outside the protrusion cap 52.) The protrusion and opening dimensions are described in the Test Methods section. According to the “accelerated compression method” (according to the designation, under pressure of either 7 kPa or 35 kPa), the protrusions that can be measured before and after compression follow the “accelerated compression method”, but under a load of 2 kPa , Having a thickness measured between the same points as the height H. All dimensions of protrusions and openings (ie, length, width, height, depth, cap size, and opening size), except thickness, are measured at the time of measurement using a 20 × magnification microscope. Measured in the absence of applied pressure.

In some forms, the length of the cap 52 can range from about 1.5 mm to about 10 mm. In some forms, the width of the cap (measured where the width is maximum) can range from about 1.5 mm to about 5 mm. The cap portion of the protrusion can have a plan view surface area of at least about 3 mm ² . In some forms, the protrusion may have a height H before compression ranging from about 1 mm to about 10 mm, alternatively from about 1 mm to about 6 mm. In some forms, the protrusions can have a height H after compression in the range of about 0.5 mm to about 6 mm, or about 0.5 mm to about 1.5 mm. In some forms, the protrusion may have an uncompressed depth D ranging from about 0.5 mm to about 9 mm, alternatively from about 0.5 mm to about 5 mm. In some forms, the protrusion may have a depth D after compression in the range of about 0.25 mm to about 5 mm, or about 0.25 mm to about 1 mm.

  Nonwoven material 30 may comprise a composite of two or more nonwoven materials joined together. In such a case, the fibers and properties of the first layer are specified accordingly (eg, the first layer consists of the first plurality of fibers), and the fibers and properties of the second and subsequent layers are appropriate. (For example, the second layer consists of a second plurality of fibers). In the structure of two or more layers, there are many possible configurations of layers that can be taken according to the deformation formation therein. These often depend on the extensibility of the nonwoven material used in the layer. At least one of the layers has a deformation that forms a protrusion 32 as described herein, wherein along at least one cross-section, the width of the protrusion cap 52 is It is desirable that the width is larger than the width of the base opening 44. For example, when one layer of the two-layer structure is used as a top sheet of an absorbent article and the other layer is used as a lower layer (for example, a capturing layer), May be included. Most typically the layer having a bulbous shape will be the layer that contacts the male forming member during the process of deforming the web. 15A-15E show different alternatives for the three-dimensional protrusion 32 in the multilayer material.

  In certain configurations, such as those shown in FIGS. 11, 12, and 15A, similarly shaped looped fibers may be formed in each layer of the multilayer nonwoven material, forming protrusions therein. During the process, a layer 30A furthest from the separable male forming element and a layer 30B closest to the male forming element during the process are included. One layer, such as 30B, fits within the other layer, such as 30A. These layers are sometimes referred to as “nested” structures. Nested structure formation may require the use of two (or more) highly extensible nonwoven precursor webs. In the case of a two-layer material, the nested structure may form two complete loops or may form two incomplete fiber loops (as shown in some of the drawings below).

  As shown in FIG. 15A, the three-dimensional protrusion 32 includes a protrusion 32A formed in the first layer 30A and a protrusion 32B formed in the second layer 30B. In one form, the first layer 30A may be incorporated into the absorbent article as a capture layer, the second layer 30B may be a topsheet, and the protrusion formed by these two layers may fit together. (Ie, nested). In this embodiment, the protrusions 32A and 32B formed by the first layer 30A and the second layer 30B are closely fitted together. The three-dimensional protrusion 32A includes a plurality of fibers 38A, and the three-dimensional protrusion 32B includes a plurality of fibers 38B. The three-dimensional protrusion 32B is nested within the three-dimensional protrusion 32A. In the illustrated form, the fibers 38A in the first layer 30A are shorter in length than the fibers 38B in the second layer 30B. In other forms, the relative lengths of the fibers in the layer may be the same, or the opposite relationship that the fibers in the first layer are longer than the fibers in the second layer. In addition, in this form, and in any of the other forms described herein, the nonwoven layer can be turned over when incorporated into an absorbent article or other article, thereby protruding. The part 32 faces upward (or outward). In such a case, a material suitable for the topsheet is used for layer 30A and a material suitable for the lower layer is used for layer 30B.

  FIG. 15B shows that the nonwoven layer need not be in contact within the entire protrusion 32. Therefore, the protrusions 32A and 32B formed by the first layer 30A and the second layer 30B may have different heights and / or widths. The two materials can have substantially the same shape within the protrusion 32 as shown in FIG. 15B (one of the materials has the same curvature as the other). However, in other forms, the layers can have different shapes. FIG. 15B shows only one possible layer arrangement and many other variations are possible, but in the case of all diagrams it is impossible to provide a diagram of all possible variations Will be understood.

  As shown in FIG. 15C, one of the layers, eg, the first layer 30A (eg, the capture layer), may have ruptured within the area of the three-dimensional protrusion 32. As shown in FIG. 15C, the protrusion 32 is only formed in the second layer 30B (for example, a top sheet) and extends through the opening in the first layer 30A. That is, the three-dimensional protrusion 32B in the second layer 30B penetrates the ruptured first layer 30A. Such a structure can place a topsheet that is in direct contact with the underlying dispensing material or absorbent core, which can result in improved dryness. In such a form, these layers are not considered “nested” in the area of the protrusion. (In other configurations shown in FIGS. 15D-15F, the layers may still be considered “nested”.) Such a structure is such that the material of the second layer 30B extends more than the material of the first layer 30A. It can be formed when the property is high. In such cases, the opening may be formed by locally rupturing the first precursor web by the process described in detail below. The ruptured layer may have any suitable shape in the area of the protrusion 32. The rupture may be accompanied by a simple delamination of the first precursor web, so that the opening of the first layer 30A remains a simple two-dimensional hole. However, for some materials, a portion of the first layer 30A can be deflected or biased out of plane (ie, out of the plane of the first layer 30A) to form the flap 70. The form and structure of any flap is strongly dependent on the material properties of the first layer 30A. The flap may have the general structure shown in FIG. 15C. In other forms, the flap 70 can have a more volcanic structure as if the protrusions 32B erupt from the flap.

  Alternatively, as shown in FIGS. 15D to 15F, one or both of the first layer 30A and the second layer 30B may be divided in the area of the three-dimensional protrusion 32 (or have an internal fracture portion). Also good). 15D and 15E show that the three-dimensional protrusion 32A of the first layer 30A can have a split 72A therein. The three-dimensional protrusions 32B of the second layer 30B that are not divided coincide with the three-dimensional protrusions 32A of the divided first layer 30A and can fit each other. Alternatively, FIG. 15F shows a form in which both the first layer 30A and the second layer 30B have a split or break (72A and 72B, respectively) in them. In this case, the breaks in the layers 30A and 30B are at different positions in the protrusion 32. FIGS. 15D-15F show unintended random or non-uniform breaks in the material, typically formed by random fiber breaks, which are generally not aligned and in the first layer or the second layer. Typically, however, both layers are not aligned and do not penetrate. Thus, typically, there is no hole at the distal end 54 of the protrusion 32 that is formed completely through all layers.

  For a two layer or other multilayer structure, the basis weight distribution (fiber density) in the deformed material 30 may vary from layer to layer. As shown in FIG. 16, the nonwoven layer (eg, 30B) in contact with the male forming element may have a large portion with the same basis weight as the original nonwoven at the distal end 54B of the protrusion 32B. As shown in FIG. 17, the basis weight within the side wall 56B of the protrusion 32B and near the base opening 44 can be less than the original material and the basis weight of the distal end 54 of the protrusion 32B. As shown in FIG. 18, the nonwoven layer (eg, 30A) in contact with the female forming element, however, can have a significantly smaller basis weight at the cap 52A of the protrusion 32A than the original nonwoven. As shown in FIG. 19, the side wall 56A of the protrusion 32A can have a smaller basis weight than the original nonwoven fabric, but can have a greater basis weight than the distal end 54A of the protrusion 32A.

The base opening 44 can be any suitable shape and size. The shape of the base opening 44 may typically be similar to or the same as the plan view shape of the corresponding protrusion 32. The base opening 44 is larger than any of the dimensions in increments of 0.1 mm beyond 0.5 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, or 1 mm before (and after) compression. Can have a width. The width of the base opening 44 can range from any of the above values up to about 4 mm or more. The base opening 44 may have a length in the range of about 1.5 mm or less to about 10 mm or more. Base opening 44 may have an aspect ratio in the range of about 1: 1 to 20: 1, alternatively about 1: 1 to 10: 1. Measurement of the size of the base opening can be performed on a micrograph. When the size of the width of the base opening 44 is specified herein, if the opening is not uniform in a particular direction, the width W _O is measured at the widest portion as shown in FIG. It will be understood that The nonwoven materials of the present disclosure, and methods of making the same, can form deformations with wider openings than certain prior art structures having a narrow base. Thereby, the visibility with the naked eye of the base part opening part 44 becomes higher. The width of the base opening 44 is of interest. This is because it is the narrowest part of the opening, and thus the size of the opening is most restricted. This deformation maintains a wide base opening 44 even after compression perpendicular to the plane of the first region 40.

  The deformation can be compressed under load. In some cases, it may be desirable for the load to be low enough so that if the nonwoven is worn facing the wearer's body and the deformation is in contact with the wearer's body, the deformation is soft. Does not form indentations on the skin. This is the case when either the protrusion 32 or the base opening 44 is oriented to contact the wearer's body. For example, it may be desirable to compress the deformation under a pressure of 2 kPa or less. In other cases, it does not matter whether this deformation forms an indentation in the wearer's skin. When at least one of the protrusions 32 of the nonwoven material 30 is tested according to the “accelerated compression method” in the test method section below, it can be collapsed or collapsed in a controlled manner as described below under a 7 kPa load. It may be desirable. Alternatively, at least some, or in other cases, the majority of the protrusions 32 can be collapsed in a controlled manner as described herein. Alternatively, substantially all of the protrusions 32 can be crushed in a controlled manner as described herein. The ability to crush the protrusion 32 can also be measured under a load of 35 kPa. Loads of 7 kPa and 35 kPa simulate manufacturing and compression packaging conditions. Wear conditions can range from zero or limited pressure (when the wearer is not sitting on the absorbent article) to a maximum of 2 kPa, 7 kPa, or more.

  The protrusion 32 can be crushed in a controlled manner to maintain a wide opening 44 at the base after compression. FIG. 13 shows the first surface 34 of the nonwoven material 30 according to the present disclosure after being subjected to compression. FIG. 14 is a side view of a single downward projection 32 after being subjected to compression. As shown in FIG. 13, when the protrusion 32 is compressed, the fiber density appears to be higher in the shape of the increased opacity ring 80 around the base opening 44. When compressive force is applied to the nonwoven material, the sidewalls 56 of the protrusions 32 can be collapsed in a more desirable / controlled manner, such that the sidewalls 56 are concave and folded, resulting in regions of overlapping layers. (For example, s-shaped / accordion type). The increased opacity ring 80 indicates a folded material layer. In other words, the protrusion 32 may have a certain degree of dimensional stability in the XY plane when a Z-direction force is applied to the protrusion. The collapsed shape of the protrusions 32 need not be symmetrical, simply this collapsed shape prevents the protrusions 32 from covering or pushing back the original surface of the nonwoven, and the Prevent significant size reduction. For example, as shown in FIG. 14, the left side of the protrusion 32 can form a z-shaped folded structure, and the right side of the protrusion is not formed, but is still folded when viewed from above. It appears to have higher opacity due to some overlap of the materials. Without being bound by any particular theory, a wide base opening 44 and a large cap 52 (greater than the width of the base opening 44) can be used to control the protrusion 32 in combination with the lack of a pivot point. It is considered to be crushed in a manner (to prevent the protrusion 32 from being covered). Thus, the protrusion 32 does not have a hinge structure that may allow it to be folded sideways when compressed. The large cap 52 also prevents the protrusion 32 from being pushed back to the original surface of the nonwoven.

This deformation can be placed at any suitable density across the surface of the nonwoven material 30. This deformation can be present, for example, at a density of about 5 to about 100, alternatively about 10 to about 50, alternatively about 20 to about 40 per 10 cm ² area.

  This deformation can be arranged in any suitable arrangement across the surface of the nonwoven material. Suitable arrangements include, but are not limited to, offset arrangements and zone arrangements. In some cases, the nonwoven material 30 may include both deformation and other features well known in the art such as embossing and holes. Deformations and other features may be in separate zones, may mesh with each other, or may overlap. The interdigitated array can be made by any suitable method. In some cases, interdigitated sequences can be created using the techniques described in US Patent Publication No. 2012/0064298 A1 by Orr et al. In other cases, the overlapping arrangement forms a deformation and then passes the nonwoven web between a forming member having a male forming element and a flexible surface, along with the forming member and the flexible surface, the web It can be manufactured by applying pressure to. These techniques for producing overlapping arrays allow deformations and other features to be combined, so they are placed at different locations on the nonwoven material, or at least some of the deformations and other features At least a portion can be placed at the same location on the nonwoven material.

  The nonwoven web or three-dimensional material 30 described herein may include any suitable element (s) of the absorbent article. For example, the nonwoven web can include a topsheet of an absorbent article, or, as shown in FIG. 25, if the nonwoven web 30 includes multiple layers, the nonwoven web is an absorbent article (eg, diaper 82). A combination of topsheet 84 and acquisition layer 86 may be included. The diaper 82 shown in FIGS. 25-27 also includes an absorbent core 88, a backsheet 94, and a dispensing material 96. The nonwoven web or material of the present disclosure can also form the outer cover of an absorbent article, such as the outer cover nonwoven material 223 (see FIG. 29). The nonwoven web 30 can be placed in an absorbent article with a deformation 31 in any suitable orientation. For example, the protrusion 32 can be upward or downward. In other words, the protrusion 32 may be oriented toward the absorbent core 88 as shown in FIG. Thus, for example, it may be desirable for the protrusion 32 to be directed inwardly toward the absorbent core 88 in the diaper (i.e., away from the wearer facing side and toward the clothing facing side). is there. Or the protrusion part 32 may be orient | assigned so that it may extend in the direction away from the absorbent core of an absorbent article, as shown in FIG. In yet another form, the nonwoven web 30 can also be manufactured such that some protrusions 32 face up and some protrusions 32 face down. While not being bound to a particular theory, such a structure can be more effective for protrusions that are upwards to clean the body from body discharge, while protrusions that are downwards are It is believed that it may be useful in that it may be more effective by absorption of body excretion into the absorbent core. Thus, without being bound by theory, the combination of these two types of protrusions can provide the advantage that two functions can be fulfilled with the same product.

  A two or more layer nonwoven structure may provide fluid treatment benefits. If the layers are integrated together and the protrusions 32 face the absorbent core, they can also provide a drying advantage. On the other hand, in wet or dry mop pads, it may be desirable for protrusions 32 to face away from the absorbent core to provide cleaning benefits. In some forms, when the nonwoven web 30 is incorporated into an absorbent article, the lower layer may be substantially free or completely free of tow fibers. A suitable lower layer free of tow fibers can include, for example, a layer or patch of crosslinked cellulose fibers. In some cases, it may be desirable that the nonwoven material 30 is not entangled with another web (ie, is not entangled with another web).

The layer of nonwoven structure (eg, topsheet and / or acquisition layer) can be colored. Color can be imparted to the web by colored pigments. The term “color pigment” encompasses any pigment suitable for imparting a non-white color to the web. Thus, the term typically does not include “white” pigments such as TiO ₂ that are added to layers of conventional absorbent articles to give them a white appearance. Pigments are usually applied dispersed in a vehicle or substrate, as found, for example, in inks, paints, plastics, or other polymeric materials. For example, the pigment can be introduced into a polypropylene masterbatch. The masterbatch contains high concentrations of pigments and / or additives, which are dispersed in a carrier medium, which is then used to color or modify the uncolored polymeric material into a colored two-component nonwoven. Can be used. An example of a suitable colored masterbatch material that can be introduced is Pantone Color 270 Sanylen Violet PP 42006634 ex Clarant, which is a PP resin containing a high concentration of violet pigment. Typically, the amount of pigment introduced can be from 0.3% to 2.5% based on the weight of the web. Alternatively, the color may be imparted to the web by impregnation of the colorant into the substrate. Colorants such as dyes, pigments, or combinations may be impregnated when forming a substrate such as a polymer, resin, or nonwoven. For example, the colorant may be added to the molten batch of polymer during fiber or filament formation.

Precursor Material The nonwoven material of the present disclosure can be made from any suitable nonwoven material (“precursor material”). Nonwoven webs can be made in a single layer or multiple layers (eg, two or more layers). If multiple layers are used, the nonwoven web may be made of the same type of nonwoven material or of different types of nonwoven material. In some cases, the precursor material may not include any film layers.

  The fibers of the nonwoven precursor material can be made from any suitable material, including but not limited to natural materials, synthetic materials, and combinations thereof. Suitable natural materials include, but are not limited to, cellulose, cotton linter, bagasse, xylem fibers, silk fibers, and the like. Cellulose fibers may be provided in any suitable form, including but not limited to individual fibers, fluff pulp, dry wrap, linerboard, and the like. Suitable rigid materials include, but are not limited to, nylon, rayon and polymeric materials. Suitable polymeric materials include, but are not limited to, polyethylene (PE), polyester, polyethylene terephthalate (PET), polypropylene (PP), and copolyester. However, in some forms, the nonwoven precursor material may be substantially free or free of one or more of these materials. For example, in some forms, the precursor material may be substantially free of cellulose and / or exclude paper. In some forms, the one or more precursor materials may include up to 100% thermoplastic fiber. Thus, in some cases, the fibers can be substantially non-absorbable. In some forms, the nonwoven precursor material may be substantially free of tow fibers or not at all.

  The precursor nonwoven material can comprise any suitable type of fiber. Suitable types of fibers include monocomponent, bicomponent and / or bicomponent, non-round (eg, molded fibers (including but not limited to fibers having a trilobal cross section) and capillary channel fibers). However, it is not limited to these. The fibers can be any suitable size. The fibers have a major cross-sectional dimension (for example, diameter in the case of round fibers), for example, in the range of 0.1 to 500 micrometers. The fiber diameter can also be expressed in denier, which is a unit of weight per fiber length. The constituent fibers can range, for example, from about 0.1 denier to about 100 denier. The constituent fibers of the nonwoven precursor web are of various fiber types that differ in characteristics such as chemistry (eg, PE and PP), constituents (mono and bi), shape (ie, capillary channels and circles), etc. It can also be a mixture.

  Nonwoven precursor webs can be formed from a number of processes, for example, from airlaid processes, wet processes, meltblown processes, spunbond processes, and carding processes. The web fibers can then be bonded by a spunlace process, hydroentanglement, calendar bonding, and resin bonding. Some of such individual nonwoven webs may have bonding sites where the fibers are bonded together.

The basis weight of the nonwoven material is usually expressed in grams per square meter (gsm). The basis weight of the single layer nonwoven material can range from about 8 gsm to about 100 gsm, depending on the ultimate use of the material 30. For example, the topsheet / capture layer laminate or composite topsheet may have a basis weight of about 8 to about 40 gsm, or about 8 to about 30 gsm, or about 8 to about 20 gsm. The acquisition layer may have a basis weight of about 10 to about 120 gsm, or about 10 to about 100 gsm, or about 10 to about 80 gsm. The basis weight of the multilayer material is the basis weight that combines the constituent layers and other optional components. The basis weight of the multilayer material of interest herein can range from about 20 gsm to about 150 gsm, depending on the ultimate use of the material 30. The nonwoven precursor web can have a density of about 0.01 to about 0.4 g / cm ³ when measured at 2 kPa (0.3 psi).

  The precursor nonwoven web may have certain desirable properties. Each of the precursor nonwoven webs has a first surface, a second surface, and a thickness. The first and second surfaces of the precursor nonwoven web can be generally flat. Typically, it is desirable for the precursor nonwoven web material to have extensibility so that the fibers can be extended and / or repositioned in the form of protrusions. If the nonwoven web includes more than one layer, it is desirable that all layers be as extensible as possible. Extensibility is desirable to maintain at least some unbroken fiber on the sidewall around the perimeter of the protrusion. 100% (which is twice the unstretched length), 110%, 120%, at or before the peak tensile force for individual precursor webs or at least one nonwoven in a multilayer structure Alternatively, it may be desirable to be able to perform one or more elongations between 130% and up to about 200% or more. Also, the precursor nonwoven web may be plastically deformed to ensure that the structure of the deformation is “fixed” in place so that the nonwoven web does not tend to recover or return to its previous shape. It may be desirable to be possible.

  A material that is not sufficiently extensible (eg, non-extensible PP) may form ruptured fibers over most of the periphery of the deformation, making it easier to form “hanging perforations” 90 (ie, cap 52 of protrusion 32). May at least partially break and separate from the rest of the protrusion (see FIG. 20)). The side area of the protrusion where the fibers are broken is indicated by reference numeral 92. For example, a material such as that shown in FIG. 20 is not suitable for a single layer structure and, if used, will typically be part of a composite multilayer structure, with other layers as described herein. A protrusion 32 is provided.

  If the fibers of the nonwoven web are not very extensible, it may be desirable for the nonwoven to have poor adhesion rather than optimal adhesion. The tensile properties of a thermally bonded nonwoven web can be adjusted by changing the bonding temperature. The web can be optimal or ideally bonded, poorly bonded, or excessively bonded. Optimal or ideally bonded webs are characterized by the highest peak tensile strength, elongation at the tensile peak, and a rapid decrease in strength after the tensile peak. Under strain, the bond location breaks and a small amount of fiber is drawn from the bond location. Thus, in an optimally bonded nonwoven fabric, the fibers 38 are stretched and broken around the bonded location 46 when the nonwoven web is pulled beyond a certain point. Often, the fiber diameter is slightly reduced in the area around the hot spot bond. A poorly bonded web has a lower peak tensile strength, elongation at the tensile peak, and a gradual decrease in strength after the tensile peak, as compared to an optimally bonded web. Under strain, some fibers are drawn from the hot spot bond location. Thus, a poorly bonded nonwoven fabric can easily separate at least a portion of the fibers 38 from the bonded locations 46 and be repositioned when the fibers 38 are pulled out of the bonded locations and the material is distorted. Can be possible. Overbonded webs also have a reduced peak tensile strength, elongation at the tensile peak, and a rapid decrease in strength after the tensile peak, as compared to optimally bonded webs. This bonded portion looks like a film, and under the strain, the bonded portion is completely broken.

  If the nonwoven web comprises two or more layers, the different layers may have the same properties or have any suitable property differences relative to each other. In one form, the nonwoven web 30 may include a two-layer structure used for absorbent articles. For convenience, the precursor web and the material formed therefrom are designated herein with the same reference numerals. The second layer 30B, which is one of the layers, can be used as a top sheet of the absorbent article, and the first layer 30A can be used as a lower layer (or sublayer) and can be used as a trapping layer. . The acquisition layer 30A receives the liquid that has passed through the topsheet and distributes it to the underlying absorbent layer. In such a case, the topsheet 30B is less hydrophilic than the sublayer 30A and thus may provide better drainage of the topsheet. In other forms, the topsheet may be more hydrophilic than the sublayer. In some cases, the pore size of the acquisition layer can be reduced, for example, by using lower denier fibers or by increasing the density of the acquisition layer material, thereby increasing the topsheet's density. It can lead to better drainage of the pores.

  The second nonwoven layer 30B that can be used as a topsheet can have any suitable properties. Properties of interest for the second nonwoven layer can include homogeneity and opacity in addition to sufficient extensibility and plastic deformability when used as a topsheet. As used herein, “homogeneity” refers to a microscopic deviation in the basis weight of a nonwoven web. As used herein, “opacity” of a nonwoven web is a measure of the impermeability of visible light and is used as a visual determination of relative fiber density on a microscopic scale. As used herein, the “opacity” of different regions of a single nonwoven deformation is determined by taking a micrograph of the nonwoven portion containing the deformation at a magnification of 20 times against a black background. . Darker areas indicate relatively lower opacity (as well as lower basis weight and lower density) than white areas.

  Some examples of nonwoven materials suitable for use as the second nonwoven layer 30B include spunbond nonwovens, carded nonwovens, and high extensibility (strain at peak tensile strength in the above range) and structure. Other non-woven fabrics that have sufficient plastic deformability to be securely fixed and not to cause significant recovery include, but are not limited to. One suitable nonwoven material for the topsheet of the topsheet / capture layer composite structure can be an extensible spunbond nonwoven, including polypropylene and polyethylene. The fibers may include a blend of polypropylene and polyethylene, or may be bicomponent fibers (eg, sheath-core fibers using polyethylene for the fiber sheath and polypropylene for the core). Another suitable material is a bicomponent fiber spunbond nonwoven with a polyethylene sheath and a polyethylene / polypropylene blended core.

  For example, the first nonwoven layer 30A that can be used as a capture layer can have any suitable properties. Properties of interest for the first nonwoven layer can include homogeneity and opacity in addition to sufficient extensibility and plastic deformability. If the first nonwoven layer 30A is used as a capture layer, its fluid treatment characteristics must also be appropriate for this purpose. Such properties may include mechanical properties such as permeability, porosity, capillary pressure, thickness, and sufficient compression resistance and elasticity to maintain the void volume. Suitable nonwoven materials for the first nonwoven layer when used as the acquisition layer include spunbond nonwovens, vent bonded ("TAB") carded nonwoven materials, spunlace nonwovens, hydroentangled nonwovens, and resin bonded carded nonwovens Examples include, but are not limited to, materials. Of course, the composite material structure can be inverted and incorporated into the article, in which case the first layer 30A is used as the topsheet and the second layer 30B is used as the acquisition layer. In such a case, the properties and exemplary methods of the first and second layers described herein can be interchanged.

  The layers of the two or more layered nonwoven web structures can be combined in any suitable manner. In some cases, the layers are not adhered to each other and may be retained self-generating (ie, by deformation generation therein). For example, both precursor webs 30A and 30B contribute to the fiber in a “nested” relationship, which “locks” the two precursor webs together and uses adhesive or thermal bonding between the layers. Alternatively, a multi-layer web is formed without need. In other forms, the layers can be joined together by other mechanisms. If desired, the adhesive of the precursor web can be selectively utilized by interlaminar adhesive, ultrasonic bonding, chemical bonding, resin or powder bonding, thermal bonding, or bonding at separate locations using a combination of heat and pressure Specific areas or the whole can be glued. If an adhesive is used, it can be applied in any suitable manner or pattern, including but not limited to slots, spirals, sprays, and curtain coatings. The adhesive can be applied in any suitable amount or basis weight, including but not limited to about 0.5 to about 30 gsm, alternatively about 2 to about 5 gsm. In addition, multiple layers can be bonded during processing, for example, a single layer of nonwoven can be carded onto a spunbond nonwoven and the combined layers can be hot spot bonded. In some cases, certain types of adhesion between layers may be excluded. For example, the layers of this structure must not be hydroentangled together.

  Where the precursor nonwoven web includes more than one layer, it may be desirable for at least one of the layers to be continuous (eg, in the form of a web unrolled). In some forms, each of the layers can be continuous. In an alternative form, as shown in FIG. 24, one or more layers may be continuous and one or more layers may have separable lengths. The layers can also have different widths. For example, when manufacturing a combination of a topsheet and a capture layer for an absorbent article, the nonwoven layer used as the topsheet may be a continuous web, and the nonwoven layer used as the capture layer is disposed on the continuous web. Can be supplied to the production line in the form of separable length pieces (eg, rectangles or other shapes). Such a trapping layer can have a narrower width than the topsheet layer, for example. These layers can be combined as described above.

Nonwoven Material Production Method Nonwoven material is produced by a method comprising the following steps: a) providing at least one precursor nonwoven web, b) a pair of formations comprising a first forming member and a second forming member. Providing a device comprising the member; and c) placing the precursor nonwoven web between the forming members and mechanically deforming the precursor nonwoven web with the forming members. The forming member has a machine direction (MD) orientation and a cross machine direction (CD) orientation.

  The first and second forming members may be plates, rolls, belts, or other suitable types of forming members. In some forms, an apparatus for stepwise stretching a web, as described in US Pat. No. 8,021,591, by Curro et al. It may be desirable to modify by providing an actuating member as described herein with a forming element of the type described in. In the form of the apparatus 100 shown in FIG. 21, the first and second forming members 102 and 104 are in the form of a non-deformable mesh-like counter-rotating roll, and a nip 106 is formed therebetween. The precursor web is fed into the nip 106 between the rolls 102 and 104. The gap between rolls 102 and 104 is described herein as a nip, but in some cases it may be desirable to avoid compression of the precursor web as much as possible, as described in more detail below. is there.

First Forming Member The first forming member 102 has a surface that includes a plurality of first forming elements that include separate and spaced male forming elements 112. The male forming elements are spaced apart in the machine direction and the cross machine direction. The term “separated” does not include continuous or non-separating forming elements such as ridges and grooves on corrugated rolls (or “ring rolls”), which corrugated rolls are machine direction and cross machine direction. On the other hand, it has ridgelines that can be separated (not in both directions).

As shown in FIG. 22, the male forming element 112 is joined to the first forming member 102 (in this case, integrally formed), a top surface 118 spaced from the base, and a male. Having a side surface 120 extending between the base and top surface of the forming element. The male element 112 also has a plan view perimeter and a height H ₁ (which is measured from the base 116 to the top surface 118). Separate elements on the male roll have a relatively large surface area top surface 118 (eg, about 1 mm to about 10 mm wide and about 1 mm to about 20 mm long) to form large area deformations. The male element 112 can have any suitable configuration. In one form, the male element 112 has a flat top surface 118, a vertical sidewall 120, and a rounded edge that forms a transition 122 between the flat top surface 118 and the vertical sidewall 120. (The vertical side wall means that the side wall 120 forms an angle of 0 degrees with respect to the vertical line from the base of the side wall). The top surface 118 of the male element 112 may have any suitable top view configuration, including a rounded diamond configuration, an American football shape, a triangle, a clover shape, a tear, as shown in FIGS. Examples include, but are not limited to, oval, oval.

  Many other shapes for the male forming element 112 are possible. In other forms, the top surface 118 of the male forming element 112 may be rounded. In other configurations, the sidewall 120 may taper inwardly toward the center of the male forming element 112, thus forming a corner that is greater than zero. In other forms, the top surface 118 of the male element 112 may have a different shape than that shown. In other configurations, the male forming element 112 does not have a length that is oriented in the machine direction, but may be disposed on the first forming member 102 in other orientations (CD orientation and between MD and CD). Including orientation).

Second Forming Member As shown in FIG. 21, the second forming member 104 has a surface 124 having a plurality of cavities or recesses 114 therein. The recess 114 is aligned and configured to receive the male forming element 112 therein. Thus, the male forming element 112 mates with the recess 114 so that a single male forming element 112 fits within the outer periphery of the single recess 114 and is at least partially recessed 114 in the Z direction. Fits within. The recess 114 has a plan view outer periphery 126 that is larger than the plan view outer periphery of the male element 112. As a result, when the rolls 102 and 104 are engaged, the recess 114 on the female roll completely encompasses the separated male element 112. Recess 114 has a depth _{D 1} shown in FIG. 23. In some cases, the depth D ₁ of the recess may be greater than the height H ₁ of the male forming element 112.

  The recess 114 has a top view configuration similar to the male element 112, a side wall 128, and an edge 130 around the bottom surface 132 of the recess, where the side wall 128 joins the bottom surface 132 of the recess. obtain. The sidewall 128 of the recess 114 can be vertical. The recessed edge 130 may be sharp or rounded.

As described above, the recess 114 may be deeper than the height H ₁ of the male element 112 so that the nonwoven material is pinched (or crushed) between the male roll 102 and female roll 104 as much as possible. ) There is nothing. However, it will be appreciated that passing a precursor web between two rolls of relatively narrow clearance tends to apply some shear and compression forces to the web. However, this method differs from some embossing steps in which the top surface of the male element compresses the material to be embossed against the bottom surface of the female element, thereby increasing the density of the region where the material is compressed. Increase.

  The depth of engagement (DOE) is a measurement of the engagement level of the forming member. As shown in FIG. 23, DOE is measured from the top surface 118 of the male element 112 to the outermost surface 124 of the female forming member 114 (eg, a roll with a recess). The DOE should be sufficiently large to form a protrusion 32 with a distal portion or cap 52 having a maximum width greater than the width of the base opening 44 when combined with a stretchable nonwoven material. is there. The DOE can range, for example, from at least about 1.5 mm or less to about 5 mm or more. In certain forms, the DOE can be about 2.5 mm to about 5 mm, alternatively about 3 mm to about 4 mm. The formation of the protrusion 32 having a distal portion with a maximum width greater than the width of the base opening 44 is considered to be different from many embossing processes, and embossing typically constitutes an embossing element. Which has a wider base opening than the rest of the embossing. As shown in FIG. 23, there is a clearance C between the side surface 120 of the male element 112 and the side surface (or side wall) 128 of the recess 114. The clearance C between the male and female rolls may be the same or may vary slightly over the outer periphery of the male element. The clearance may range from about 0.13 mm (0.005 inches) to about 1.3 mm (0.05 inches). Clearance and DOE are related so that larger clearances may allow the use of larger DOEs.

  The precursor nonwoven web is disposed between the forming members 102 and 104. The precursor nonwoven web can be disposed between the forming members with any surface (first surface 34 or second surface 36) of the precursor web facing the first forming member (male forming member 102). For convenience of explanation, the second surface 36 of the precursor nonwoven web is described herein as being disposed in contact with the first forming member 102. (Of course, in other forms, the second surface 36 of the precursor nonwoven web can be placed in contact with the second forming member 104.) The precursor material forces the nonwoven web through the forming members 102 and 104. When applied, it is mechanically deformed by the forming members 102 and 104. This force can be applied in any suitable manner. If the forming members 102 and 104 are in the form of plates, the force is applied when the plates are brought together. If the forming members 102 and 104 are in the form of counter-rotating rolls (or belts, or any combination of rolls and belts), the force is applied when the precursor nonwoven web passes through the nip between the counter-rotating elements. Applied. The force applied by the forming member impacts the precursor web and mechanically deforms the precursor nonwoven web.

  When deforming a multilayer web that is a laminate laminated with an adhesive, it may be desirable to cool the forming member to prevent the adhesive from adhering to and fouling the forming member. The forming member can be cooled using processes well known in the art. One such process may be an industrial chiller that utilizes a refrigerant, such as propylene glycol. In some cases, it may be desirable to perform the process in a humid environment so as to form a layer of condensate on the forming member.

The precursor nonwoven web includes a plurality of deformations including a generally flat first region, a protrusion extending outwardly from the first surface 34 of the nonwoven web, and an opening in the second surface of the nonwoven web. A nonwoven web is formed that includes a separate integral second region. (Of course, when the second surface 36 of the precursor nonwoven web is placed in contact with the second forming member 104, the protrusions extend outward from the second surface of the nonwoven web and the openings are the nonwoven web. While not being bound by any particular theory, the extensibility of the precursor web (or at least one of its layers) is reduced by the male forming element 112. when pushed into having a depth of less engagement DOE than the concave depth D ₁ recess 114, by extending the portion of the nonwoven web, a large cap and wide base opening as described above It is considered that a deformation including the provided protrusion is formed. (This can be similar to pressing a finger against an uninflated balloon, which stretches and permanently deforms the balloon material.)

  In the case where the precursor nonwoven material 30 includes a plurality of layers, if one of the layers is a piece of separated nonwoven material, as shown in FIG. 24, the base opening is a continuous layer (eg, 30B). Yes, it may be desirable for the deformation to be formed so that the protrusions 32 extend toward this separated layer (eg, 30A). Of course, in other forms, such structural modifications may be reversed. The deformation can be distributed in any suitable manner over the surface of such a continuous or separated layer. For example, the deformation can be distributed over the entire length and / or width of the continuous layer, can be distributed in an area narrower than the width of the continuous layer, or can be limited to an area of separated layers.

  The method of manufacturing the nonwoven material described herein may exclude (or distinguish) the following processes: hydroforming, hydromolding, use of air jets, stiffness versus elasticity ( For example, embossing of steel / rubber) and the use of a patterned surface for a flat anvil surface. This method may also exclude (or distinguish) the Procter & Gamble Company process ("SELF" process) for manufacturing Structural Elastic-Like Films. The forming member used herein is the same as the forming member used in the SELF process that forms the corrugated structure (and the tuft structure), where the SELF teeth typically have a relatively small diameter tip. The ridge line of the fitting ring roll is different in that it only forms the boundary of the side surface of the SELF tooth and does not form the boundary before and after the tooth.

Absorbent articles The three-dimensional nonwoven material of the present disclosure and the method for producing the same have been described above. The use of these three-dimensional nonwoven materials will now be described in more detail in the context of example absorbent articles. These absorbent articles can include designs and / or patterns of various colors and displays. The absorbent article may also include channels in one or more layers between the topsheet and the absorbent core.

Overview of Absorbent Article An example of an absorbent article in the form of a diaper 220 is shown in FIGS. FIG. 28 is a plan view of an exemplary diaper 220 in a flattened state, with a portion of the structure cut away to better illustrate the structure of the diaper 220. The surface of the diaper 220 of FIG. 28 that faces the wearer faces the viewer. The three-dimensional nonwoven material of the present disclosure can be used as one or more elements of an absorbent article, such as a topsheet, a capture layer, individual topsheets and capture layers, or a laminate formed from a topsheet and a capture layer. Because it can be used, this diaper 220 is shown for illustrative purposes only. In any case, the three-dimensional nonwoven material of the present disclosure can be liquid permeable. The channel may be present in the absorbent core, in the distribution material, and / or in the carrier layer (if a carrier layer is provided). Channels can also be present in the acquisition layer if the acquisition layer is not combined with a topsheet. In some examples, the distribution material may not be provided and the channel may be in the acquisition layer or in another layer between the topsheet and the absorbent core. If the channels are provided in more than one of these materials between the topsheet and the absorbent core, the channels may all overlap each other completely, partially overlap each other in the Z direction, or There may be no mutual overlap.

  The absorbent article 220 includes a liquid permeable material or topsheet 224, a liquid impermeable material or backsheet 225, an absorbent core 228 disposed at least partially between the topsheet 224 and the backsheet 225, and a barrier. A leg cuff 234 may be included. The absorbent article may also include ADS 250, which in the example shown includes distribution material 254 and acquisition layer 252 which are further described below. The acquisition layer 252 may be nested with the topsheet as described herein and shown in the various figures. Also, the absorbent article 220 typically joins the absorbent article chassis through the topsheet and / or backsheet, and includes an elastic gasket cuff that includes an elastic body 233 that is substantially planar with the diaper chassis. 232 may be included.

  FIGS. 28 and 31 also show a typical taped diaper component, such as a fastening system with a tab 242, that is attached toward the rear edge of the article and landing in front of the absorbent article. Working with zone 244. The absorbent article may also include other exemplary elements not shown such as, for example, a rear elastic waist feature, a front elastic waist feature, a lateral barrier cuff (s), and / or a lotion application.

  Further, the absorbent article 220 has a front waist part edge 210, a rear waist part edge 212 that faces the front waist part edge 210 in the longitudinal direction, a first side edge part 203, and a first side edge part 203 laterally. 2nd side edge part 204 which opposes a direction. The front waist edge 210 is the edge of the article intended to be placed toward the front of the user when worn, and the back waist edge 212 is the opposite edge. When the absorbent article 220 is laid flat and viewed from above as shown in FIG. 28, from the side midpoint of the front waist edge 210 to the side midpoint of the back waist edge 212 of the article. And has a longitudinal axis 280 that divides the article into two halves that are substantially symmetrical with respect to the longitudinal axis 280. In addition, the absorbent article 220 may have a horizontal axis 290 that extends from the longitudinal intermediate point of the first side edge 203 to the longitudinal intermediate point of the first side edge 204. The length L of the article may be measured along the longitudinal axis 280 from the front waist edge 210 to the back waist edge 212. The width W of this absorbent article can be measured along the horizontal axis 290 from the first side edge 203 to the second side edge 204. This absorbent article is defined herein as a crotch point defined as a point placed on the longitudinal axis at a distance of two-fifths (2/5) of L starting from the leading edge 210 of the article 220. C may be included. The article may include a front waist region 205, a back waist region 206, and a crotch region 207. The front waist region 205, the back waist region 206, and the crotch region 207 may each define 1/3 of the longitudinal length L of the absorbent article.

  The topsheet 224, backsheet 225, absorbent core 228, and other article components can be assembled in a variety of configurations, for example, particularly by glue bonding or hot embossing.

  The absorbent core 228 comprises at least 80 wt%, at least 85 wt%, at least 90 wt%, at least 95 wt%, or at least 99 wt% superabsorbent polymer and a core wrap encapsulating the superabsorbent polymer. An absorbent material may be included. The core wrap typically can include two materials, a substrate, or a nonwoven material 216 on the top surface and a nonwoven material 216 'on the bottom surface. These core types are known as air felt free cores. The core may include one or more channels shown in FIG. 28 as four channels 226, 226 'and 227, 227'. Channels 226, 226 ', 227, and 227' are optional mechanisms. Alternatively, the core may not have channels or may have any number of channels (eg, two).

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

Topsheet In the present disclosure, the topsheet (the part of the absorbent article that contacts the skin of the wearer and receives the fluid) is a portion of one or more three-dimensional nonwoven materials described herein, Or may be formed of and / or have one or more nonwoven materials disposed thereon and / or joined thereto, whereby the nonwoven material is applied to the wearer's skin To touch. Other parts of the topsheet (other than the three-dimensional nonwoven material) may also contact the wearer's skin. The three-dimensional nonwoven material can be placed as a strip or patch on a typical topsheet. Alternatively, the three-dimensional nonwoven material may form only the CD central area of the topsheet. The CD central area may extend the entire MD length of the topsheet or may be shorter than the MD length of the topsheet. In some examples, the topsheet can be generally flat.

  The topsheet 224 can be bonded to the backsheet 225, the acquisition layer 252, the absorbent core 228, and / or any other layer as is known in the art. Typically, the topsheet 224 and the backsheet 225 are joined directly to each other at some locations (eg, at or near the outer periphery of the absorbent article) and at other locations one or more other elements of the article 220. These are indirectly joined together by directly joining them.

  The topsheet 224 may be conformable to the wearer's skin, have a soft feel, and may be non-irritating. Furthermore, a portion or all of the topsheet 224 is liquid permeable so that liquid can easily penetrate through its thickness. Any portion of the topsheet 224 can be coated with a lotion and / or skin care composition as generally disclosed in the art. The topsheet 224 can also include or be treated with an antimicrobial agent.

Backsheet The backsheet 225 is generally positioned adjacent to the garment-facing surface of the absorbent core 228 and the fluids and body discharges absorbed and contained therein contaminate items such as bed sheets and underwear. The part of the absorbent article 220 that prevents or at least inhibits. The backsheet 225 is typically impermeable to fluid (eg, urine) or at least substantially impermeable. The backsheet may be or include a thin plastic film, such as, for example, a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm. Other suitable backsheet materials may include breathable materials, which allow vapors to escape from the absorbent article 220 while still preventing fluid from passing through the backsheet 225, Or at least inhibit.

  The backsheet 225 may be joined to the topsheet 224, the absorbent core 228, and / or any other element of the absorbent article 220 by any attachment method known in the art.

  The outer cover 223 of the absorbent article 220 covers at least a portion or the entire backsheet 225 to form a soft surface facing the garment of the absorbent article. The outer cover 223 may form a bulky three-dimensional nonwoven material as described herein. Alternatively, the outer cover 223 can include one or more known outer cover materials, such as conventional nonwoven materials. When the outer cover 223 includes one or more three-dimensional nonwoven materials of the present disclosure, the three-dimensional nonwoven material of the outer cover 223 is a topsheet of an absorbent article, a capture layer, or a laminate of a topsheet and a capture layer. It may or may not match the three-dimensional nonwoven material used (eg, the same material and / or the same pattern, or a similar material and / or a similar pattern). In other examples, the outer cover 223 comprising one or more three-dimensional nonwoven materials comprises one or more three-dimensional nonwoven materials used as a topsheet, acquisition layer, or a combination of topsheet and acquisition layer. Can complement or collaborate with them. In other examples, the outer cover matches, visually resembles, complements, or cooperates with a pattern of a three-dimensional nonwoven material used as a topsheet, acquisition layer, or laminate of topsheet and acquisition layer of an absorbent article. It can have a pattern that works, printed or otherwise applied. The outer cover 223 is indicated by a broken line in FIG. 29 as an example. The outer cover 223 can be joined to at least a portion of the backsheet 225 by mechanical bonding, adhesive bonding, or any other suitable attachment method.

Absorbent core An absorbent core is an element which has the greatest absorptive power among absorbent articles, and includes an absorbent material and a core wrap or a core bag enclosing the absorbent material. The absorbent core does not include the capture and / or distribution system or any other component of the absorbent article that is not an integral part of or disposed within the core wrap or core bag. The absorbent core comprises, or consists essentially of, a core wrap, an absorbent material described herein (eg, a superabsorbent polymer with little or no cellulosic fibers), and a paste. Or may consist of them. In other examples, the absorbent material may comprise a mixture of superabsorbent polymer and air felt or cellulose fibers. This mixture of superabsorbent polymer and air felt or cellulose fibers can be positioned in the core bag. The core bag may form a C wrap around this mixture or be formed in other forms. An adhesive may be present in the core bag to at least partially hold the mixture in place during manufacture and wear. Channels may be present in this absorbent material including superabsorbent polymers and air felt. In other examples, the embossed area may form a compressed area within the absorbent core.

  The absorbent core 228 may include an absorbent material in which a large amount of superabsorbent polymer (abbreviated herein as “SAP”) is encapsulated within a core wrap. The SAP content is 70% to 100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99% by weight of the absorbent material contained within the core wrap. % Or 100% by weight. The core wrap is not considered an absorbent material for the purpose of assessing the percentage of SAP in the absorbent core.

  “Absorptive material” means a material having some absorptive or liquid retention properties such as SAP, cellulosic fibers and synthetic fibers. Usually, the glue used to make the absorbent core has little or no absorbent properties and is not considered an absorbent material. The SAP content is greater than 80% of the weight of the absorbent material contained within the core wrap, such as at least 85%, at least 90%, at least 95%, at least 99%, and even up to 100% (including 100%) Can be. This air felt free core is a relatively thin core as compared to a conventional core which typically contains 40 wt% to 60 wt% SAP and a high content of cellulose fibers. The absorbent material may in particular comprise less than 15% or less than 10% by weight of natural, cellulose or synthetic fibers, or less than 5%, less than 3%, less than 2%, 1% % Natural fibers, cellulose fibers, or synthetic fibers, or may be substantially free of natural fibers, cellulose fibers, and / or synthetic fibers.

  Airfelt-free cores with little or no natural, cellulose, and / or synthetic fibers are much thinner than conventional cores, so cores containing mixed SAP and cellulose fibers (eg, 40- Resulting in an absorbent article that is generally thinner than an absorbent article with 60%). This thinness of the core can give the consumer the impression of reduced absorbency and performance, but technically does not reduce absorbency and performance. Currently, these thin cores are typically used with a substantially flat or perforated topsheet. Further, absorbent articles having these thin air felt free cores have reduced capillary void space due to little or no natural, cellulose or synthetic fibers in the core. Thus, in some cases, there may not be enough capillary void space in the absorbent article to fully accept multiple bodily drainage events or a single high volume event.

  To solve such problems, the present disclosure provides these thin air felt free cores as a topsheet, acquisition layer, or bulky three-dimensional described herein as a laminate of topsheet and acquisition layer. In combination with one of the nonwoven materials, an absorbent article is provided. In one such example, the increased thickness of the absorbent article due to the additional thickness provided by the bulky three-dimensional nonwoven material increases the consumer's impression of absorbency and performance. In addition, three-dimensional nonwoven materials can be used with these thin air felt-free cores and when used as topsheets, acquisition layers, or laminates of topsheet and acquisition layers, again add capillary void space to the absorbent article At the same time, the stack height in the bag can still be minimized, resulting in cost savings for consumers and manufacturers. Thus, the absorbent article of the present disclosure can easily absorb multiple bodily drainage events or a single large number of events due to this increased capillary void space. In addition, absorbent articles comprising nonwoven materials as topsheets, acquisition layers, or laminates of topsheets and acquisition layers increase the thickness compared to flat topsheets or perforated topsheets. Thus, it provides an aesthetically pleasing topsheet with an increased consumer impression of absorbency and performance.

  An exemplary absorbent core 228 of the absorbent article 220 of FIGS. 31-32 is shown alone in FIGS. The absorbent core 228 may include a front side 480, a rear side 482, and two longitudinal sides 484, 486 that join the front side 480 and the rear side 482. The absorbent core 228 can also include a generally flat top surface and a generally flat bottom surface. The front side 480 of the core is the side of the core that is intended to be placed toward the front waist edge 210 of the absorbent article. The core 228 may have a longitudinal axis 280 'that substantially corresponds to the longitudinal axis 280 of the absorbent article 220 when viewed from the top in plan view as in FIG. In certain absorbent articles, the absorbent material may be distributed in a greater amount toward the front side 480 than toward the back side 482 as higher absorptivity may be required at the front side. Also good. The front side portion 480 and the rear side portion 482 of the core may be shorter than the longitudinal side portions 484, 486 of the core. The core wrap may be formed by two nonwoven materials, substrates, laminates, or other materials 216, 216 'that may be at least partially sealed along the sides 484, 486 of the absorbent core 228. The core wrap is at least partially sealed along its front side 480, rear side 482, and two longitudinal sides 484, 486 so that there is substantially no absorbent material leaking from the absorbent core wrap. obtain. The first material, substrate, or nonwoven 216 may at least partially surround the second material, substrate, or nonwoven 216 'to form a core wrap, as shown in FIG. The first material 216 may surround a portion of the second material 216 'proximate the first and second sides 484 and 486.

  Absorbent cores, particularly when the core wrap is made from two or more substrates, for example to help immobilize the SAP in the core wrap and / or to ensure integration of the core wrap In addition, an adhesive may be included. This adhesive is, for example, H.264. B. It can be a hot melt adhesive supplied from Fuller. The core wrap may extend to a larger area than is strictly necessary to house the absorbent material therein.

  The absorbent material may be a continuous layer present in the core wrap. Alternatively, the absorbent material may consist of individual pockets or stripes of absorbent material enclosed within a core wrap. In the first case, the absorbent material may be obtained, for example, by applying a single continuous layer of absorbent material. A continuous layer of absorbent material, in particular SAP, may also be obtained by combining two absorbent layers having a discontinuous absorbent material application pattern, for example, the resulting layer is described in US Pat. As disclosed in published application 2008/0312622 A1 (Hundorf), it is distributed substantially continuously throughout the entire area of the absorbent particulate polymer material. The absorbent core 228 can include a first absorbent layer and a second absorbent layer. The first absorbent layer may include a first material 216 and a first layer 261 of absorbent material that may be 100% or less SAP. The second absorbent layer may include a second material 216 'and a second layer 262 of absorbent material that may also be 100% or less SAP. The absorbent core 228 may also include a fibrous thermoplastic adhesive material 251 that at least partially bonds each layer of absorbent material 261, 262 to the corresponding material 216 or 216 ′, respectively. By way of example, this is illustrated in FIGS. 34-35, where the first and second SAP layers are applied as transverse stripes or “land areas”, which are combined with their respective bases before being combined. It has the same width as the desired absorbent material deposition area on the material. The stripes may include different amounts of absorbent material (SAP) to provide a weighed profile along the longitudinal axis of the core 280. The first material 216 and the second material 216 'may form a core wrap.

  The fibrous thermoplastic adhesive material 251 may be at least partially in contact with the absorbent material 261, 262 in the land area and may be at least partially in contact with the material 216, 216 ′ in the joint area. . This imparts an essentially three-dimensional structure to the fibrous layer of thermoplastic adhesive material 251 that is itself a two-dimensional structure that is inherently relatively thin compared to its length and width dimensions. Is done. Thereby, the fibrous thermoplastic adhesive material can provide a cavity covering the absorbent material in the land area, thereby immobilizing this absorbent material, which may have SAP of 100% or less To do.

  The thermoplastic adhesive used in the fiber layer may have elastomeric properties so that the web formed by the fibers on the SAP layer can be stretched as the SAP swells.

Superabsorbent polymer (SAP)
SAPs useful in the present disclosure can include various water-swellable polymers that are water-insoluble but can absorb large amounts of fluid.

  The superabsorbent polymer may be in particulate form so that it is fluid in the dry state. The particulate absorbent polymer material can be formed from a poly (meth) acrylic acid polymer. However, starch-based particulate absorbent polymer materials can also be used, as well as polyacrylamide copolymers, ethylene maleic anhydride copolymers, cross-linked carboxymethyl cellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and polyacrylonitrile starch graft copolymers. Can be used.

  The SAP can be in various shapes. The term “particle” refers to granules, fibers, flakes, spheres, powders, platelets, and other shapes and forms known to those skilled in the art of superabsorbent polymer particles. The SAP particles may be in the form of fibers, ie, elongated needle-like superabsorbent polymer particles. The fibers may also be in the form of long woven filaments. The SAP may be a spherical particle. The absorbent core can include one or more SAPs.

  For most absorbent articles, liquid discharge from the wearer occurs mainly in the first half of the absorbent article, especially in the case of diapers. The front half of the article (defined as the area between the front edge and the transverse line placed at half the distance L from the front waist edge 210 or the rear waist edge 212) is therefore of the core. It may contain most of the absorption capacity. Therefore, at least 60% of the SAP, or at least 65%, 70%, 75%, 80% or 85% of the SAP is present in the first half of the absorbent article and the remaining SAP is located in the second half of the absorbent article. May be. Alternatively, the SAP distribution may be uniform throughout the core or may have other suitable distributions.

The total amount of SAP present in the absorbent core may vary depending on the assumed user. Neonatal diapers may not require SAP as much as infant, pediatric or adult incontinence diapers. The amount of SAP in the core can be about 5-60 g, or 5-50 g. The average SAP basis weight within the SAP (or “at least one” if more than one) deposit area 8 may be at least 50, 100, 200, 300, 400, 500 g / m ² or more. To calculate this average basis weight, the area of the channels present in the absorbent material deposition area 8 (eg, 226, 226 ′, 227, 227 ′) is estimated from the absorbent material deposition area.

Core wrap A core wrap may be made from a single substrate, material or nonwoven that is folded around an absorbent material, or two (or more) substrates, materials or nonwoven that are attached to each other. May be included. A typical attachment is a so-called C wrap and / or sandwich wrap. In the C wrap, for example, as shown in FIGS. 29 and 34, the longitudinal edge and / or the transverse edge of one substrate are folded on the other substrate to form a flap. These flaps are then joined to the outer surface of the other substrate, usually by glue bonding.

  The core wrap can be formed of any material suitable to receive and contain the absorbent material. Typical substrate materials used to produce conventional cores can be used, particularly paper, tissue, film, woven or non-woven, or any laminate or composite thereof.

  The substrate may also be breathable (in addition to liquid or fluid permeability). Thus, films useful herein may have fine pores.

  The core wrap may be at least partially sealed along all sides of the absorbent core such that there is substantially no absorbent material leaking from the absorbent core. By “substantially free of absorbent material” is meant that the absorbent material that leaks from the core wrap is less than 5 wt%, less than 2 wt%, less than 1 wt%, or about 0 wt%. The term “sealing” should be understood broadly. The seal need not be continuous along the entire periphery of the core wrap, but is discontinuous along part or the entire core wrap, such as formed by a series of sealing points spaced apart on the line. May be. The seal can be formed by glue bonding and / or thermal bonding.

  If the core wrap is formed by two substrates 216, 216 ', four seals may be used to encapsulate the absorbent material 260 within the core wrap. For example, the first substrate 216 may be disposed on one side of the core (shown as the top surface in FIGS. 33-35) and the longitudinal edge of the core at least partially wraps around the opposite bottom surface of the core. Extending around. The second substrate 216 ′ may be present between the wrapped flap of the first substrate 216 and the absorbent material 260. In order to provide a strong seal, the flap of the first substrate 216 may be glued to the second substrate 216 '. This so-called C-wrap structure can provide advantages such as improved burst resistance under wet loading conditions compared to sandwich seals. The front and back sides of the core wrap may then be sealed by glueing the first and second substrates together, providing complete encapsulation of the absorbent material throughout the periphery of the core Can bring For the front side and the back side of the core, the first and second substrates extend and can be joined together in a substantially planar direction so that a so-called sandwich arrangement is formed against these edges. Can be formed. In so-called sandwich constructions, the first and second substrates can also extend outwardly on all sides of the core, and are typically glued and / or heat / pressure bonded. Can be sealed flat or substantially flat along all or part of the periphery of the core. In one example, both the first and second substrates need not have a specific shape and may be cut into a rectangle for ease of manufacture, but other shapes are within the scope of the present disclosure. .

  The core wrap may also be formed by a single substrate, which may encapsulate the absorbent material as seen in a parcel wrap, and the front and back sides of the core and one longitudinal It can be sealed along the direction seal.

SAP Deposition Area As seen from the top surface of the absorbent core, the absorbent material deposition area 208 may be defined by the perimeter of the layer formed by the absorbent material 260 within the core wrap. The absorbent material deposition area 208 may have a variety of shapes, in particular the so-called “dog bone” or “hourglass” shape, with its width toward the center or “crotch” region of the core. Shown to taper along. Thus, the absorbent material deposition area 8 may have a relatively narrow width in the area of the core intended to be placed in the crotch region of the absorbent article, as shown in FIG. Thereby, a better wearing feeling can be brought about. Also, the absorbent material deposition area 8 may be generally rectangular, for example, as shown in FIGS. 31-33, but is rectangular, “T”, “Y”, “hourglass” or “dog bone” shape. Other deposition areas are within the scope of this disclosure. The absorbent material can be deposited using any suitable technique that can deposit SAP relatively quickly and relatively accurately.

Channels in the absorbent core The absorbent material deposition area 208 may include at least one channel 226 and is at least partially oriented in the longitudinal direction of the article 280 (ie, having longitudinal vector elements). Other channels may be oriented at least partially in the lateral direction (ie, having lateral vector elements) or in any other direction. In the following, when “channel” is used in a plural form, it means “at least one channel”. The channel may have a length L ′ that protrudes on the longitudinal axis 280 of the article and is at least 10% of the length L of the article. The channel can be formed in various ways. For example, the channel may be formed by a zone in the absorbent material deposition area 208 that may be substantially free of or substantially free of absorbent material, particularly SAP. In addition or alternatively, the channel may also be formed by continuously or discontinuously coupling the upper portion of the core wrap to the lower portion of the core wrap throughout the absorbent material deposition area 208. Good. The channel may be continuous, but it is also conceivable that the channel can be intermittent. The capture-distribution system or layer 250, or another layer of the article, may also include a channel, which may or may not correspond to the channel of the absorbent core.

  In some examples, the channel has at least the same longitudinal height as the crotch point C or the transverse axis 260 of the absorbent article, as shown in FIG. 28 having two channels 226, 226 ′ extending longitudinally. Can exist. The channel may also extend from the crotch region 207 or may be in the front waist region 205 and / or the back waist region 206 of the article.

  The absorbent core 228 may also include more than two channels, for example at least 3, at least 4, at least 5, or at least 6 or more channels. Shorter channels may also be present toward the front of the article, for example, in the back waist region 206 or the front waist region 205 of the core, as represented by the pair of channels 227, 227 'in FIG. The channels may include one or more pairs of channels arranged symmetrically with respect to the longitudinal axis 280 or otherwise arranged.

  Channels are particularly useful in absorbent cores when the absorbent material deposition area is rectangular, because the flexibility of the core can be increased until the channel has less advantage of using a non-rectangular (shaped) core. obtain. Of course, the channel may also be present in a layer of SAP having a deposition area having a certain shape.

  The channel may be fully oriented parallel to the longitudinal and longitudinal axes, or fully oriented parallel to the transverse and transverse axes, but may have at least a curved portion.

  In order to reduce the risk of fluid leakage, the longitudinal main channel may not extend until it reaches one of the edges of the absorbent material deposition area 208 and, for this reason, the core May be completely enclosed within the absorbent material deposition area 208. The minimum distance between the channel and the nearest edge of the absorbent material deposition area 208 may be at least 5 mm.

  The channel may have a width Wc along at least a portion of its length, for example, this width Wc is at least 2 mm, at least 3 mm, at least 4 mm, for example at most 20 mm, 16 mm or 12 mm. The width of the channel may be constant over the entire length of the channel or may vary along its length. If the channel is formed by an absorbent material-free zone in the absorbent material deposition zone 208, the width of the channel is considered to be the width of the non-material zone and there may be a core wrap in the channel. Is ignored. If the channel is not formed by an absorbent material-free zone but is formed primarily by, for example, a core wrap bond through the absorbent material zone, the width of the channel will be the width of this bond.

  At least some or all of the channels may be permanent channels, meaning that their integrity is at least partially maintained in both dry and wet conditions. . Permanent channels can be created by providing one or more adhesive materials, for example, a fibrous layer of adhesive material, or a building glue that assists in adhering the absorbent material and substrate within the walls of the channel May be obtained. Permanent channels can also bond the upper and lower portions of the core wrap (eg, first substrate 216 and second substrate 216 ′) and / or topsheet 224 to the backsheet 225 and through the channels to each other. May be formed. Typically, an adhesive may be used to join the core wrap sides or topsheet and backsheet through the channel, but other known such as pressure bonding, ultrasonic bonding, thermal bonding, or combinations thereof It can be adhered by the process. The core wrap or topsheet 224 and the backsheet 225 can be joined together along the channel or can be joined intermittently. The channel is advantageously still visible or at least visible through the topsheet and / or backsheet when the absorbent material is completely filled with fluid. This can be achieved by ensuring that the channel is substantially free of SAP so that the channel does not swell even when wet, and by making the channel sufficiently large so that the channel does not close even when wet. Furthermore, it may be advantageous to adhere the core wrap to itself via the channel or to adhere the topsheet to the backsheet via the channel.

Barrier leg cuff The absorbent article may include a pair of barrier leg cuffs 34. Each barrier leg cuff can be formed by a single material that is bonded to the absorbent article so that it can extend upward from the wearer-facing surface of the absorbent article and the wearer Improved containment of fluid and other body discharges near the torso and leg joints. The barrier leg cuff is delimited by a proximal edge 64 and a free end edge 266 that are joined directly or indirectly to the topsheet 224 and / or the backsheet 225 to contact the wearer's skin. Intended to form a seal. The barrier leg cuff 234 is at least partially present on the opposite side of the longitudinal axis 280 between the front waist edge 210 and the back waist edge 212 of the absorbent article, and at least the crotch point (C ) Or at the level of the crotch region. The barrier leg cuff may be joined to the chassis of the article at a proximal edge 264 portion by a joint 265 that may be made, for example, by a combination of glue bonding, fusion bonding, or other suitable bonding processes. The bond 265 at the proximal edge 264 may be continuous or intermittent. The joint 265 closest to the leg cuff raised section delimits the proximal edge 264 of the leg cuff rising section.

  The barrier leg cuff may be integral with the topsheet 224 or the backsheet 225 or may be a separate material joined to the chassis of the article. Each barrier leg cuff 234 may include one, two, or more elastic strings 235 proximate the free end edge 266 to provide a better seal.

  In addition to the barrier leg cuff 234, the article may comprise a gasket cuff 232 joined to the absorbent article chassis, in particular the topsheet 224 and / or the backsheet 225, and is disposed outwardly relative to the barrier leg cuff. May be. The gasket cuff 232 can provide a better seal around the wearer's thigh. Each gasket leg cuff may include one or more elastic strings or elements 233 in the absorbent article chassis between the topsheet 224 and the backsheet 225 in the area of the leg opening. All or a portion of the barrier leg cuff and / or gasket cuff may be treated with a lotion or another skin care composition.

Capture and Distribution System The absorbent article of the present disclosure may comprise a capture and distribution layer or system (“ADS”). One function of ADS is to quickly capture one or more fluids in an efficient manner and distribute it to the absorbent core. The ADS may comprise one, two, or more layers, which may form an integral layer or remain as separate layers that can be attached to each other. In one example, the ADS may comprise two layers, a distribution material 254 and a capture layer 252 disposed between the absorbent core and the topsheet, although the present disclosure is not so limited.

  In one example, the bulky three-dimensional nonwoven material of the present disclosure may comprise a topsheet and a capture layer as a laminate, or simply a topsheet, or may comprise separate capture layers. The dispensing material may also be provided on the garment facing side of the topsheet / capture layer laminate, the garment facing side of the garment layer, or the garment facing side of the carrier layer, as described below.

Carrier Layer In one example where the bulky three-dimensional nonwoven material of the present disclosure includes a laminate of a topsheet and a capture layer, or simply a capture layer, the distribution material must be supported by a carrier layer (shown in the figures below). This may include one or more nonwoven materials, cellulosic materials, and / or other materials, as described in more detail below. The material of the distribution material can be applied or placed on the carrier layer. In this way, the carrier layer may be disposed between the acquisition layer and the distribution material and may be in a face-to-face relationship with the acquisition layer and the distribution material. The carrier layer may also be disposed between the dispensing material and the surface facing the wearer of the core bag.

Distribution Material The distribution material of ADS may comprise at least 50% by weight of crosslinked cellulose fibers. The crosslinked cellulosic fibers may be crimped, twisted or curled, or a combination thereof including crimped, twisted and curled. This type of material is disclosed in US Patent Application Publication No. 2008/0312622 A1 (Hundorf). Cross-linked cellulosic fibers provide high resilience and hence high resistance to compression within the product package or to the first absorbent layer, for example under use conditions under the weight of the wearer To do. This can impart high void volume, permeability, and liquid absorption to the core, thus reducing leakage and improving dryness.

  The distribution material comprising the crosslinked cellulose fibers of the present disclosure may comprise other fibers, but this layer is advantageously at least 50%, or 60%, or 70%, or 80, based on the weight of the layer. % Or 90%, or even 100% or less of crosslinked cellulose fibers (including a crosslinking agent).

  In other examples, the dispensing material can include cellulose fibers or pulp. In some examples, the dispensing material may include at least 80%, at least 90%, at least 99%, or 100% cellulose fiber or pulp. In certain instances, such distribution materials can be formed from a single layer or multiple layers. In yet other examples, such dispensing material may include a monolayer that is folded any suitable number of times on itself. The cellulosic fiber or pulp-based distribution material can be a three-dimensional material. In yet other examples, the distribution material can be formed from any suitable distribution material.

Acquisition Layer The acquisition layer may be disposed between the distribution material 254 or carrier layer and the topsheet 224. The acquisition layer may or may not be nested with the topsheet, as described herein. If the acquisition layer is not nested with the topsheet, it can be flat or three-dimensional. The acquisition layer 252 can comprise any suitable material, such as, for example, a high elongation spunbond material.

Fastening System The absorbent article may include a fastening system. This fastening system can be used to provide lateral tension around the absorbent article to hold the absorbent article to the wearer, as is common in taped diapers. Since the waist region of the training pant article is already joined, this fastening system may not be required for these articles. Fastening systems may include fasteners such as, for example, tape tabs, hook and loop fastening elements, engaging fasteners such as tabs and slots, buckles, buttons, snaps, and / or hermaphroditic fastening elements, but others Any suitable fastening mechanism is within the scope of this disclosure. Typically, the landing zone 244 is provided on the garment facing surface of the front waist region 205 so that fasteners can be removably attached.

Front Ear and Rear Ear The absorbent article may include a front ear 246 and a rear ear 240. The ears may be an integral part of the chassis, such as formed from a topsheet 224 and / or a backsheet 226 as a side panel. Alternatively, as shown in FIG. 28, the ears may be separable elements that are attached by glue bonding, hot embossing and / or pressure bonding. The rear ear 240 may be extensible so that the tab 242 can be easily attached to the landing zone 244 and the taped diaper can be maintained in place around the wearer's waist. Also, the rear ear 240 initially fits the absorbent article to fit the wearer, and such elastic ears can expand and contract the side of the absorbent article, To provide a more comfortable and wrap-around fit by maintaining this fit while worn considerably after the absorbent article contains fluid or other body discharge Furthermore, it may be elastic or extensible.

Elastic waist feature The absorbent article 220 may also include at least one elastic waist feature (not shown) that helps to provide improved fit and containment. The elastic waist mechanism is generally intended to elastically expand and contract to dynamically fit the wearer's waist. The elastic waist feature may extend at least longitudinally outward from at least one waist edge of the absorbent core 228 and generally forms at least a portion of the distal edge of the absorbent article. The disposable diaper may be configured to have two elastic waist features, one being located in the front waist region and the other being located in the rear waist region.

Channels in layers other than the absorbent core Various channels in the absorbent core have been described above, such as 226, 226 ', for example. In order to achieve fluid distribution along the length of the absorbent article and / or such consumer impression, the present disclosure includes a core bag in addition to one or more channels in the absorbent core. One or more channels are provided in one or more other layers between the acquisition layer. That is, in some examples, these one or more additional channels are provided in the distribution material, carrier layer, and / or any other suitable layer between the absorbent core and the acquisition layer. Can be done. In some examples, if the acquisition layer is not formed in a laminate with the topsheet and is generally flat, the channel can also be formed in the acquisition layer. In one such example, the topsheet can include the three-dimensional material of the present disclosure. In this example, the acquisition layer may be disposed between the topsheet and the absorbent core, or may have other layers between itself and the absorbent core.

  36-43 and 45-52, the protrusion 250 extends toward the absorbent core 228, while in FIG. 44, the protrusion 250 extends away from the absorbent core. The present disclosure includes a form in which the protrusion extends away from the absorbent core and toward the absorbent core.

  FIG. 36 shows an example absorbent article 320. Absorbent article 320 includes a longitudinal axis 380 and a transverse axis 390. Absorbent core channels 226 and 226 ′ are defined in absorbent material 308 of absorbent core 228. The absorbent material 308 is encapsulated in a core bag 360 having two layers, namely nonwoven layers 316 and 316 '. The two nonwoven layers 316 and 316 'may form a C wrap around the absorbent material 308 or otherwise encapsulate the absorbent material. The absorbent article 320 may comprise a dispensing material 254. The absorbent article also includes a topsheet 224 and acquisition layer 252 nested together to form a three-dimensional topsheet / capture layer laminate 245 as described in more detail herein. Can do. The three-dimensional topsheet / capture layer stack may include a plurality of protrusions 250. The absorbent article 320 may also include a backsheet 225. Other features of the absorbent article 320 (eg, fastening systems) may be the same or similar to those described herein and, therefore, are not repeated here for the sake of brevity.

  FIG. 37 shows a cross-sectional view of the absorbent article along line 37-37 in FIG. As can be seen, the laminate of the exemplary absorbent article 320 consists of the nested topsheet / capture layer in order from the wearer facing surface ("WFS") to the garment facing surface ("GFS"). Laminate 245, distribution material or layer 254, absorbent core 228 (core bag 360), and backsheet 225. An outer cover nonwoven material can also be provided to the GFS to cover the backsheet.

  FIG. 38 shows a cross-sectional view of FIG. 37 with the absorbent core 228 at least partially filled with fluid.

  FIG. 39 shows a cross-sectional view of another example absorbent article 320 '. As can be seen, the dispensing material 254 may include one or more channels 326 and 326 '. Any suitable number of channels, such as one, two, three, or more channels, can be provided in the distribution material 254. This distribution material 254 may comprise air felt or any other suitable material, for example a distribution material as described above. Channels 326 and 326 'may have any suitable size, shape, and / or orientation. Channels 326 and 326 'in distribution material 254 may or may not overlap with channels 226 and 226' in absorbent core 228 in the Z direction. If channels 326 and 326 'and channels 226 and 226' overlap in the Z direction, they may overlap partially or completely. For example, channels 326 and 326 'may be shorter in width or length than channels 226 or 226' and vice versa. In one example, only one of channels 326 and 326 'may or may not overlap at least partially in the Z direction with only one of channels 226 and 226'.

  40 shows a cross-sectional view of the absorbent article 320 'of FIG. 39 with the absorbent core 228 at least partially filled with fluid.

  FIG. 41 shows a cross-sectional view of another example absorbent article 320 ″. Distribution material 254 may include channels 326 and 326 'that may be the same as or similar to the distribution material channels described above with respect to FIG. However, in this example, an optional carrier layer 325 can be provided. The carrier layer 325 may also include one or more channels 327 and 327 '. The carrier layer 325 may comprise a nonwoven material, cellulosic fiber or pulp-based material, and / or any other suitable material. Where the carrier layer 325 includes cellulosic fiber or pulp-based material, it can include at least 80%, at least 90%, at least 99%, or 100% by weight cellulosic fiber or pulp-based material. The carrier layer 325 may comprise a three-dimensional material comprising at least 80%, at least 90%, at least 99%, or 100% by weight cellulose fibers or pulp. In one example, the three-dimensional material of the carrier layer 325 can be a material with different basis weights and different densities. The carrier layer 325 may be optional in some absorbent article forms. For example, the carrier layer may be undesirable, for example when the acquisition layer 252 is generally flat. In some examples, the dispensing material 254 is attached to a three-dimensional garment-facing surface of a three-dimensional material, whether it is a capture layer 252 or a topsheet / capture layer stack. May be difficult. In such cases, carrier layer 325 can be used to provide a bonding surface for the dispensing material.

  Any suitable number of channels, such as one, two, three, or more channels, can be provided in the carrier layer 325. Channels 327 and 327 'may or may not overlap in the Z direction with channels 326 and 326' in distribution material 254 and / or channels 226 and 226 'in absorbent core 228. If any of channels 327 and 327 ', 326 and 326', and 226 and 226 'overlap in the Z direction, they may overlap partially or completely. For example, channel 327327 'may be shorter in width or length than channels 326 and 326' and / or channel 226 or 226 'and vice versa. Some or all of the channels in the various layers may or may not overlap at least partially in the Z direction. In another example, at least one channel in one layer (eg, distribution material 254) may overlap at least one channel in another layer (eg, absorbent core 228) in the Z direction. , At least one other channel in the one layer (eg, distribution material 254) may not overlap with at least one channel in the other layer (eg, absorbent core 228) in the Z direction. .

  FIG. 42 shows a cross-sectional view of an example of an absorbent article 420 with the same channel configuration as the absorbent article 320 ′ of FIG. 39 except that the carrier sheet 325 and a topsheet comprising a generally flat or planar material. 224. The acquisition layer 252 includes a three-dimensional nonwoven material in this example.

  FIG. 43 shows a cross-sectional view of an example of an absorbent article 420 ′ with the same channel configuration as the absorbent article 320 ′ of FIG. 39 except that it includes a carrier layer 325 and a generally flat or planar material. Layer 252. The topsheet 224 includes a three-dimensional nonwoven material in this example.

  FIG. 44 shows a cross-sectional view of an example of an absorbent article 420 ″ with the same channel configuration as the absorbent article 320 ′ of FIG. 39, except that the protrusion 250 of the three-dimensional nonwoven material 245 has an absorbent core. Extending outward from 228.

  FIG. 45 shows a plan view of an absorbent article 520 having a longitudinal axis 580 and a transverse axis 590. The absorbent article 520 may include one or more channels 226 and 226 'in the absorbent material 308 of the absorbent core 228 and one or more channels 326 and 326' in the distribution material 254. Also, although not shown in FIG. 45, a carrier layer may be provided between the acquisition layer 252 and the distribution material 254. The carrier layer can include one or more channels (eg, channels 327 and 327 'in FIG. 41). The three-dimensional nonwoven material 245, the topsheet 224, and / or the acquisition layer 252 can include one or more designs 546 and 546 '. Designs 546 and 546 'are merely examples of some suitable designs. Other designs having different shapes, sizes, and / or orientations are within the scope of this disclosure. In one example, one design may be the same as or different from the other design. Any suitable number of designs can be provided. The design can vary in color, size, shape, orientation, or other visual aspects. In general, the design should be visible from the wearer facing surface of the absorbent article 520. In one example, the protrusions 250 may be present only in the area of the absorbent article 520 corresponding to the capture layer 252, for example, and may be present only in an area smaller than the capture layer 252. In such an example, the protrusion 250 may not extend completely over the length of the absorbent article 520 and may not extend completely over the width of the absorbent article 520.

  In some forms, the design may include structural differences in, for example, ink or material. The ink can include, for example, a pigment that is visually distinguishable from the topsheet and / or the remainder of the capture material. The ink can be printed, applied, or formed on any surface of the topsheet 224 or any surface of the acquisition layer 252. The structural differences in the material can be, for example, embossing, or different sizes, shapes, and / or orientations of the protrusions 250. Structural differences should be visible from the wearer-facing surface. The structural difference may be an area without protrusions.

  In some examples, for example, one or more specific designs may be in the topsheet 224 and one or more other specific designs may be in the acquisition layer.

  Designs 546 and 546 'may be elongate and may or may not partially or completely overlap the channels in any layer.

  46 shows a cross-sectional view of the absorbent article 520 along line 46-46 of FIG. In the example shown in FIG. 46, designs 546 and 546 ′ include non-nested compressed areas within three-dimensional nonwoven material 245. In some examples, the design can be a compressed or non-nested area in the topsheet 224 and / or the acquisition layer 252 (eg, FIG. 48). In any case, the design 546 and 546 ′ in this example, or other design, includes channels 226 and 226 ′ in the absorbent core 228, channels 326 and 326 ′ in the distribution material 254, and / or in the carrier layer. Channels 327 and 327 ′ (if provided) may both be fully overlapped, at least partially overlap, or have no overlap in the Z direction. In some examples, designs 546 and 546 ′ are shorter, longer, wider, narrower or different than any of channels 226, 226 ′, 326, 326 ′, 327, and / or 327 ′. You may have a shape. Designs 546 and 546 'may include a color that is different from the rest of the material they are part of, applied to, and / or printed on.

  47 shows a cross-sectional view of the absorbent article 520 'of FIG. 46 with the absorbent core 228 at least partially filled with fluid.

  48 is a cross-sectional view of another example of the absorbent article 520 of FIG. 45 taken along line 48-48. The example of FIG. 48 includes the same channel configuration as the example of FIG. 46 and has designs 546 ″ and 546 ″ ″. Designs 546 ″ and 546 ″ ″ are areas within the three-dimensional material that do not include, or at least substantially exclude, the three-dimensional protrusion 250. In other words, designs 546 "and 546" "are non-nested areas or are substantially non-nested areas.

  FIG. 49 shows a schematic view of a three-dimensional material 245 for a person looking at the wearer-facing surface. The three-dimensional material 245 includes one or more designs 546 ″ and 546 ″ ″ formed in an area that does not include the protrusions 250. In some examples, the designs 546 ″ and 546 ′ ″ have an ink, adhesive, or other material that has a different color than the rest of the topsheet 224 and / or the rest of the acquisition layer 252. Can be included. The protrusion 250 of the three-dimensional material 245 may face the side within the page, may face the side outside the page, or may face the side inside or outside the page. If the designs 546 ″ and 546 ′ ″ include ink, adhesive, or other material that has a different color than the rest of the topsheet 224 and / or the rest of the acquisition layer 252, the ink Adhesives or other materials can be applied to the protruding or non-protruding areas, for example.

  FIG. 50 shows a schematic view of the three-dimensional material 245 for a person looking at the wearer-facing surface. The three-dimensional material 245 can include one or more designs 547 and 547 'that can be at least partially formed by the first pattern of protrusions 250'. The protrusions 250 ′ can have the same or different size, shape, and / or orientation compared to other protrusions 250 of the three-dimensional material 245. The protrusion 250 ′ may be smaller or larger than the protrusion 250. The protrusions 250 'may be the same or different in one or more of the designs. The protrusion 250 'may be continuous or discontinuous.

  In one form, the designs 547 and 547 ′ may include a first plurality of protrusions 250 ′ and the remaining portion of the three-dimensional nonwoven material 245 may include a second plurality of protrusions 250. The first plurality of protrusions 250 ′ may be the same as or different from the second plurality of protrusions 250. Designs 547 and 547 'may also include areas of three-dimensional nonwoven material 245 that do not include any protrusions. Both protrusions 250 and 250 'may face the side in the page, face the outside side of the page, or face the side and the outside side of the page.

  FIG. 51 is a cross-sectional view of an example absorbent article 620 having a specific channel configuration that does not overlap in the Z direction. The dispensing material 254 may have one or more channels 326 and 326 '. The absorbent core 228 can have one or more channels 226 and 226 '. Channels 326 and 326 'may not overlap with channels 226 and 226' in the Z direction.

  FIG. 52 is a cross-sectional view of an example absorbent article 720 having a specific channel configuration that does not overlap in the Z direction. The dispensing material 254 may have one or more channels 326 and 326 '. The absorbent core 228 can have one or more channels 226 and 226 '. The carrier layer 325 may have one or more channels 327 and 327 '. Channels 326 and 326 'may not overlap with channels 226 and 226' and channels 327 and 327 'in the Z direction. In other examples, the channels may all at least partially overlap each other in the Z direction, but may not completely overlap in the Z direction.

Display and / or Color FIG. 52 is referenced in this section to illustrate the construction of an example absorbent article that may include a display and / or color, except for the example shown herein. Any configuration of absorbent article is within the scope of this disclosure. For example, the carrier layer 325 may or may not be provided, or the carrier layer 325 may be provided under the distribution material 254. In another example, carrier layer 325 and distribution material 254 may or may not be provided. In other examples, the topsheet 224 or acquisition layer 254 can be generally planar or flat, as shown in previous figures. The carrier layer 325 may or may not have channels 327 and 327 ′. Further, the dispensing material 254 may or may not have channels 326 and 326 ′. Further, the absorbent core 228 may or may not have channels 226 and 226 ′. Channels 327 and 327 ′, 226 and 226 ′, and 326 and 326 ′ (if provided) may all overlap at least partially with each other in the Z direction, and may not overlap each other in the Z direction, and / or Alternatively, they may completely overlap each other in the Z direction. In some examples, the first channel set (eg, 226 and 226 ′) may overlap the second channel set (eg, 326 and 326 ′) in the Z direction, while the third channel set (eg, 327), for example. And 327 ′) may not overlap any of the first and second channel sets. The core bag 360 may have the configuration shown in FIGS. 52, 48, or any other suitable configuration.

  The term “indicator” as used herein refers to, for example, one or more inks with pigments, adhesives with pigments, words, designs, trademarks, figures, patterns, and / or colorings. May include areas. The display is not simply a fully colored or dyed layer, for example a capture layer. The display can typically: (1) be a different color from the layer on which it is printed, placed, or applied, or (2) be a different color from the other layers of the absorbent article. The expression “different colors” means different shades of the same color (eg, dark blue and light blue) or may be completely different colors (eg, blue and gray). The display part should be at least partially visible from the surface facing the wearer of the absorbent article, the surface facing the garment, or both, provided that the display part is absorbent article It may not be printed, arranged, or applied to the wearer's or clothing-facing surface. The indicator can be printed, arranged, or applied to, for example, the protruding and non-projecting areas, only the protruding areas, or only the non-projecting areas. The display unit is made of a photoactivatable material, a liquid activatable material, a pH activatable material, a temperature activatable material, a menstrual blood activatable material, a urine activatable material, a stool activator. Possible materials and / or other activatable materials. These activatable materials typically undergo a chemical reaction or other reaction to visually distinguish or be within an absorbent article from one color to a different color, from one color to a different darkness of the same color. From an indistinguishable color to a color that is visually distinguishable or distinguishable in the absorbent article, or from a color that is visually distinguishable or distinguishable in the absorbent article to a color that is not visually distinguishable or distinguishable in the absorbent article The display portion can be changed. In one example, the display unit may enlarge or reduce or display the diagram after the display unit has reacted, or may or may not display the diagram. In other examples, the display can be activated by stress or strain during manufacture or wear. The display unit may be white or non-white. If the display is white, at least one layer may be non-white, so that, for example, the display is visible from the surface facing the wearer and / or clothing of the absorbent article. The display may include embossing, melt bonding, or other mechanical deformation. In other examples, the display may at least partially overlap with embossing, melt bonding, or other mechanical deformation. In some examples, the indicator may be formed in either a bicomponent fiber sheath or core. For example, the core may be white while the sheath may be blue or vice versa.

  The display may be on a particular layer, may be disposed on, may be formed thereon, may be formed together, may be printed, or may be applied in whole or in part. . The indicator may also be in one or more layers of the absorbent article, or all suitable layers, arranged, formed thereon, formed together, printed Or may be applied. The indicator may also be on, disposed on, formed on, or formed together on either or both sides of one or more layers of the absorbent article, It may be printed or applied. In some examples, suitable layers for display placement are: topsheet, secondary topsheet, capture material, dispensing material, carrier layer, core bag, core bag wearer facing side, core bag One or more of additional layers disposed at least partially between the garment facing side and / or the topsheet and the core bag wearer facing side (hereinafter, Sometimes called “suitable layer for display placement”).

  In addition to the display unit described above or separately from the display unit described above, a suitable layer for arranging any one or a plurality of display units, or a part thereof is a remaining layer for display unit arrangement. May have a different color from one or more of, or a portion thereof. The definition of the expression “different colors” above also applies to this part of the disclosure. In some examples, the display may have a different color than a suitable layer for any one or more display arrangements. Alternatively, the display is on one of the preferred layers for display placement, while another one of the preferred layers for the remaining display placement is a different color than the display. It can be. An example is where the blue display is on the white carrier layer and the acquisition layer or topsheet is blue-green. In another example, the blue display is on a white carrier layer and the acquisition layer and topsheet are also white. In this way, the blue display can be visible from the surface facing the wearer. In another example, the blue display may be on the acquisition layer, while the topsheet and the acquisition layer are nested together within the protrusion 250. In one example where the topsheet and acquisition layer are nested together within the protrusion 250, the indicator can be applied to the acquisition layer or topsheet before or after such nesting. As an example, two different display units can be arranged in the same layer or different layers for display unit arrangement. The two different display portions may be different in color, pattern, and / or figure, for example. If the two different displays are on different layers for display placement, the two layers may be the same color or different colors, or the same color or different color parts You may have.

  In some examples, as described in detail in US Pat. No. 8,936,584, a portion or the entire visible color inside the absorbent article (the surface facing the wearer) It may be harmonized and / or complemented with a visible color on a part or the entire exterior (clothing-facing surface) of the article. The display part visible from the inside can be in harmony with and / or complement the display part visible from the outside of the absorbent article. In such an example, the display part visible from the outside of the absorbent article may be on the outer cover nonwoven fabric or the back sheet film. In yet another example, the display and / or color visible from the inside may also match and / or complement the display and / or color visible from the outside of the absorbent article.

  In addition to the above, one first portion of a suitable layer for display arrangement may be a first color, and a second portion of the same suitable layer for display arrangement is a second color. Can be color. The first and second colors may be different colors. In another example, one first portion of a suitable layer for display arrangement may be a first color and another second portion of a suitable layer for display arrangement is a second color. It can be. The first and second colors may be different colors.

  In one example, in the absorbent article, one of the topsheet, capture material, part of the core bag, or additional layer (eg, carrier layer) is the topsheet, capture material, part of the core bag, or additional It can be a different color than another one of the layers. In another example, in an absorbent article, one of a portion of a topsheet, a portion of a capture material, a portion of a core bag, or a portion of an additional layer is a portion of the topsheet, a portion of the capture material, a core bag. Or a different color from another one of the additional layer portions. In another example, in an absorbent article, the first portion of one of the topsheet, capture material, core bag, or additional layer is the same as the topsheet, capture material, core bag, or additional layer. The color may be different from the second part.

Cellulose fibers in suitable layers for some display arrangements In certain instances, it may be desirable to use a carrier layer 325 or distribution material 254 comprising cellulose fibers or pulp. In some examples, the carrier layer 325 or distribution material 254 comprises at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt% or more cellulose fibers for each layer or material. May be included. The carrier layer or distribution material may comprise one or more layers comprising cellulose fibers. This layer may be an individual layer or a single layer folded any number of times on itself. The carrier layer comprising cellulosic fibers can be generally flat or, in some examples, can be three dimensional. The distribution material 254 may include one or more generally flat or three-dimensional layers comprising cellulose fibers. A three-dimensional layer containing these cellulose fibers can be wet-formed using a papermaking process. Referring to FIGS. 53 and 54, an example three-dimensional material or layer 720 is shown. 53 is a plan view of the three-dimensional layer 721, and FIG. 54 is a cross-sectional view of the three-dimensional layer 721 along the line 54-54 in FIG. The three-dimensional layer 721 can include a continuous network region 722 and a plurality of separate zones 724. The continuous mesh region 722 may include a first average density, and each of the plurality of separated zones 724 may include a second average density. The plurality of separated zones 724 may be distributed throughout the continuous network region 722. The first and second average densities may be different. The three-dimensional layer (s) 721 can also include a wet strong resin.

  The continuous mesh region 722 and the plurality of separated zones 724 may have a common strength. The common strength of the continuous mesh region 722 may have a first value. The common strength of the plurality of separated zones 724 may have a second value. The first value may be different from the second value. This common strength can be, for example, basis weight, thickness, opacity, average density, or height. Such three-dimensional materials are all in the context of distribution materials, U.S. Patent Application Nos. 14 / 543,967 (P & G Case No. 13605Q), 14 / 543,973, filed November 18, 2014. No. (P & G case number 13606Q) and 14 / 543,984 (P & G case number 13607Q), which can also be used in the context of the carrier layer. These cellulose fiber-containing layers, whether three-dimensional or not, can be colored as described herein or can include a display.

Adhesive and Colored Layers In some instances, for example, having a layer, such as carrier layer 325, for example under the acquisition layer / topsheet laminate (as described herein), in this case carrier layer 325 However, it may be desirable to have a different color than the acquisition layer / topsheet laminate. For example, the laminate may be white and the carrier layer may be blue. In one such example, when the acquisition layer / topsheet laminate is combined (as described herein), zones of different opacity and density are present in the laminate. Thus, the color of the carrier layer is more visible when viewed from the wearer-facing surface in various zones of the laminate, with laminates having high and low density, and high and low opacity zones. May be more or less visible. In one example where an adhesive or perforated layer having a first color is disposed over a layer having a second different color, the second different color of the layer is compared to the rest of the layer, Visibility may be higher or lower in adhesion or holes. In other examples, the laminate and carrier layer can be different shades of the same color to enhance the impression of the depth of the laminate when viewed from the surface facing the wearer of the absorbent article. If a single three-dimensional nonwoven material is used as the topsheet or capture material, the same may be true for these as described above for the different color layers.

Display Unit The three-dimensional nonwoven material of the present disclosure may have a plurality of different patterns. At least some of these patterns may exhibit protrusions (eg, such as protrusions 250 described herein), and other portions may exhibit embossed or printed areas. Some exemplary patterns 601 are shown in FIGS. 55, 58, 60, 63, 65, 68, 70, and 72. These figures may represent patterns in the topsheet, acquisition layer, or topsheet / capture layer stack. These patterns 601 of the three-dimensional nonwoven material can be combined with a lower layer including a display such as a colored adhesive or ink. Some example display patterns 701 are shown in FIGS. 56, 59, 61, 64, 66, 69, 71 and 73. These figures can represent the acquisition layer, the carrier layer, or another layer between the topsheet and the absorbent core. 55, 58, 60, 63, 65, 68, 70, and 72 have the same pattern as any one of the display portion patterns 701 of FIGS. 56, 59, 61, 64, 66, 69, 71, and 73, and Z. It may overlap in the direction or at least partially overlap. An example of the overlap of the pattern 601 in FIG. 55 and the display portion pattern 701 in FIG. 56 is shown in FIG. An example of the overlap of the pattern 601 in FIG. 60 and the display portion pattern 701 in FIG. 61 is shown in FIG. An example of overlapping of the pattern 601 in FIG. 65 and the display portion pattern 701 in FIG. 66 is shown in FIG. 58 and 59, 63 and 64, 68 and 69, 70 and 71, and 72 and 73, any one of the pattern 601 and the display portion pattern 701 can be overlapped in the same or similar manner. Also, any of the patterns 601 in FIGS. 55, 58, 60, 63, 65, 68, 70, and 72 is the display unit pattern in FIGS. 56, 59, 61, 64, 66, 69, 71, and 73. Overlapping with any one of 701 is possible.

  As can be seen from FIGS. 57, 62 and 67, the overlapping pattern 601 and the display pattern 701 form an aesthetically pleasing part of the absorbent article structure, which is (1) a three-dimensional topsheet, A dimension capture layer, or a laminate of a three-dimensional topsheet / capture layer; (2) an impression of depth; (3) a soft impression or softness; and (4) an absorbent impression or absorptivity ( 5) Provide the impression that the body discharge is contained and (6) the impression that the body discharge does not remain in contact with the skin. All of these factors are favorable for consumers.

  In addition to the patterns and display part patterns shown in FIGS. 55-73, the absorbent article may be such that any or part of the layers of the absorbent article further enhances the aesthetically pleasing appearance of the absorbent article. May have a different color than the other layers.

  The size of the display unit pattern 701 may be larger, smaller, or the same as the pattern 601 depending on the desired appearance of the overlapping pattern 601 and the display unit pattern 701.

ΔE ^*
Absorbent articles of the present disclosure can have, for example, greater than about 1, greater than about 1.5, greater than about 2, greater than about 2.5, greater than about 3, greater than about 3.5, greater than about 3.5, according to the ΔE ^* test herein. Greater than 5, greater than about 10, greater than about 12, greater than about 15, greater than about 20, greater than about 25, or in the range of about 1 to about 400, in the range of about 1 to about 350, in the range of about 1 to about 300, about 1 To about 250, about 1 to about 200, about 1 to about 150, about 1 to about 125, about 1 to about 100, about 1 to about 75, about 1 to about 50 range, about 1 to about 40 range, about 1 to about 30 range, about 1 to about 25 range, about 1 to about 20 range, about 1 to about 15 range, about 1 to about 12 The range may have a ΔE ^* in the range of about 2 to about 10. All 0.1 increments associated with the ranges listed above, and all ranges formed within or by them, are also specifically disclosed and described herein, but for the sake of brevity, Enumeration is not performed.

Sanitary Napkins The three-dimensional nonwoven material of the present disclosure can form part of a sanitary napkin, for example, part or whole of a topsheet, part or whole of a capture layer (or secondary topsheet), or top A portion or all of the nesting can be formed by combining the sheet and the acquisition layer (or secondary topsheet). In another example, the three-dimensional nonwoven material may form a strip or patch that is disposed on a sanitary napkin topsheet.

  An example sanitary napkin 800 is disclosed in FIG. The sanitary napkin 800 may include a liquid permeable topsheet 814, a liquid impermeable or substantially liquid impermeable backsheet 816, and an absorbent core 818. Absorbent core 818 may have any or all of the features described herein with respect to absorbent core 228, including one or more channels. Acquisition layer 815 may have any or all of the features described herein with respect to acquisition layer 252, including one or more channels. A carrier layer (such as carrier layer 325 herein) and a distribution material (such as distribution material 254 herein) may also be provided as desired, including one or more channels in each layer. The sanitary napkin 800 may also include a vane 820 that extends outwardly relative to the longitudinal axis 880 of the sanitary napkin 800. The sanitary napkin 800 can also have a transverse axis 890. The blade 820 may be bonded to the top sheet 814, the back sheet 816, and / or the absorbent core 818. The sanitary napkin 800 also includes a leading edge 822, a trailing edge 824 that is longitudinally opposed to the leading edge 822, a first side edge 826, and a first edge 826 that is longitudinally opposed to the first edge 826. Two side edges 828. The longitudinal axis 880 can extend from the midpoint of the leading edge 822 to the midpoint of the trailing edge 824. The transverse axis 890 can extend from the midpoint of the first side edge 826 to the midpoint of the second side edge 828. The sanitary napkin 800 may also include additional features commonly found in sanitary napkins, as is well known in the art.

Spunbond Web In the case of a spunbond web, the web may have a hot spot adhesion pattern that is difficult to see with the naked eye. For example, a dense hot spot adhesion pattern with equal and even spacing is usually difficult to see with the naked eye. Even after processing the web by fitting male and female rolls, the hot spot bonding pattern may still be difficult to see with the naked eye. Alternatively, the web may have a hot spot adhesion pattern that is easily visible with the naked eye. For example, hot spot adhesion placed in a macro pattern (eg, a diamond pattern) can be easily visible with the naked eye. Even after processing the web by mating male and female rolls, this hot spot bonding pattern may still be readily visible to the naked eye and provide a secondary visual texture element to the web.

Fiber Density In one example, the topsheet can include a generally flat first region of the topsheet. The capture material can include a generally flat first region of the capture material. Each topsheet and capture material three-dimensional protrusion may include a plurality of separate integral second regions. The term “generally flat” does not imply any particular flatness, smoothness or dimensionality. Thus, the first region of the topsheet may include other features that provide the first region of the topsheet with topography. The first region of capture material may include other features that provide the first region of capture material with topography. Such other features may include, but are not limited to, a small protrusion, a raised mesh area around the base that forms the opening, and other types of features. Thus, the first region of the topsheet and / or the first region of the capture material can be generally flat when compared to the respective second region. The first region of the topsheet and / or the first region of the capture material can include any suitable top view configuration. In some examples, the first region of the topsheet and / or the first region of the capture material may be in the form of a continuously interconnected network, which is each of the three-dimensional protrusions or one Including the part surrounding the part.

  The side wall of the three-dimensional protrusion and the area surrounding most of the base of the three-dimensional protrusion are compared to the topsheet and / or the portion of the capture material in the unformed first region of the respective topsheet and capture material. Per a given area, it can have a clearly lower fiber density by sight (this may be evidence of lower basis weight or lower opacity). Also, most of the three-dimensional protrusions can have fibers that are narrowed at the sidewalls. Thus, the fibers can have a first cross-sectional area when in the undeformed topsheet and capture material and a second cross-sectional area at the majority of the sidewalls of the three-dimensional protrusion of the topsheet / capture material laminate, This first cross-sectional area is larger than the second cross-sectional area. The sidewall may also include a number of broken fibers. In some examples, the sidewalls can include about 10%, about 20%, about 30% or more, or about 50% or more of broken fibers.

  As used herein, the term “fiber density” has a similar meaning to basis weight, but basis weight is g per area, whereas fiber density is the number of fibers per given area. Point to.

  The topsheet / capture material laminate may include most of the three-dimensional protrusions, which are base-up, and the fiber density at the distal end of each respective topsheet and capture material is determined by the topsheet. And the capture material is different.

  The fiber density in the first region of the capture material and at the most distal end of the three-dimensional protrusion may be greater than the fiber density at the most sidewall of the three-dimensional protrusion of the capture material.

  The fiber density in the first region of the topsheet and at the most distal end of the three-dimensional protrusion may be greater than the fiber density at the most sidewall of the three-dimensional protrusion of the topsheet.

  Alternatively, the fiber density in the first region of the capture material may be greater than the fiber density in most of the sidewalls of the three-dimensional protrusion of the capture material, and the fiber density in most of the sidewalls of the capture material's three-dimensional protrusion It may be greater than the fiber density that forms the distal end of most of the three dimensional protrusions of the material.

  The fiber density in the first region of the capture material may be greater than the fiber density at the most distal end of the three-dimensional protrusion of the capture material, and in the first region of the topsheet and most of the three-dimensional protrusion. The fiber density at the top end may be greater than the fiber density at most side walls of the three-dimensional protrusion of the topsheet.

  A portion of the fibers forming the first region fibers in the capture material and / or topsheet may include hot spot bonding and the capture material and / or topsheet forming the majority sidewall and distal end of the three-dimensional protrusion. A portion of the fibers in may be substantially free of hot spot adhesion. In at least some of the three-dimensional protrusions, at least some of the fibers in the capture material and / or the topsheet surround the periphery of the three-dimensional protrusion at the transition between the side wall and the base of the three-dimensional protrusion. Nests or rings can be formed.

  In some examples, the topsheet or capture material may have multiple bonds (eg, hot spot bonds) inside to hold the fibers together. Any such adhesion is typically present in the precursor material or web to form the respective topsheet or capture material.

  Forming a three-dimensional protrusion in the topsheet / capture material stack may also affect adhesion (hot spot adhesion) within the topsheet and / or capture material.

  Adhesion within the distal end of the three-dimensional protrusion can remain intact (uninhibited) even by the mechanical deformation process that forms the three-dimensional protrusion. However, at the side walls of the three-dimensional protrusion, the adhesion originally present in the precursor topsheet web and / or the precursor capture material web can be inhibited. When adhesion can be inhibited, this can take several forms. The bond can be broken, leaving a bond residue. In other instances, such as when the precursor material of each topsheet web or capture material web is inadequate adhesion, the fibers are unwound from the lightly formed adhesion site (just like unwinding the ribbon). , The adhesion site can essentially disappear. In some examples, after the mechanical deformation process, most of the sidewalls of the three-dimensional protrusion may be substantially free (or completely free) of hot spot adhesion.

  The adhesion within the first region of the topsheet and within the distal end of the three-dimensional protrusion can remain intact. However, at the sidewalls of the three-dimensional protrusion, the adhesion originally present in the precursor topsheet web can be inhibited, whereby the sidewall is substantially free of hot spot adhesion. Such a topsheet can be combined with a capture material, where the fiber density in the first region of the topsheet and in the distal end of the three-dimensional protrusion is also the fiber density in the sidewall of the three-dimensional protrusion. Bigger than.

  The capture material may have a hot spot adhesion in the first region of the capture material and in the distal end of the three-dimensional protrusion, which remains intact. However, on the sidewalls of the three-dimensional protrusion, the adhesion originally present in the precursor capture material web containing the capture material can be inhibited, whereby the capture layer sidewalls are substantially free of hot spot adhesion.

Package An absorbent article of the present disclosure comprising a three-dimensional nonwoven material and a particular channel configuration can be placed in a package. The package may include a polymer film and / or other materials. A graphic and / or display relating to the properties of the absorbent article can be formed, printed, placed and / or placed on the outer portion of the package. Each package may include a plurality of absorbent articles. The absorbent article may be packaged under compression, thereby reducing the size of the package and at the same time providing an appropriate quantity of absorbent article per package. By packaging the absorbent article under compression, the caregiver can easily handle and store the package, while the size of the package can provide the manufacturer with distribution cost savings.

  Accordingly, the package of absorbent articles of the present disclosure is less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 85 mm according to the in-bag stack height test described herein, It may have an in-bag stack height that is greater than about 75 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm, or less than about 74 mm, in particular all within and within or within a predetermined range. Can be enumerated in 0.1 mm increments. Alternatively, the package of absorbent articles of the present disclosure is about 70 mm to about 100 mm, about 70 mm to about 95 mm, about 72 mm to about 85 mm, about 72 mm to about 80 mm, according to the in-bag stack height test described herein. Or in-bag stack heights of about 74 mm to about 78 mm, and in particular, all in 0.1 mm increments within a predetermined range and within all ranges formed therein or thereby.

  FIG. 75 shows an example package 1000 that includes a plurality of absorbent articles 1004. The package 1000 defines an internal space 1002 in which a plurality of absorbent articles 1004 are disposed. The plurality of absorbent articles 1004 are arranged in one or more stacks 1006.

Comparative Example 1
In Comparative Example 1, the material was applied in a spiral pattern at an add-on level of 1 gsm. B. A composite material in which two materials are bonded using a D3166ZP hot melt adhesive from Fuller (St. Paul, Minnesota, USA). This composite material is 7.6 meters per minute (25 feet per minute (fpm)) and DOE 3.43 mm (0.135 ") as described in US Pat. No. 7,410,683 B2 (Curro et al.). The material layer in contact with the SELF roll is manufactured by Fitesa (Simpsonville, SC, USA), which is processed through a nip formed by one of the SELF roll and ring roll of the Procter & Gamble Company. Such a material is described in Fitesa US Patent Application No. 14 / 206,699, entitled “Extensible Nonwoven Fabric” and includes a blend of PP and PE fibers. Made of 5 denier fiber. The material layer in contact with the ring roll is a 43 gsm spunbond nonwoven manufactured by Reicofil (Troisdorf, Germany) and consists of 7 denier co-PET / PET tip trilobal bicomponent fibers.

Example 1. Single Layer In Example 1, the material is a 50 gram / m ² (gsm) PE / PP sheath / core bicomponent spunbond nonwoven obtained from Fitesa. This is passed through a male / female mold (former) with an engagement (DOE) of 7.6 meters (25 fpm) per minute and a depth of 3.94 mm (0.155 inches). The male mold tooth has a rounded diamond shape, as shown in FIG. 21, and a vertical side wall, with a rounded or rounded edge at the transition between the tooth top and side walls. Have The teeth are 4.72 mm (0.186 inches) long and 3.18 mm (0.125 inches) wide, with a CD spacing of 3.81 mm (0.150 inches) and an MD spacing of 8.79 mm (. 346 inches). The recess of the female roll to be fitted also has a rounded diamond shape similar to the male roll, and the clearance between the rolls slightly varies around the outer periphery of the recess, and is 0.813 to 1.6 mm (0.032 to 0.063 inch).

Example 2.2 Layer In Example 2, the material was a composite of two materials bonded together by using the same hot melt adhesive applied in a spiral pattern as described in Comparative Example 1. It is. This is processed through the male / female mold described in Example 1 at 24.4 meters per minute (800 feet per minute (fpm)) and DOE 3.94 mm (0.155 inches). The material layer in contact with the male roll is a 20 gsm spunbonded nonwoven fabric made by Fitesa consisting of 2.5 denier fibers of PP and PE blends described in Comparative Example 1. The material layer in contact with the female roll is a 60 gsm breathable bonded carded non-woven fabric made of 5 denier PE / PET sheath / core bicomponent fibers manufactured by Beijing Dayuyan Non-Woven Fabric Co, LTD (Beijing, China). is there.

Example 3.2 Layer In Example 3, the material was a composite of two materials bonded together by using the same hot melt adhesive applied in a spiral pattern as described in Comparative Example 1. It is. This is processed through the male / female mold described in Example 1 at 24.4 meters per minute (800 fpm) and DOE 3.94 mm (0.155 inch). The material layer in contact with the male roll is a 20 gsm spunbond nonwoven fabric made by Fitesa consisting of 2.5 denier fibers of the PP and PE blends described in Example 2. The material layer in contact with the female roll is an 86 gsm spunbond nonwoven manufactured by Reicofil and consists of 7 denier co-PET / PET tip trilobal bicomponent fibers.

  The sample is compressed with a load of 7 kPa according to the “accelerated compression method”. The thickness of the sample before and after compression is measured according to the “accelerated compression method”. The dimensions of the protrusion and the opening are measured using a microscope with a magnification of 20 times. The outer dimension of the cap is measured from a perspective view with the protrusions facing up, as shown in FIG. The protrusion depth and the inner cap width are measured from the cross section of the material as shown in FIG.

^＊測定値が小さすぎたため測定困難

^* Measurement is difficult because the measured value is too small

Test method:
A. Accelerated compression method 10 specimen samples to be tested and 11 paper towels are cut into 7.6 cm × 7.6 cm (3 inch × 3 inch) squares.
2. Using a Thwing-Albert ProGage thickness gauge, or equivalent equipped with a 50-60 millimeter diameter circular leg, the thickness of each of the 10 samples is measured at 2.1 kPa and a residence time of 2 seconds. Record the thickness before compression to the nearest 0.01 mm.
3. The layers of the sample to be tested and the paper towel strips are alternately stacked so that the first and last are paper towels. The choice of paper towels is not a problem and this is to prevent the protrusions of the sample under deformation from being “nested”. The sample orientation should be such that the edges of each sample and each paper towel are relatively aligned, and the sample protrusions are all in the same direction.
4). Place the sample stack in a 40 ° C. oven and place a weight on the stack. This weight must be larger than the bottom area of the thickness gauge. For simulations with high pressure or low stack height in the bag, 35 kPa is applied (eg 17.5 kg weight over an area of 70 × 70 mm). For simulations with low pressure or high stack height in the bag, 7 kPa is applied (eg, 3.5 kg weight over an area of 70 × 70 mm).
5. Place the sample in the furnace for 15 hours. When time has elapsed, remove the weight from the sample and remove the sample from the furnace.
6). Within 30 minutes after removing the sample from the furnace, the thickness after compression is measured as shown in step 2 above. At this time, the same order as when the thickness before compression is recorded is maintained. The compressed thickness of each of the 10 samples is recorded in units of 0.01 mm.
7). The sample is left undisturbed for 24 hours at 23 ± 2 ° C. and 50 ± 2% relative humidity.
8. After 24 hours, as shown in Step 2 above, measure the recovered thickness of each of the 10 samples. At this time, the same order as when recording the thickness before and after compression is maintained. The recovered thickness of each of the 10 samples is recorded to the nearest 0.01 mm. The amount of thickness recovery is calculated by subtracting the thickness after compression from the thickness after recovery and recorded in units of 0.01 mm.
9. If desired, the average of 10 samples can be calculated for thickness before compression, after compression, and after recovery.

B. Tensile Methods MD and CD tensile properties are measured using method WSP 110.4 (05) Option B, sample width 50 mm, gauge length 60 mm, and stretching speed 60 mm / min. Note that the gauge length, stretch rate, and resulting strain rate are different from those specified for this method.

B. In-bag stack height test The in-bag stack height of the absorbent article of the present disclosure is measured as follows:

Apparatus A thickness gauge with a flat rigid horizontal slide plate is used. The thickness gauge is configured such that the horizontal slide plate moves freely in the vertical direction with the horizontal slide plate always maintaining a horizontal orientation directly above the flat rigid horizontal base plate. The thickness gauge includes a suitable device for measuring the gap between the horizontal slide plate and the horizontal base plate within ± 0.5 mm. The horizontal slide plate and the horizontal base plate are larger than the surface of the absorbent article package that contacts each plate, i.e., each plate extends in all directions beyond the contact surface of the absorbent article package. The horizontal slide plate exerts a downward force of 8.34 N (850 ± 1 gram) on the absorbent article package, which is suitable for the center of the upper surface of the horizontal slide plate where the package is not in contact. This can be accomplished by placing a weight so that the total mass of the slide plate and the additional weight is 850 ± 1 grams.

Test Procedure Absorbent article packages are equilibrated at 23 ± 2 ° C. and 50 ± 5% relative humidity prior to measurement.

  Raise the horizontal slide plate and place the absorbent article package in the lower center of the horizontal slide plate so that the absorbent article in the package is oriented horizontally (see FIG. 75). Package surface handles or other packaging features that can contact either plate fold to flatten the surface of the package to minimize these effects on the measurement. Slowly lower the horizontal slide plate until it touches the top surface of the package and release it when touched. Ten seconds after releasing the horizontal slide plate, the gap between the horizontal plates is measured within ± 0.5 mm. Five identical packages (same size package, same number of absorbent articles) are measured and the arithmetic average is reported as the package width. “Stack height in bag” = (package width / number of absorbent articles per stack) × 10 is calculated and reported within ± 0.5 mm.

C. ΔE ^* Test Sample Preparation-Absorbent Article The absorbent article is taped to a rigid flat surface in a flat configuration with the body facing surface up. Carefully remove any ear, any leg cuff, any waist band, and any landing zone, leaving the rest of the article intact.

  If the absorbent article is a permanent side seam pant, the side seam is first cut to allow the absorbent article to lie flat on a rigid flat surface. Next, carefully remove any ears, any leg cuffs, any waist band or elastic belt, and any landing zones, leaving the rest of the article intact.

  Turn the absorbent article over and carefully remove the absorbent article's backsheet film and any outer cover nonwoven. If desired, a knife and / or a freezing spray (eg, Cyto-Freeze from Control Company, Houston, TX) can be used. The remaining part of the article is the sample. Five replicate samples obtained from five substantially similar absorbent articles are prepared for analysis. Samples are preconditioned at about 23 ° C. ± 2 ° C. and about 50% ± 2% relative humidity for about 2 hours prior to testing.

Color-corrected image The color difference (delta E ^* ) measurement is based on the CIE L ^* a ^* b ^* color system (CIELAB). A flatbed scanner capable of scanning a minimum of 24-bit color with a resolution of at least 400 dpi and having manual control of color management (preferred scanner is Epson Perfection V750 from Epson America Inc. (Long Beach CA)) Acquire an image using Pro). The scanner is linked to color management software running on a computer (a preferred color management software is Monaco EZColor available from X-Rite (Grand Rapids, MI)). The scanner uses color management software to calibrate against a color reflection target and a corresponding reference file in accordance with ANSI method IT8.7 / 2-1993 to build a calibrated color profile. In an image analysis program that supports sampling in CIE L ^* a ^* b ^* using a calibrated scanner profile (a preferred program is Photoshop S4 available from Adobe Systems Inc. (San Jose, Calif.)) Then, color correction of the image obtained from the test sample is performed. All tests are conducted in a conditioned room maintained at about 23 ± 2 ° C. and about 50 ± 2% relative humidity.

  Turn on the scanner for 30 minutes before calibration. Deselect all automatic color correction or color management options that may be included in the scanner software. If automatic color management cannot be disabled, the scanner is unsuitable for this application. Place the IT8 target face down on the scanner glass, close the scanner lid, acquire a 24-bit color image at 200 dpi, and remove the IT8 target. The color management software opens the image file on the computer. Create and export a calibrated color profile according to the recommended procedure within the color management software. This procedure may include verifying that the scanned image is correctly oriented and cropped correctly. The calibrated color profile must be compatible with the image analysis program. The color management software uses this acquired image and compares it with the included reference file to create a calibrated color profile and export it. After the profile is created, the scan resolution (dpi) of the test sample can be changed, but all other settings need to be kept constant during sample imaging.

Open the scanner lid and place the sample on the scanner glass with the body-facing surface facing the glass. Cover the sample with a white background (in this test method, white is defined as a color with L ^* > 94, -2 <a ^* <2, and -2 <b ^* <2) and close the lid. Apply sufficient pressure to the sample and press it flat against the scanner glass. Acquire a 24-bit color and at least 400 dpi image of only the area of the sample facing the body covering the core wrap or core bag. This image is imported into image analysis software. If the size of the sample exceeds the available scan area, multiple scans covering the entire sample are acquired and combined for analysis to form a single image. Assign a calibrated color profile to the image and change the mode to L ^* a ^* b ^* Color corresponding to the CIE L ^* a ^* b ^* standard. Thereby, a color-corrected image is generated.

ΔE ^* Measure—Absorbent Article The color corrected image is divided into a grid of square areas, each representing a 2 mm × 2 mm area of the sample. Record the average of the L ^* , a ^*, and b ^* values of the pixels in each square area. Use the following formula to calculate a preliminary ΔE ^* for each 2 mm square area for reference white values of L ^* = 100, a ^* = 0 and b ^* = 0.

And the highest 2mm square area 10 preliminary Delta] E ^* value, the preliminary Delta] E ^* values to identify the lowest 2mm square area 10. Average the original L ^* , a ^* and b ^* values of the 2 mm square area identified as having the highest preliminary ΔE ^* value and record these values as L ^* ₁ , a ^* ₁ and b ^* ₁ To do. Average the original L ^* , a ^* and b ^* values of the 2 mm square area identified as having the lowest preliminary ΔE ^* value and record these values as L ^* ₂ , a ^* ₂ and b ^* ₂ To do. Using these average values, ΔE ^* is calculated using the following formula:

The ΔE ^* of the article is reported in 0.01 units. Calculate the sum of five substantially identical samples. The average of the ΔE ^* values for the five articles is calculated and reported in units of 0.1.

  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 “90 °” shall mean “about 90 °”.

  Any maximum numerical limit given throughout this specification should be understood to include any lower numerical limit as if such lower numerical limits were expressly set forth herein. It is. Any minimum numerical limitation given throughout this specification will include any higher numerical limitation as if such higher numerical limitations were expressly set forth herein. Every numerical range given throughout this specification includes every narrower numerical range that falls within such a wider numerical range, as if all such narrower numerical ranges were expressly set forth herein.

  All documents cited in “DETAILED DESCRIPTION” are incorporated herein by reference in the relevant part. Citation of any document should not be construed as an admission that it is prior art with respect to the present disclosure. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of a term in a document incorporated by reference, the meaning or definition given to that term in this specification shall apply. .

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

Claims (16)

An absorbent article,
A liquid permeable three-dimensional material comprising a first surface and a second surface, comprising a plurality of fibers, the three-dimensional material being out of the first surface of the three-dimensional material and a generally flat first region. A plurality of separate integral second regions including a protrusion extending in a direction and a deformation forming an opening in the second surface of the three-dimensional material, wherein the protrusion is formed from the fiber. And wherein at least a portion of the protrusions are proximal to the first surface of the three-dimensional material, opposite distal ends extending outwardly from the base in the Z direction, and the protrusions A side wall between the base and the distal end, and a cap including at least a portion of the side wall and the distal end of the protrusion, the side wall having an inner surface, and a plurality of fibers protruding from the base Extending from the base of the portion to the distal end of the protrusion, and Contributes to form a portion of the output portion side surface and the cap of the fibers is at least substantially surrounds the sides of the projecting portion, and a liquid permeable three-dimensional material,
A liquid impervious backsheet;
An absorbent core disposed at least partially between the three-dimensional material and the liquid-impermeable backsheet, the absorbent core comprising an absorbent material at least partially surrounded by a core bag; Including,
The absorbent article, by Delta] E ^* Test herein, has a Delta] E ^* of greater than 1, the absorbent article. The absorbent article, by Delta] E ^* Test herein, has a Delta] E ^* of greater than 2, the absorbent article according to claim 1. The absorbent article, by Delta] E ^* Test herein, has a Delta] E ^* of more than 3, the absorbent article according to claim 1. The absorbent article, by Delta] E ^* Test herein, has a Delta] E ^* in the range of from about 1 to about 15, the absorbent article according to claim 1.   The three-dimensional material includes a topsheet or a capture material, and the topsheet, the capture material, the core bag, or an additional layer disposed at least partially between the topsheet and the core bag The absorption according to any one of claims 1 to 4, comprising a display part on any of the above, wherein the display part is visible when viewing a surface facing the wearer of the absorbent article. Sex goods.   The absorptive article according to claim 5 in which said indicator includes an adhesive.   The absorbent article according to claim 6, wherein the adhesive is colored.   The absorptive article according to claim 5 in which said indicator contains ink.   The absorbent article according to claim 8, wherein the ink is colored.   The three-dimensional material includes a topsheet or a capture material, and the topsheet, the capture material, a portion of the core bag, or an additional layer disposed at least partially between the topsheet and the core bag 10. The method of any one of claims 1-9, wherein one of the colors is different from the topsheet, the capture material, the portion of the core bag, or another one of the additional layers. Absorbent articles.   The three-dimensional material includes a topsheet or capture material and is at least partially disposed between the topsheet portion, the capture material portion, the core bag portion, or between the topsheet and the core bag. One portion of the added additional layer is a different color from the other portion of the portion of the topsheet, the portion of the capture material, the portion of the core bag, or the portion of the additional layer. The absorbent article as described in any one of Claims 1-9 which is.   The three-dimensional material includes a topsheet or a capture material, and the topsheet, the capture material, the core bag, or an additional layer disposed at least partially between the topsheet and the core bag 10. The first part of claim 1 is in a different color from the second part of the same one of the topsheet, the capture material, the core bag, or the additional layer. The absorbent article as described.   The three-dimensional material includes a topsheet or capture material and includes an additional layer disposed at least partially between the topsheet and the core bag, the additional layer including a nonwoven material or pulp fibers The absorptive article according to any one of claims 1 to 12 containing a material.   The absorptive article according to any one of claims 1 to 13 containing a display part, and the display part contains fusion adhesion or an embossing field.   15. A package comprising a plurality of absorbent articles according to any one of claims 1 to 14, wherein an in-bag stack height in the range of about 70 mm to about 100 mm is determined by the in-bag stack height test herein. Have a package.   The at least a portion of the protrusion has a bulbous shape, and the three-dimensional material includes a topsheet and a capture material nested together in at least a portion of the protrusion. Absorbent material.

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