Absorbent article having ears

Abstract

To provide a combined ear / fastening system that has stretch balanced with adequate strength, that provides proper fit and flexibility and that minimizes roping, while reducing costs and enhancing efficiency in creating stretch ear laminates.SOLUTION: An absorbent article 10 comprises: a first waist region 14, a second waist region 18, and a crotch region 16 disposed between the first and second waist regions; a chassis 20 comprising a topsheet 24, a backsheet 26, and an absorbent core 28 disposed between the topsheet and backsheet; and an ear 30. The ear comprises a laminate comprising first and second nonwovens and an elastomeric material sandwiched between the first and second nonwovens, where the laminate further comprises a plurality of ultrasonic bonds. The ear further comprises a first inelastic region and an elastic region. The ear is joined to the chassis in the first inelastic region, and a fastening system is joined to the ear in the elastic region.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to absorbent articles having ears, particularly elasticated ears. [Background technology]

[0002] It has been known for some time that absorbent articles, such as conventional absorbent articles (e.g., diapers, adult incontinence articles, feminine hygiene pads), provide the advantage of receiving and containing urine and / or other bodily exudates (e.g., feces, menses, feces and urine mixtures, menses and urine mixtures, etc.) To effectively contain bodily exudates, the articles need to fit snugly around the waist and legs of the wearer.

[0003] Manufacturers often use extensible regions, such as stretch side panels (i.e., ears), in articles to help achieve a comfortable fit. When worn, the elastic ears allow the article to stretch around the hips and waist of the wearer, securing the product in place during use while allowing the wearer to move comfortably. A fastening system is typically bonded to the ears to further secure the product around the wearer. Elastic ears are typically laminates of a covering material (e.g., a nonwoven) and an elastomeric material. The laminates can be manufactured in several ways to achieve the desired stretchability. For example, the nonwoven and elastomeric materials can be bonded by an adhesive and then activated. When laminated, the nonwoven and elastic layers may be bonded at near zero relative strain (i.e., neither layer strains more than the other). Zero strain laminates are activated by a mechanical strain loading process, which causes the nonwoven to separate or deform, rendering the laminate elastically extensible. Activated ears can provide high stretchability, but the activation process typically requires a stretchable nonwoven, a convenient adhesive for activation, and a high basis weight or very strong elastic material to ensure high stretch ears.

[0004] Another method of forming stretchable ears is extrusion lamination. In extrusion lamination, an elastomeric material is extruded and bonded to a nonwoven or other covering material immediately after extrusion and without the use of adhesives. To provide stretchability, the elastomeric material can either be stretched prior to bonding with the nonwoven or the nonwoven is modified in such a way that it provides extensibility. Stretchable laminates made using such processes can be expensive due to the use of elastomeric material across the width of the laminate.

[0005] It has been proposed to make stretch laminates using ultrasonic bonding. In such cases, the elastomeric material can be stretched and then combined in the stretched state with the nonwoven via ultrasonic bonding. These laminates can produce highly stretchable ears (depending on the level of stretch imparted in the elastomeric material) while avoiding the use of adhesives and mechanical activation. Also, unlike extrusion lamination, the elastomeric material does not need to extend across the entire width of the laminate.

[0006] However, ultrasonically bonded ears lack the strength that other ears have. If the ears lack the necessary strength during use, the ears themselves may break, the fasteners may come off the ears, and / or the ears may become detached from the rest of the article. Such breakage may render the article unusable. Additionally, fastening systems in combination with elastic ears may increase the likelihood of product failure. In use, elastic ears tend to rope (or pinch) and collapse in height due to their relatively low modulus compared to the relatively high modulus of the fastening system. The fastening system tends to flex inwardly due to the roping of the elastic ears. The roping results in reduced surface area coverage and reduced contact area for frictional lock of the elastic ears on the wearer's body, and the flexing of the fastening system results in discomfort and strain to the wearer. Summary of the Invention [Problem to be solved by the invention]

[0007] This leaves a continuing need for stretch ears that balance adequate strength with desirable stretch. Similarly, there is a need for combined ear / fastening systems that provide proper fit and flexibility and minimize undesirable roping. There is also a need to reduce costs and improve efficiency in making stretch ear laminates. [Means for solving the problem]

[0008] In one embodiment, the absorbent article comprises a first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region. The absorbent article further comprises a chassis including a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, and an ear. The ear comprises a laminate including a first nonwoven and a second nonwoven, and an elastomeric material sandwiched between the first nonwoven and the second nonwoven. The laminate comprises a plurality of ultrasonic bonds. The ear also comprises a first inelastic region and an elastic region. The ear is joined to the chassis at the first inelastic region. A fastening system is joined to the ear at the elastic region.

[0009] In a further embodiment, an absorbent article is constructed comprising a first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region. The absorbent article further comprises a chassis including a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, and an ear. The ear comprises a laminate including a first nonwoven and a second nonwoven, and an elastomeric material sandwiched between the first nonwoven and the second nonwoven. The laminate comprises a plurality of ultrasonic bonds. The first and second nonwovens each have a basis weight of 17 gsm or less. The ear has an average load at break of 18 N or more.

[0010] In another embodiment, the absorbent article comprises a first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region. The absorbent article further comprises a chassis including a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The ears comprise a laminate including a first nonwoven and a second nonwoven, and an elastomeric material sandwiched between the first nonwoven and the second nonwoven. The laminate comprises a plurality of ultrasonic bonds. The ears are at least 1 m long. 3 / m 2 / min and a length ratio of about 3 or less. [Brief description of the drawings]

[0011] [Figure 1] 1 is a schematic plan view of an exemplary absorbent article according to one non-limiting embodiment of the present invention.The absorbent article is shown in a flat, uncontracted state. [Diagram 2] 2 is a schematic plan view of an exemplary ear, according to one non-limiting embodiment of the present invention. FIG. [Diagram 3] FIG. 2 is an exploded perspective view of an exemplary ear, according to a non-limiting embodiment of the present invention. [Figure 4] 2 is a schematic plan view of an exemplary ear, according to one non-limiting embodiment of the present invention. FIG. [Diagram 5] 5 is a schematic cross-sectional view of the ear of FIG. 4 taken along the lateral centerline of the ear. [Figure 6] 4 is a schematic cross-sectional view of an exemplary ear according to another non-limiting embodiment of the present invention. [Figure 7] 1 is a chart showing exemplary ears versus load (N) elongation (mm). [Figure 8] FIG. 2 is a schematic plan view of an exemplary bonding pattern according to one non-limiting embodiment of the present invention. [Figure 9] 2 is a schematic plan view of an exemplary ear shape according to one non-limiting embodiment of the present invention. FIG. [Figure 10]1 is a chart showing average load at break (N) and associated fit curves for ears having basis weights and shapes according to non-limiting examples of the present invention. [Figure 11] 1 is a schematic perspective view of a package according to one embodiment of the present invention; [Figure 12] FIG. 1 is a schematic perspective view of a grip suitable for use in the tensile testing method herein. [Figure 13] FIG. 1 is a schematic side view of a grip suitable for use in the tensile testing method herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] definition "Disposable" in relation to absorbent articles means that the absorbent articles are generally not intended to be washed or otherwise restored or reused as absorbent articles (i.e., they are intended to be discarded after a single use and preferably recycled, composted, or disposed of in an environmentally compatible manner).

[0013] "Absorbent article" refers to a device that absorbs and contains bodily exudates, and more specifically, to a device that is placed against or in close proximity to the wearer's body to absorb and contain various exudates discharged from the body. Examples of absorbent articles include diapers, training pants, pull-on pant diapers (i.e., diapers with preformed waist and leg openings as shown in U.S. Pat. No. 6,120,487), refastenable or pant diapers, incontinence briefs and undergarments, diaper holders and liners, feminine hygiene garments such as panty liners, absorbent inserts, and the like.

[0014] "Activation" is the mechanical deformation of a plastically extensible material that results in a permanent elongation of the extensible material, or a portion of the extensible material, in the direction of activation in the XY plane of the material. For example, activation occurs when a web or a portion of a web is subjected to a stress that induces a strain in the material higher than plasticization occurs, which may or may not include complete mechanical failure of the material or a portion of the material. Activation of a laminate that includes an elastic material bonded to a plastically extensible material typically results in a permanent deformation of the plastic material, while the elastic material substantially returns to its original dimensions. Activation processes are disclosed, for example, in U.S. Patent Publication No. 2013 / 0082418, U.S. Patent No. 5,167,897, and U.S. Patent No. 5,993,432.

[0015] "Body-facing" and "garment-facing" refer to the relative position of an element, or a surface of an element, or a group of elements, respectively. "Body-facing" means that the element or surface is closer to the wearer when worn than any other element or surface. "Garment-facing" means that the element or surface is farther away from the wearer when worn (i.e., the element or surface is closer to the wearer's garment, which may be worn over the disposable absorbent article), than any other element or surface.

[0016] "Longitudinal" refers to a direction extending substantially perpendicularly from a waist edge of the article to the opposing waist edge and generally parallel to the maximum linear dimension of the article. Directions within 45 degrees of the longitudinal direction are considered to be "longitudinal".

[0017] "Transverse" refers to a direction extending from a longitudinal edge of the article to the opposite longitudinal edge, generally perpendicular to the longitudinal direction. Directions within 45 degrees of the transverse direction are considered to be "transverse."

[0018] "Disposed" and "disposed" refer to an element being placed in a particular place or location.

[0019] "Jointed" refers to an element being directly secured to another element by directly attaching the element to the other element, and also to an element being indirectly secured to another element by attaching the element to one or more intermediate members which are in turn attached to the other element.

[0020] "Film" means a sheet-like material in which the length and width of the material exceed (e.g., 10 times, 50 times, or even 1000 times) the thickness of the material. Films are typically liquid impermeable, but can be configured to be breathable.

[0021] "Laminate" means two or more materials bonded together by any suitable method known in the art (e.g., adhesive bonding, thermal bonding, ultrasonic bonding, or high pressure bonding using unheated or heated patterned rolls).

[0022] "Nonwoven" means a porous fibrous material made from continuous (long) filaments (fibers) and / or discontinuous (short) filaments (fibers), such as from processes such as spunbonding, meltblowing, airlaying, carding, co-forming, hydroentangling, and the like. Nonwovens do not have a woven or knitted filament pattern. Nonwovens may be liquid permeable or impermeable.

[0023] "Relaxed" means the state of an element, material or component at rest, where there are substantially no external forces acting on the element other than gravity.

[0024] "Elastic," "elastomeric," and "elastically extensible" refer to the ability of a material to stretch at least 100% in one of the directions by the Hysteresis Test described herein at a given load without rupture or breakage, and when the load is removed, the elastic material or component exhibits at least 80% recovery (i.e., has less than 20% set). Elongation, stretch ratio, or elongation, which may also be referred to as strain, percent strain, engineering strain, as well as recovery and set, may each be measured by the Hysteresis Test described in more detail below. Materials that are not elastic are referred to as nonelastic.

[0025] "Extensible" means the ability to stretch or elongate by at least 50% (substituting 50% strain for a specific 100% strain) according to step 5(a) in the Hysteresis Test herein without rupture or breakage.

[0026] Absorbent articles 1 is a plan view of an exemplary, non-limiting embodiment of an absorbent article 10 of the present invention in a flat, uncontracted state. The body-facing surface 115 of the absorbent article 10 faces toward the viewer. The absorbent article 10 includes a longitudinal centerline 100 and a lateral centerline 110.

[0027] The absorbent article 10 includes a chassis 20. The absorbent article 10 and chassis 20 are shown as having a first waist region 14, a second waist region 18 opposite the first waist region 14, and a crotch region 16 located between the first waist region 14 and the second waist region 18. The waist regions 14 and 18 generally include those portions of the absorbent article 10 that, when worn, encircle the waist of a wearer. The waist regions 14 and 18 may include elastic members 55 that gather around the waist of the wearer to improve fit and containment. The crotch region 16 is the portion of the absorbent article 10 that, when worn, is generally positioned between the legs of a wearer.

[0028] The periphery of the chassis 20 is defined by the longitudinal edges 12 and waist edges (i.e., the first waist edge 13 of the first waist region 14 and the second waist edge 19 of the second waist region 18). The chassis 20 may have opposing longitudinal edges 12 oriented generally parallel to a longitudinal centerline 100. However, for a better fit, the longitudinal edges 12 may be curved or angled to form an "hourglass" shaped article when viewed in plan view, for example, as shown in FIG. 1. The chassis 20 may have opposing lateral edges 13, 19 (i.e., the first waist edge 13 and the second waist edge 19) oriented generally parallel to a lateral centerline 110.

[0029] The chassis 20 may comprise a liquid permeable topsheet 24, a backsheet 26, and an absorbent core 28 between the topsheet 24 and the backsheet 26. The topsheet 24 may be joined to the core 28 and / or the backsheet 26. The backsheet 26 may be joined to the core 28 and / or the topsheet 24. It will be understood that other structures, elements, or substrates may be positioned between the core 28 and the topsheet 24 and / or between the core 28 and the backsheet 26. In some embodiments, an acquisition distribution system 27 is disposed between the topsheet 26 and the absorbent core 28.

[0030] In certain embodiments, the chassis 20 comprises the primary structure of the absorbent article 10, along with additional other features to form a composite absorbent article structure. The topsheet 24, backsheet 26, and absorbent core 28 may be assembled in a variety of well-known configurations, although absorbent article construction is generally as described in U.S. Patent Nos. 3,860,003, 5,151,092, 5,221,274, 5,554,145, 5,569,234, 5,580,411, and 6,004,306.

[0031] Top sheet: The topsheet 24 is generally the portion of the absorbent article 10 that may be at least partially in contact with or immediately adjacent to the wearer. Suitable topsheets 24 may be made from a variety of materials, such as porous foams, reticulated foams, perforated plastic films, or woven or nonwoven webs of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or a combination of natural and synthetic fibers. The topsheet 24 is generally supple, soft-feeling, and non-irritating to the wearer's skin. Typically, at least a portion of the topsheet 24 is liquid pervious, allowing liquids to readily penetrate through its thickness. One topsheet 24 useful herein is available from BBA Fiberweb, Brentwood, Tenn., under supplier code 055SLPV09U. The topsheet 24 may be perforated.

[0032] Any portion of the topsheet 24 may be coated with a lotion or skin care composition as known in the art. Non-limiting examples of suitable lotions include those described in U.S. Patent Nos. 5,607,760, 5,609,587, 5,635,191, and 5,643,588. The topsheet 24 may be fully or partially elasticated or foreshortened so as to provide a void space between the topsheet 24 and the core 28. Representative structures including elasticated or foreshortened topsheets are described in more detail in U.S. Patent Nos. 4,892,536, 4,990,147, 5,037,416, and 5,269,775.

[0033] Absorbent Core: The absorbent core 28 may include a wide variety of liquid absorbent materials commonly used in disposable diapers and other absorbent articles. Examples of suitable absorbent materials include comminuted wood pulp, commonly referred to as airfelt crepe paper cotton, meltblown polymers including coforms, chemically stiffened, modified, or crosslinked cellulose fibers, tissue including tissue wrappers and flakes, absorbent foams, absorbent sponges, superabsorbent polymers, absorbent gelling materials, or any other absorbent material or combination of materials. In one embodiment, at least a portion of the absorbent core is substantially cellulose-free, contains less than 10% by weight cellulose fibers, less than 5% by weight cellulose fibers, less than 1% by weight cellulose fibers, trace amounts of cellulose fibers, or no cellulose fibers. It will be understood that trace amounts of cellulose material do not substantially affect at least one of the thinness, flexibility, and absorbency of the portion of the substantially cellulose-free absorbent core. Among other advantages, when at least a portion of the absorbent core is substantially free of cellulose, this portion of the absorbent core is believed to be significantly thinner and more flexible than a similar absorbent core containing more than 10% by weight of cellulose fibers. The amount of absorbent material, e.g., absorbent particulate polymeric material, present in the absorbent core may vary, but in certain embodiments is present in the absorbent core in an amount greater than about 80% by weight of the absorbent core, or greater than about 85% by weight of the absorbent core, or greater than about 90% by weight of the absorbent core, or greater than about 95% by weight of the core. In some embodiments, the absorbent core may comprise one or more channels 29, which are substantially free of absorbent particulate polymeric material. The channels 29 may extend in the longitudinal or transverse direction. The absorbent core may further comprise two or more channels. The channels may be straight, curved, or any workable combination thereof. In one non-limiting example, the two channels are symmetrically disposed about the longitudinal axis.

[0034] Exemplary absorbent structures for use as the absorbent core 28 are described in U.S. Pat. Nos. 4,610,678, 4,673,402, 4,834,735, 4,888,231, 5,137,537, 5,147,345, 5,342,338, 5,260,345, 5,387,207, 5,397,316, and U.S. patent application Ser. Nos. 13 / 491,642 and 15 / 232,901.

[0035] Backsheet: The backsheet 26 is generally positioned to be at least a portion of the garment-facing surface of the absorbent article 10. The backsheet 26 can be designed to prevent exudates absorbed by and contained within the absorbent article 10 from soiling articles that may come in contact with the absorbent article 10, such as bed sheets and undergarments. In certain embodiments, the backsheet 26 is substantially water impermeable. Suitable backsheet 26 materials include films such as those manufactured by Tredegar Industries Inc. (Terre Haute, IN) and sold under the trade names X15306, X10962, and X10964. Other suitable backsheet 26 materials can include breathable materials that allow vapors to escape from the absorbent article 10 while preventing exudates from passing through the backsheet 26. Exemplary breathable materials include composites such as woven webs, nonwoven webs, film-coated nonwoven webs, and microporous films such as those manufactured by Mitsui Toatsu Co., Japan under the name ESPOIR NO and by EXXON Chemical Co., Bay City, TX under the name EXXAIRE. A suitable breathable composite material comprising a polymer blend is available from Clopay, Inc., Cincinnati, OH under the name HYTREL Blend P18-3097. Such breathable composite materials are described in more detail in WO 95 / 16746 and U.S. Pat. No. 5,865,823. Other breathable backsheets comprising nonwoven webs and aperture-forming films are described in U.S. Pat. No. 5,571,096. Exemplary suitable backsheets are disclosed in U.S. Pat. No. 6,107,537. Other suitable materials and / or manufacturing techniques may be used to provide a suitable backsheet 26, including, but not limited to, surface treatments, particular film selection and processing, particular filament selection and processing, and the like.

[0036] The backsheet 26 may also be constructed of two or more layers. The backsheet 26 may comprise an outer cover and an inner layer. The outer cover may be made of a soft nonwoven material. The inner layer may be made of a substantially liquid-impermeable film, such as a polymeric film. The outer cover and the inner layer may be joined together by adhesive or any other suitable material or method. A particularly suitable outer cover is available from Corovin GmbH, Peine, Germany, under supplier code A18AH0, and a particularly suitable inner layer is available from RKW Gronau GmbH, Gronau, Germany, under supplier code PGBR4WPR. While various backsheet configurations are contemplated herein, it will be apparent 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.

[0037] Ears / fasteners: The absorbent article 10 may include one or more ears 30, including, for example, a front ear 32 disposed in a first waist region and / or a back ear 34 disposed in a second waist region. The ears 30 may be integral with the chassis or separate elements joined to the chassis 20 at chassis attachment bonds 35 that may join one or more layers of the ear to the chassis. The ears 30 may be stretchable or elastic. The ears 30 may be formed from one or more nonwoven webs, woven webs, knit fabrics, polymeric and elastomeric films, perforated films, sponges, foams, scrims, or combinations and / or laminates of any of the foregoing.

[0038] As shown in FIG. 2, the ear can include an outer edge 36 and an inner edge 38. The outer edge 36 is the free distal longitudinal edge of the ear when the ear is joined to the chassis 20. The inner edge 38 is substantially opposite the outer edge and is joined to or overlaps the chassis when the ear is joined to the chassis. The inner edge has a length Li. The ear can further include a first side 40 and an opposing second side 42, and a lateral centerline 43 that is generally parallel to the lateral centerline 110 of the article when the ear is joined to the article. The ear can further include a maximum width W extending between the outer edge and the inner edge, and a maximum length L extending between the first side and the second side. In some embodiments, the maximum length is the length Li of the inner edge.

[0039] In some embodiments, the ears 30 may include an elastomer such that the ears are stretchable. In certain embodiments, the ears 30 may be formed from a stretchable laminate, such as a nonwoven / elastomeric laminate or a nonwoven / elastomeric / nonwoven laminate, which makes the ears stretchable. The ears 30 may be extensible in the lateral direction. In some embodiments, the ears are elastic in the lateral direction. In further embodiments, the ears 30 may extend more in the lateral direction than in the longitudinal direction. Alternatively, the ears may extend more in the longitudinal direction than in the lateral direction.

[0040] In some embodiments, the ear comprises a laminate of a first nonwoven 300 and an elastomeric layer 304. In the particular embodiment illustrated in Figure 3, the ear comprises a first nonwoven 300, a second nonwoven 302, and an elastomeric layer 304. The elastomeric layer 304 may be sandwiched between the first and second nonwovens. Additional layers may be included (e.g., additional nonwovens, nonelastic materials, elastic or extensible materials, etc.).

[0041] Any suitable nonwoven may be used in the ears 30. Suitable nonwovens may comprise a basis weight of at least about 8 gsm, or less than about 22 gsm, or less than about 17 gsm, or from about 10 gsm to about 17 gsm (with increments therein recited for each range). Typically, low basis weight nonwovens reduce the overall strength of the ears. However, the inventors have discovered that ears designed according to the principles herein can achieve high strength despite being low basis weight nonwovens.

[0042] Nonwoven webs can be formed by a direct extrusion process, where the fibers and web are formed at about the same time, or by preformed fibers that can obviously be made into a web at a later time. Examples of direct extrusion processes include, but are not limited to, spunbonding, meltblowing, solvent spinning, electrospinning, and combinations thereof, which typically form layers.

[0043] As used herein, the term "spunbond fibers" refers to small diameter fibers formed as filaments by extruding molten thermoplastic material from a plurality of fine, usually circular capillary spinnerets. Spunbond fibers are quenched as they are deposited on a collecting surface and are typically not tacky. Spunbond fibers are generally continuous.

[0044] As used herein, the term "meltblown fibers" refers to fibers formed by extruding molten thermoplastic material as molten threads or filaments through a plurality of fine, usually circular capillary-type spinnerets into a high-velocity converging air stream (e.g., air) that attenuates the molten thermoplastic material and reduces the diameter of the filaments. The meltblown fibers are then carried by the high-velocity gas stream and deposited on a collecting surface to form a web of randomly disbursed meltblown fibers.

[0045] Examples of "lay" processes include wet lay and dry lay. Examples of dry lay processes include, but are not limited to, air lay, carding, and combinations thereof, typically forming layers. Combinations of the above processes result in nonwovens, commonly referred to as hybrids or composites. Examples of combinations include, but are not limited to, spunbond-meltblown-spunbond (SMS), spunbond-carded (SC), spunbond-airlaid (SA), meltblown-airlaid (MA), and combinations thereof, typically in layers. Combinations involving direct extrusion can be combined almost simultaneously with direct extrusion processes (e.g., spinform and coform of SA and MA), or can be combined sequentially. In the above examples, one or more of each layer can be made by each process. For example, SMS can mean a 3-layer "sms" web, a 5-layer "ssmms" web, or any reasonable variation thereof, with lower case letters referring to separate layers and upper case letters referring to an organization of similar adjacent layers. The fibers in a nonwoven web are typically bonded to one or more adjacent fibers at some of the overlapping junctions. This includes bonding of the fibers within each layer and bonding of the fibers between layers when there is more than one layer. The fibers can be bonded by mechanical entanglement, by chemical bonding, or a combination of these.

[0046] In some embodiments, the nonwoven fabrics can be unbonded nonwoven webs, electrospun nonwoven webs, flash pan nonwoven webs (e.g., TYVEK™ by DuPont), or combinations thereof. These fabrics can include fibers of polyolefins such as polypropylene or polyethylene, polyesters, polyamides, polyurethanes, elastomers, rayon, cellulose, copolymers thereof, or blends or mixtures thereof. Nonwoven fabrics can also include fibers that are homogeneous or include bicomponent structures such as sheath / core, side-by-side, islands-in-the-sea, and other bicomponent structures. For a detailed description of some nonwoven fabrics, see "Nonwoven Fabric Primer and Reference Sampler" by E A Vaughn, Association of the Nonwoven Fabrics Indus, 3d Edition (1992).

[0047] Nonwoven fabrics can include fibers or can be made from fibers having a cross section perpendicular to the fiber longitudinal axis that is substantially non-circular. By substantially non-circular, it is meant that the ratio of the longest axis of the cross section to the shortest axis of the cross section is at least about 1.1. The ratio of the longest axis of the cross section to the shortest axis of the cross section can be about 1.1, about 1.2, about 1.5, about 2.0, about 3.0, about 6.0, about 10.0, or about 15.0. In some embodiments, the ratio can be at least about 1.2, at least about 1.5, or at least about 2.0. For example, these ratios can be about 3.0 or less, about 6.0 or less, about 10.0 or less, or about 15.0 or less. The shape of the cross section perpendicular to the fiber longitudinal axis of the substantially non-circular fibers can be rectangular (e.g., with rounded corners), which is also referred to as a "flat" fiber, trilobal, or oval (e.g., elliptical) in cross section. These substantially non-circular fibers can provide more surface area for bonding to the elastomeric fibers than nonwovens having circular fibers in cross section, and such increased surface area can increase the bonding strength between the fibers and the substrate.

[0048] The softness of a nonwoven fabric is often related to the sense of touch. A sleek or silky feel is often preferred over a rough texture. Various approaches can be used to impart a silky feel.

[0049] In one approach, the nonwoven web can be made from bicomponent or multicomponent fibers. One of the components of the fiber, preferably the outer component, is a soft polymer such as polyethylene or elastic polyolefin, elastic polyurethane, etc. For example, in a sheath / core bicomponent fiber, the sheath can be made of polyethylene while the core can be made of polypropylene.

[0050] In another approach, the nonwoven web can be made of monocomponent fibers. However, the fibers are made from polymer blends to impart a silky, soft feel. For example, polypropylene nonwovens can be coarse. However, blending with elastomeric polypropylene (VISTAMAXX® from Exxon) can help improve the feel of the fibers.

[0051] In another approach, nonwoven webs can be made from elastomeric polymers. For example, elastomeric polyolefins are used in fiber spinning and in the manufacture of nonwoven webs. Such webs have a very shiny feel and elastic properties that are often desired in consumer products.

[0052] In another approach, additives can be added to the polymer before the fibers are spun. During fiber spinning and the subsequent process steps to make a nonwoven web, the additive migrates to the fiber surface and gives a silky feel. Amine and amide based additives are commonly used up to 5% to impart softness.

[0053] In another approach, shiny chemical finishes can be coated onto the fibers or nonwoven webs. Chemical finishes based on oils, silicones, esters, fatty acids, surfactants, etc. can be used. Softeners such as anionic, cationic or nonionic can also be used to improve drape and touch. The finishes can be applied using a variety of coating techniques such as roll coating, screen coating, gravure coating, slot coating, spray coating.

[0054] In another approach, the diameter of nonwoven fibers can be reduced to produce fine fibers that provide a silky feel. Meltblown fibers are one technique that reduces fiber diameters to less than 20 microns. Alternatively, nanofibers with diameters less than 1 micrometer, made from a melt film fibrillation process with a polymer composition disclosed in U.S. Pat. No. 8,835,709, can be used to provide softness.

[0055] Drape is another measure of softness. The flexibility or flexibility under its own weight without any external force conveys softness. This can be influenced by various factors such as fiber chemistry, thickness, nonwoven bonding pattern, and combinations thereof. Softness or drape is related to the inherent modulus of elasticity of the material and bending stiffness with respect to thickness. For example, in the use of nonwovens in contour matching, such as in medical and sanitary products, it has proven advantageous for nonwovens to have minimum and maximum bending stiffness, since excessively stiff materials are undesirable. Polyolefin resins with low modulus and / or low crystallinity allow for lower bending stiffness. Low modulus materials (elastomers) can be mixed with conventional polyolefin resin-manufactured fibers to make low modulus fibers. The bending stiffness of the web can also be altered in the desired direction by optimizing the bonding. Bonds with a large aspect ratio between the longitudinal and transverse dimensions provide better drape in the transverse dimension and provide adequate stiffness and strength for web handling. Another factor that affects drape is the thickness of the web. The thicker the web, the less flexible or pliable it is. By combining the proper thickness with fiber chemistry or bond pattern, better drape can be obtained while still providing suitable web performance for processing.

[0056] In a non-limiting example, the nonwoven comprises a meltblown layer. Additionally or alternatively, the nonwoven may comprise a spunbond layer. In a non-limiting example, the nonwoven comprises two or more spunbond layers. In a further non-limiting example, one or more of the nonwovens may comprise an SMS configuration. Alternatively, one or more of the nonwovens in the ears may be free of a meltblown layer. Although meltblown layers have been found to enhance bonding in ears that require adhesive (given the inhibition of adhesive diffusion through the porous nonwoven structure of the meltblown layer), meltblown layers often lack strength. In some embodiments, the nonwoven consists essentially of a spunbond layer. In some non-limiting examples, both the first and second nonwovens comprise at least two spunbond layers, or three or more spunbond layers.

[0057] When an ear 30 comprises two or more nonwovens, the nonwovens may comprise the same basis weight or different basis weights. Similarly, the nonwovens may comprise the same layer construction or different layer constructions. Additionally, the nonwovens within an ear may comprise the same or different features of the nonwovens in the backsheet, topsheet, leg gasketing system, and / or waist feature.

[0058] The elastomeric layer 304 includes one or more elastomeric materials that provide elasticity to at least a portion of the layer 304. Non-limiting examples of elastomeric materials include films (e.g., polyurethane films, films derived from rubber and / or other polymeric materials), elastomeric coatings applied to another substrate (e.g., hot melt elastomers, elastomeric adhesives, printed elastomers or elastomers coextruded onto another substrate), elastomeric nonwovens, scrims, etc. The elastomeric materials can be formed from any suitable known elastomer, including, but not limited to, elastomeric polymers including polymers including styrene derivatives, polyesters, polyurethanes, polyetheramides, polyolefins, combinations thereof, or coextruded VISTAMAXX®. Exemplary elastomers and / or elastomeric materials are disclosed in U.S. Pat. Nos. 8,618,350, 6,410,129, 7,819,853, 8,795,809, 7,806,883, 6,677,258, and U.S. Patent Publication No. 2009 / 0258210.Commercially available elastomeric materials include KRATON (styrene block copolymer, available from Kraton Chemical Company, Houston, TX), SEPTON (styrene block copolymer, available from Kuraray America, Inc., New York, NY), VECTOR (styrene block copolymer, available from TSRC Dexco Chemical Company, Houston, TX), ESTANE (polyurethane, available from Lubrizol, Inc, Ohio), PEBAX (polyether block amide, available from Arkema Chemicals, Philadelphia, PA), HYTREL (polyester, available from DuPont, Wilmington, DE), VISTAMAXX (homopolyolefin and random copolymer, as well as blends of random copolymers, available from EXXON Mobile, Spring, TX), and VERSIFY (homopolyolefin and random copolymer, as well as blends of random copolymers, available from Dow Chemical Company, Midland, Michigan).

[0059] In a non-limiting example, the elastomeric layer 304 comprises a film. The film may include a single layer or multiple layers. The film may be laterally elastic. The elastomeric layer may include a width Y, for example as shown in FIG. 2. In some embodiments, Y is at least about 10 mm less than the width W of the ear 30. In addition to the width of the elastomeric layer, the elastomeric layer may have a longitudinal dimension of the elastomeric layer that is the same as the ear 30, or may have a longitudinal dimension that is less than the longitudinal length of the ear at any point in the width of the elastomeric layer. In some embodiments, the elastomeric layer may have a basis weight of about 5 to about 150 gsm, or about 10 to about 100 gsm, or less than about 150 gsm (5 gsm increments therein are listed for each range).

[0060] As also shown in FIG. 2, the ear 30 can include an elastic region 306. The elastic region 306 is generally defined by the perimeter of the elastomeric material 304. In the elastic region, the ear is elastically stretchable. In some embodiments, the area of ​​the elastic region comprises at least about 20%, or about 30% to about 80% of the total area of ​​the ear (with 5% increments therein being recited for each range). In further embodiments, Y (i.e., the maximum width of the elastomeric layer) is at least about 20%, or about 25% to about 85%, or about 35% to about 80% of the total width W of the ear (with 5% increments therein being recited for each range). The ear further includes one or more inelastic regions. In one particular embodiment, the ear 30 includes a first inelastic region 308 extending laterally outward from the inner edge 38 and adjacent the elastic region 306 at a first elastomeric material edge 307. The ear may further include a second inelastic region 310 that may extend laterally inward from the outer edge 36 and may be adjacent to the elastic region 306 at a second elastomeric material edge 309. The first and second inelastic regions may be made from the same material or materials or different materials.

[0061] Referring to FIG. 4, in certain embodiments, the ear 30 comprises a gathered laminate 44 in which one of the layers distorts more than the remaining layers during lamination. In this manner, the less extensible layer (i.e., nonwoven 300, 302) forms gathers when the laminate 44 is in a relaxed state. In some embodiments, the elastomeric layer distorts during lamination while the nonwoven(s) are in a relaxed state. The elastomeric layer can be stretched in one or more directions. Corrugations are then formed in the nonwoven layer(s) when the subsequently formed laminate 44 is in a relaxed state. In a non-limiting example, the elastomeric layer is stretched in a direction corresponding to the cross direction of the article. In other words, following lamination, when the ear is joined to the chassis, the ear laminate is oriented such that the ear is stretchable in the cross direction of the article. In a further non-limiting example, the ear is also stretchable in the longitudinal direction.

[0062] The laminate layers may be joined by one or more ultrasonic bonds 46, as shown in Figure 4. The ultrasonic bonds may join the nonwoven layers through the elastomeric layers. Ultrasonically bonded laminates may be formed by the processes and / or apparatus disclosed in commonly assigned U.S. patent application Ser. Nos. 62 / 374,010 and 62 / 419,515.

[0063] In some embodiments, the laminate may be adhesive-free. In some non-limiting examples, the ears include adhesive bond(s) only at the chassis attachment bond 35 and / or only at the fastener attachment bond 52 (discussed below).

[0064] The absorbent article 10 may also include a fastening system 48, which when fastened interconnects the first waist region 16 and the rear waist region 18, thereby providing a waist circumference that may encircle the wearer while the absorbent article 10 is being worn. The fastening system 48 may include fastening elements 50, such as, for example, tape tabs, hook and loop fastening components, mating fasteners such as tabs and slots, buckles, buttons, snaps and / or non-sex fastening elements, although any other known fastening means may generally be used. The absorbent article may further include a landing zone where the fastening elements may be engaged and / or a release tape to protect the fastening elements from damage prior to use. Some exemplary surface fastening systems are disclosed in U.S. Patent Nos. 3,848,594, 4,662,875, 4,846,815, 4,894,060, 4,946,527, 5,151,092, and 5,221,274. An exemplary interlocking fastening system is disclosed in U.S. Patent No. 6,432,098. In some embodiments, the fastening system 48 and / or elements 50 are foldable.

[0065] The fastening system 48 may be joined to any suitable portion of the article 10 by any suitable means. In some embodiments, the fastening system is joined to the ear 30 at a fastener attachment joint 52, as shown in Figures 4-6. The fastening system may be joined to the ear between layers. The fastening system may be joined to the ear on an exterior surface, for example, as shown in Figure 4. In one non-limiting example, the fastening system 48 and / or fastening elements 50 are mechanically coupled to the ear 30. In another non-limiting example, the fastening system and / or fastening elements may be ultrasonically bonded to the ear. The fastener attachment joint 52 includes a maximum length L1 measured parallel to the longitudinal centerline. The maximum length may be about 30 mm or less, or about 28 mm or less, or about 20 mm to about 35 mm (ranges are recited with 1 mm increments therein).

[0066] It was found that ears formed from ultrasonically bonded gathered laminates had lower overall strength than comparable ears formed by activation. In fact, ear 30ZS formed by zero strain activation is compared to ultrasonically bonded ear 30US as shown in FIG. 7. The zero strain activation process is disclosed, for example, in U.S. Patents 5,167,897 and 5,156,793. The 30ZS specimen is an ear taken from a PAMPERS® CRUISERS® size 3 product sold in the United States in July 2016. The 30US ear contains the same materials as 30ZS, except that 30US does not contain adhesive. During lamination of 30US, the elastomeric layer was stretched while the nonwoven layer was in a relaxed state, and the layers were joined using ultrasonic bonding. The 30US and 30ZS specimens have substantially identical dimensions. When tested using the tensile test method herein with a 2.5 cm (1") top grip (to better approximate the length of the fastening system attached to the ear) and a 15 cm (6") bottom grip, both ear laminates exhibited similar stretch from 0N to 22N. However, the ultrasonically bonded ear tore at approximately half the breaking load (N) as shown in Figure 7. It is believed that the laminate construction contributes to this difference. With the activated back ear laminate, the nonwoven breaks during the activation process. Thus, when the laminate is stretched during tensile testing, the elastomeric film will localize (shorten in the direction perpendicular to the stretch direction) and the broken nonwoven does not offer any resistance to such localized shrinkage. In stark contrast, the ultrasonically bonded ear has a substantially (transversely) continuous nonwoven and when stretched, the nonwoven resists localized shrinkage of the elastomeric layer. Additionally, because the film is stretched during lamination in ultrasonically bonded ear 30US, the elongation during tensile testing does not result in the same level of localized contraction as 30ZS. The lack of localized contraction and / or a substantially continuous nonwoven contributes to a higher stress buildup at the outer surface 36 of the ear.However, the inventors have found that designing ultrasonically bonded ears in accordance with the teachings herein results in enhanced strength even when lower basis weight nonwovens are utilized (e.g., each nonwoven is 17 gsm or less).

[0067] Returning to Figures 4-6, the fastening system 48 may be bonded to the ear adjacent the outer edge 36. The fastening system may be disposed in the second inelastic region 310. In further embodiments, the fastening system 48 may be bonded in the elastic region 306 of the ear. The inventors have found that bonding the fastening system to the ear in the elastic region 306 improves the overall strength of the ear / fastening system combination during use and / or application. Without being bound by theory, it is believed that breaks in an ear formed from an ultrasonically bonded laminate occur first in the inelastic region near the outer edge 36 as the intact nonwoven resists the elastomer layer from stretching, and thus bonding of the fastening system in the elastic region 306 reduces stress on the inelastic portion of the ear. In some embodiments, the fastening system 48 is bonded in the elastic region such that it overlaps by a maximum lateral overlap distance D as shown in Figure 6. In certain non-limiting examples, D may be from about 0.05% to about 5% of Y (i.e., the maximum width of the elastic region), or from about 1% to about 5% (with 0.02% increments therein being recited for each range).

[0068] In further embodiments, the ears comprise a length ratio of about 3 or less, or about 2.95 or less, or about 1 to about 3, or about 1.75 to about 3, or about 1 to about 2.5, as determined by the Tensile Test Method herein (each range is recited with 0.05 intervals therein). Forming the ears with such length ratios reduces the potential for roping within the ears. The specified length ratios also provide improved strength for the ears.

[0069] The ears can include an average load to break of 15N or more, or 20N or more, or 25N or more, or 30N or more, or 40N or more, or from about 15N to about 45N, according to the tensile test methods herein (with 1N increments therein recited). The specified average load to break values ​​can also be obtained when the first and second nonwovens include basis weights of about 17gsm or less, or about 14gsm or less, or about 12gsm or less, or from about 8gsm to about 17gsm, (with 1N increments therein recited). Once joined to the ears, the fastening system 48 can include an average load to break of 24N or more, or about 30N or more, or from about 17N to about 40N, according to the tensile test methods herein (with 1N increments therein recited). The specified average load at break values ​​can be obtained even when the first and / or second nonwovens comprise a basis weight of about 17 gsm or less, or about 14 gsm or less, or about 12 gsm or less, or from about 8 gsm to about 17 gsm (ranges therein with 1 gsm increments being recited).

[0070] In certain embodiments, the ears have an air permeability of at least about 1 mm according to the Air Permeability Test herein. 3 / m 2 / min, or about 2m 3 / m 2 / min ~ approx. 125m 3 / m 2 / min, or about 5m 3 / m 2 / min ~ approx. 35m 3 / m 2 The air permeability value can be calculated by dividing the range by 2m 3 / m 2 / min increments).

[0071] Leg Gasket System Returning to FIG. 1 , the absorbent article 10 may include a leg gasketing system 70 attached to the chassis 20, which may comprise one or more cuffs 71. The leg gasketing system may comprise a pair of barrier leg cuffs 72. Each barrier leg cuff may be formed by a piece of material that is adhered to the absorbent article, and thus may extend upwardly from a wearer-facing surface of the absorbent article, and may provide improved containment of liquids and other bodily exudates near the junction of the wearer's torso and legs. The barrier leg cuffs may be bounded by a proximal edge that is joined, directly or indirectly, to the topsheet 24 and / or backsheet 26, and a free edge 75 that is intended to contact and form a seal with the wearer's skin. In some embodiments, the free edge 75 comprises a folded edge. The barrier leg cuffs 72 extend at least partially between the front waist edge 13 and the back waist edge 19 of the absorbent article on either side of the longitudinal centerline 100 and reside at least in the crotch region. The barrier leg cuffs may be joined to the chassis of the article at their proximal edges by bonds that may be implemented by a combination of glue bonding, melt bonding, or other suitable bonding processes.

[0072] The barrier leg cuffs may be integral with the topsheet 24 or backsheet 26 or may be separate pieces of material joined to the chassis of the article. Each barrier leg cuff 72 may include one, two or more elastic elements 55 near its free edge 75 to provide a better seal.

[0073] In addition to the barrier leg cuffs 72, the article may comprise gasket cuffs 76 joined to the chassis of the absorbent article, particularly the topsheet 24 and / or backsheet 26, and positioned outwardly relative to the barrier leg cuffs 72. The gasket cuffs 76 may provide a more effective seal around the wearer's thighs. The gasket cuffs may comprise a proximal edge and a free edge 77. The free edge 77 may comprise a folded edge. Each gasket cuff may comprise one or more elastic elements 55 in the region of the leg opening between the topsheet 24 and the backsheet 26 in the chassis of the absorbent article. All or a portion of the barrier leg cuffs and / or gasket cuffs may be treated with a lotion or another skin care composition.

[0074] In a further embodiment, the leg gasketing system includes a barrier leg cuff integrated with the gasket cuff.

[0075] Suitable leg gasket systems which may be part of the absorbent article are disclosed in US patent application Ser. Nos. 62 / 143,622, 14 / 077,708, US Pat. Nos. 8,939,957, 3,860,003, 7,435,243 and 8,062,279.

[0076] Elastic waist feature As shown in FIG. 1, the absorbent article 10 may include at least one elastic waist feature 80 that helps provide improved fit and containment. The elastic waist feature 80 is generally intended to stretch to dynamically fit the waist of the wearer. Elastic waist features include waistbands, waist cuffs having pockets formed from portions of the waist feature 80 that are unattached from the chassis 20, and waist panels designed to fit snugly around the wearer's abdomen. Non-limiting examples of elastic waist features are disclosed in U.S. Patent Application Nos. 13 / 490,543, 14 / 533,472, and 62 / 134,622. The waist feature 80 may be joined to the chassis 20 at the first waist region 14 and / or the second waist region 16. The waist feature may be used in conjunction with the ears 30 to provide the desired stretch and flexibility for proper fit of the article to the wearer.

[0077] Example of ear: Example 1 of the present invention Inventive Example 1 includes a first nonwoven and a second nonwoven, and an elastomeric film sandwiched between the first and second nonwoven. Each of the first and second nonwovens is a 17 gsm SMS available from Avgol, USA under the trade name AVMN1048007001. The nonwoven has an average basis weight of 16.9±0.6 gsm as measured by the basis weight test method herein. The elastomeric film is ElastiPro™ 4407 available from Clopay, USA and has a basis weight of 53.5±1.2 gsm. The film has a width of 45 mm in a relaxed state. The film is stretched to a strain of 130% (i.e., 45 mm stretched to about 104 mm, including 7 mm dead (non-stretched) zones on both sides), and in the stretched state, the width has increased to about 4 mm due to curing. In this stretched state, the first and second nonwoven fabrics were ultrasonically bonded via the film using the bonding pattern shown in FIG. 8 and an ultrasonic bonding pressure of 300N.

[0078] Example 2 of the present invention Inventive Example 2 includes a first nonwoven and a second nonwoven, and an elastomeric film sandwiched between the first and second nonwoven. Each of the first and second nonwovens is a 14 gsm SMS available from Avgol, USA under the trade name AVMN1050678001. The nonwoven has an average basis weight of 13.7±0.2 gsm as measured by the basis weight test method herein. The elastomeric film is ElastiPro™ 4407 available from Clopay, USA and has a basis weight of 53.5±1.2 gsm. The film includes a width of 45 mm in a relaxed state. The film is stretched to a strain of 130% (i.e., 45 mm stretched to about 104 mm with 7 mm dead zones on each side) and in the stretched state, the width has increased to about 4 mm due to curing. In this stretched state, the first and second nonwoven fabrics were ultrasonically bonded via the film using the bonding pattern shown in FIG. 8 and an ultrasonic bonding pressure of 300N.

[0079] Example 3 of the present invention Inventive Example 3 includes a first nonwoven and a second nonwoven, and an elastomeric film sandwiched between the first and second nonwoven. Each of the first and second nonwovens is a 10 gsm SMS available from Avgol, Israel under the trade name AVTI1028419002. The nonwoven has an average basis weight of 10.6±0.1 gsm as measured by the basis weight test method herein. The elastomeric film is ElastiPro™ 4407 available from Clopay, USA, and has a basis weight of 53.5±1.2 gsm. The film has a width of 45 mm in a relaxed state. The film is stretched to 130% strain (i.e., 45 mm stretched to about 104 mm, including 7 mm dead zones on each side), and in the stretched state, the width has increased to about 4 mm due to curing. In this stretched state, the first and second nonwoven fabrics were ultrasonically bonded via the film using the bonding pattern shown in FIG. 8 and an ultrasonic bonding pressure of 300N.

[0080] Example 4 of the present invention Inventive Example 4 includes a first nonwoven and a second nonwoven, and an elastomeric film sandwiched between the first and second nonwoven. Each of the first and second nonwovens is a 12 gsm SSS available from FQN, USA under the trade name XA0048483. The nonwoven has an average basis weight of 12.9±0.3 gsm as measured by the basis weight test method herein. The elastomeric film is ElastiPro™ 4407 available from Clopay, USA and has a basis weight of 53.5±1.2 gsm. The film has a width of 45 mm in a relaxed state. The film is stretched to 130% strain (i.e., 45 mm stretched to about 104 mm, including a 7 mm dead zone on each side), and in the stretched state, the width has increased to about 4 mm due to curing. In this stretched state, the first and second nonwoven fabrics were ultrasonically bonded via the film using the bonding pattern shown in FIG. 8 and an ultrasonic bonding pressure of 300N.

[0081] Example 5 of the present invention Inventive Example 5 includes a first nonwoven and a second nonwoven, and an elastomeric film sandwiched between the first and second nonwoven. Each of the first and second nonwovens is a 17 gsm SMS available from Avgol, USA under the trade name AVMN1048007001. The nonwoven has an average basis weight of 16.9±0.6 gsm as measured by the basis weight test method herein. The elastomeric film is ElastiPro™ 4407 available from Clopay, USA and has a basis weight of 53.5±1.2 gsm. The film has a width of 36 mm in a relaxed state. The film is stretched to 130% strain (i.e., 36 mm stretched to about 83 mm, including 7 mm dead zones on each side) and in the stretched state, the width has increased by about 4 mm due to curing. In this stretched state, the first and second nonwoven fabrics were ultrasonically bonded via the film using the bonding pattern shown in FIG. 8 and an ultrasonic bonding pressure of 300N.

[0082] The exemplary ears are cut into specimens having shapes with dimensions detailed in Tables 1A and 1B below. In FIG. 9, the dimensions are shown generally and are not to scale. Inventive Examples 1, 2, 3, and 4 are cut in shapes of Base, A, B, C, D. Inventive Example 1 is also cut in shapes E and G. Inventive Example 5 is cut into shape F. Inventive Example 5 with shape F is identical to Inventive Example 1 with shape A, except that the film width Y is smaller in Inventive Example 5. A die having a corresponding shape is used to cut the specimens. The specimens are cut to have inelastic regions on both sides of the elastic region. Specimens having shapes A-F were cut to have inelastic regions of at least about 10 mm measured laterally inward from the outer edge 36. Specimens having shape G were cut to have inelastic regions of at least about 10 mm measured laterally outward from the inner edge 38.

[0083] In each shape, a first side 40 intersects the outer edge 36 at a first corner 37, and the first side 40 intersects the inner edge 38 at a second corner 39. The longitudinal distance Loff between the corners indicates the placement of the fastening system (i.e., relative to the top of the ear, the middle of the ear, etc.).

[0084] Exemplary specimens were tested using the tensile testing methods herein to determine their average load at break, average elongation at 5N and 10N, and / or their average elongation at break.

[0085] The outer surface of the specimen was attached to the top grip at position G1, located at distance X in Tables 1A and 1B, which corresponds to the inner edge 52a of fastener mounting joint 52 (see FIG. 5). The bottom grip was attached at position G2 with a gauge length of 55 mm according to the tensile test method.

[0086] Table 1A - Legend In Table 1A, length is measured along a line perpendicular to the lateral centerline 43 and width is measured along a line parallel to the lateral centerline.

[0087] [Table 1]

[0088] [Table 2]

[0089] The base shapes include dimensions commonly used in back ears in known diapers. Shapes A, D, E, and F have the same length ratio. However, the shapes vary in size, film width, and / or taper angle. The stress buildup for these shapes is different due to different α and / or β angles and / or different film width Y. As will be seen below, the stress buildup has little effect on strength.

[0090] The effect of the length ratio was investigated in inventive Examples 1, 2, and 3 in the base configuration, A, B, and C configurations. Table 2 shows the mean load at break for each of the examples.

[0091] [Table 3]

[0092] As can be seen, the strength of the ears improves as the length ratio decreases, even with lower basis weight nonwovens. In fact, by decreasing the length ratio, the ears with 10 gsm nonwoven (Inventive Example 3) can achieve average load at break (i.e., strength) values ​​comparable to higher basis weight ears. Furthermore, compared to the base, each of Configurations A, B, and C exhibited improved strength.

[0093] The build-up angles (α, β) appear to have little effect on the strength of the ears. Shapes A and D have the same length ratio of 2.92. However, Shape D has a higher build-up angle. The break loads of both shapes were tested for inventive Examples 1-4, and the results are shown in the table below. As can be seen in Table 3, the specimens failed at nearly the same mean load to break.

[0094] [Table 4]

[0095] In addition to the above, Inventive Example 1 is cut into Shape E. Shape E has the same length ratio as Shape A, but a different build-up angle. Again, the build-up angle shows little effect on strength (see Table 4). In other words, the placement of the fastening system (e.g., placement on the top of the ears vs. placement on the bottom of the ears) does not significantly affect strength, provided the length ratio is maintained.

[0096] [Table 5]

[0097] Inventive Example 5 is cut into shape F. Inventive Example 5 with shape F is identical to Inventive Example 1 with shape A, except that the film width Y is smaller in Inventive Example 5. As shown in Table 5, the film width Y is: There was little effect on strength, however, as the film width was reduced the overall extensibility of the edge portions was reduced.

[0098] [Table 6]

[0099] Although the examples vary in overall extensibility, all specimens exhibit similar elongation profiles. Each of the inventive examples having any of Shapes A-G exhibits an elongation of about 20 mm or more at 5 N and about 40 mm or more at 10 N.

[0100] Furthermore, Table 6 illustrates the difference in strength between SMS and SSS constructions. Inventive Example 4 is made with 12 gsm SSS nonwoven on both sides of the film. Eliminating the meltblown layer improves strength to the extent that it equates to a basis weight 2-4 gsm higher than the nonwoven with SMS construction. As the length ratio decreases, the strength of the SSS ears becomes significantly more pronounced than the SMS ears. Table 6 below and Figure 10 compare the mean load at break of Inventive Examples 1-4 for Configurations A-C. As can be seen from Figure 10, Inventive Example 4 is outside the fitted curve for each configuration.

[0101] [Table 7]

[0102] Table 7 compares inventive examples 1 and 3 of shapes A and G. Shapes A and G have the same length ratio. However, shape G was gripped within the elastic region during testing. As can be seen, the mean load at break values ​​were lower when the specimens were gripped inside the inelastic region (i.e., shape A). However, when the specimens were gripped 1 mm inside the elastic region (shape G), the mean load at break improved by at least 10%, and in some cases by at least 40%.

[0103] [Table 8]

[0104] package The absorbent article 10 of the present disclosure may be placed in a package. The package may include polymeric films and / or other materials. Graphics and / or indicia relating to the properties of the absorbent article may be formed, printed, positioned, and / or disposed on an exterior portion of the package. Each package may include multiple absorbent articles. The absorbent articles may be packaged under compression to reduce the size of the package and still provide a reasonable amount of absorbent articles per package. Packaging the absorbent articles under compression allows caregivers to easily handle and store the package while providing manufacturers with reduced distribution costs due to the size of the package.

[0105] Thus, a package of absorbent articles of the present disclosure may have an In-Bag Stack Height according to the In-Bag Stack Height Test described herein that is less than about 110 mm, less than about 105 mm, less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm, less than about 74 mm, less than about 72 mm, or less than about 70 mm, specifically including all 0.1 mm increments within the specified ranges and all ranges within or formed by the ranges. Alternatively, a package of absorbent articles of the present disclosure may have an In-Bag Stack Height according to the In-Bag Stack Height Test described herein of from about 70 mm to about 110 mm, from about 70 mm to about 105 mm, from about 70 mm to about 100 mm, from about 70 mm to about 95 mm, from about 70 mm to about 90 mm, from about 70 mm to about 85 mm, from about 72 mm to about 80 mm, or from about 74 mm to about 78 mm, specifically including all 0.1 mm increments within the specified ranges, and all ranges formed within or by the ranges.

[0106] 11 illustrates an exemplary package 1000 including a plurality of absorbent articles 1004. The package 1000 defines an interior space 1002 into which the plurality of absorbent articles 1004 are placed. The plurality of absorbent articles 1004 are arranged in one or more stacks 1006.

[0107] combination: A. a first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region; a chassis including a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet; It is attached to the chassis, a separate ear comprising a laminate including a first nonwoven and a second nonwoven and an elastomeric material sandwiched between the first nonwoven and the second nonwoven, the laminate further comprising a plurality of ultrasonic bonds; the first and / or second nonwoven fabric has a basis weight of 17 gsm or less; An absorbent article, wherein the ears have an average load at break of 18N or more. B. The absorbent article of paragraph A, wherein the ear includes a first inelastic region and an elastic region, the ear is joined to the chassis at the first inelastic region, and the fastening system is joined to the ear at the elastic region. C. The absorbent article of paragraph B, wherein the ear further has a second inelastic region substantially opposite the first inelastic region, and the fastening system is disposed in both the second inelastic region and the elastic region. D. The absorbent article of any of paragraphs A-C, wherein the ears comprise a length ratio of about 3 or less. E. The absorbent article of paragraph D, wherein the length ratio is from about 1.5 to about 2.5. F. The absorbent article of any of paragraphs A-D, wherein the fastening element includes an average load at break of 24 N or greater. G. The absorbent article of any of paragraphs A-F, wherein the first nonwoven and / or the second nonwoven have a basis weight of 14 gsm or less. H. The absorbent article of any of paragraphs A-G, wherein the first nonwoven and / or the second nonwoven consist essentially of spunbond layers. I. The absorbent article of any of paragraphs A-H, wherein the ears are disposed in the second waist region. J. The ears are at least about 1.0 m long. 3 / m 2 The absorbent article of any of paragraphs AI, comprising an air permeability value of 0.1 to 0.5 mm / min. K. The absorbent article of any of paragraphs A-J, wherein the ear has an ear area and an elastic region having an elastic region area, the elastic region area being no greater than about 80% of the ear area. L. The absorbent article of any of paragraphs A-K, wherein the first nonwoven and / or the second nonwoven each have a basis weight of 14 gsm or less and an average load at break of 22 N or greater. M. The absorbent article described in any of paragraphs A-L, wherein the first nonwoven and / or the second nonwoven each consist essentially of a spunbond layer and have an average load at break of 22 N or greater. N. The absorbent article according to any one of paragraphs A to M, wherein the ear portions are stretchable by 20 mm or more at 5 N. O. The absorbent article of any of paragraphs A-N, wherein the first and / or second nonwoven has a basis weight of 12 gsm or less. P. The absorbent article of any of paragraphs A-O, having an average load at break of about 30 N or greater. Q. The absorbent article of any of paragraphs A-P, wherein the basis weight of the first nonwoven fabric is different from the basis weight of the second nonwoven fabric. R. The absorbent article of any of paragraphs A-Q, wherein the ear portions are stretchable by 50 mm or more at 10 N. S. The absorbent article of any of paragraphs A-R, wherein the absorbent core comprises less than 10% by weight cellulosic fibers. T. The absorbent article of any of paragraphs A-S, further comprising an elastic waist feature. U. A package comprising an absorbent article according to any of paragraphs A-T and having an in-bag stack height of less than about 110 mm. V. The absorbent article of any of paragraphs A-U, wherein the first and / or second nonwoven has a basis weight of 10 gsm or less.

[0108] Test Method Tensile Test Method Tensile testing is used to measure the strength of specimens at relatively high strain rates representative of the product's application. This method uses a suitable tensile tester with a servo-hydraulic actuator capable of speeds in excess of 5 m / s after 28 mm of travel, approaching 6 m / s after 40 mm of travel, such as an MTS810 available from MTS Systems Corp., Eden Prairie Minn, or equivalent. The tensile tester is fitted with a 50 lb force transducer available from Kistler North America, Amherst, NY, as product code 9712 B50 (50 lb), and a signal conditioner with dual mode amplifier (e.g., available from Kistler North America as product code 5010). Grips as shown in Figures 12 and 13 should be used to secure the specimen during tensile testing. (FIG. 13 is a side view of one of the grips of FIG. 12 having anti-slip material 505.) The opposing grips 500 may have the same width or different widths as specified.

[0109] (a) Grip Line contact grips 500 are selected to provide a well defined gauge and avoid excessive slippage. The specimen is positioned so that it has minimal slack between the grips. The tops 507 of the grips 500 are placed to provide good gauge definition while avoiding breaking or cutting the specimen. The tops are placed to provide a radius in the range of 0.5-1.0 mm. One or both portions of the grips 500 may be constructed to include a material 505 (e.g., a urethane or neoprene rubber strip having a Shore A hardness of 50-70) that reduces the tendency of the specimen to slip, as shown in FIG. 13. Unless otherwise specified, 15 cm (6 inch) wide top and bottom grips are used to clamp the specimen.

[0110] (b) Tensile testing of specimens from absorbent articles The ears are typically bonded to the chassis via thermal or adhesive or similar bonds. The ears should be separated from the chassis in such a way that the ears are not damaged and the performance of the ears is not altered. If the bond to the chassis is too strong (i.e., the ears would break upon removal), then the portion of the chassis bonded to the ear should be cut within the chassis material without damaging the ear. Folded fastening systems (e.g., release tape covering the fastening elements) should be unfolded.

[0111] The specimen is clamped in the top grip at a first grip position G1, which is the inner edge 52a of the fastener attachment joint 52 (see FIG. 5). The grip line G1 is kept parallel to the longitudinal centerline of the product. If the fastener attachment joint is at an angle, the specimen is gripped in the center of the joint area so that the grip line is kept parallel to the longitudinal centerline of the product in the center. The width of the top grip should be equal to the maximum length (L1) of the fastener attachment joint 52 measured parallel to the longitudinal centerline of the article. If the specimen length is the same as the maximum length of the fastener attachment joint at the G1 position, then any grip width greater than the specimen length at G1 can be used. The specimen is attached to the top grip and suspended from it. The opposing edge 38 of the specimen is attached to the bottom grip in a relaxed state. The bottom grip position G2 is adjusted so that the specimen is gripped at the outer edge 35b of the chassis joint. If the chassis joints are curved, the specimen is gripped at the outer edge of the outermost joint. The bottom grip is greater than the length of the ears at the second grip position G2. The top and bottom grips are parallel to each other.

[0112] The specimens are tested as follows: The vertical distance (perpendicular to the grip line) from the first grip position G1 to the second grip position G2 is measured to the nearest 0.1 mm with a ruler and this is used as the test gauge length. The specimens are tested for 9.1 seconds with the gauge length selected for the specimen. -1 The test speed is set to provide a strain rate of 9.1 mm / s. -1It is calculated by multiplying by the gauge length in mm. Before the test, 5 mm of slack is left between the grips.

[0113] Each specimen is pulled until it breaks. One grip is held stationary while the opposite grip is moved during the test. Force and actuator displacement data generated during the test are recorded using a MOOG SmarTEST ONE STO03014-205 stand-alone controller with the data collection frequency set at 1 kHz. The resulting load data can be expressed in Newtons as the load at break. The extension (mm) at 5N and 10N are also recorded. For example, a total of five specimens are run. The mean load at break and standard deviation, the mean extension and standard deviation at 5N, and the mean extension and standard deviation at 10N of at least four specimens are recorded. If the recorded standard deviation is higher than 5%, a new set of five specimens is run.

[0114] (c) Length ratio Grips are placed at the first and second gripping positions as in the previous step. The ratio of the length of the specimen at the second gripping position (L2) to the maximum length of the bond (L1) is the length ratio. The corresponding lengths are measured with a ruler to an accuracy of 0.1 mm.

[0115] Basis Weight Test Method Weigh each specimen using a digital balance to within ±0.1 milligrams. Measure the length and width of the specimen to within ±0.1 mm using a digital vernier caliper or equivalent. All testing is performed at 22±2°C and 50±10% relative humidity. Calculate basis weight using the following formula:

[0116]

number

[0117] A total of eight linear specimens of at least 10 mm x 25 mm are used to calculate the basis weight of the substrate.

[0118] The average basis weight and standard deviation are recorded.

[0119] Nonwoven specimens are obtained from the ears as follows: specimens should be taken from areas that have no additional material (i.e., only nonwoven). Each nonwoven layer is separated from the other layers of the ear without damaging or tearing the nonwoven layer. If one continuous nonwoven covers the outer and inner inelastic regions of the ear, the nonwoven is separated from the inelastic region and used as the specimen. If the nonwoven layer is inseparable from the other ear layers, specimens are collected from the outer inelastic region of the ear. If the outer inelastic region is smaller than the specified specimen dimensions or has additional material (other than the nonwoven layer), and if the inner inelastic region has the same nonwoven as the outer inelastic region, specimens (either the nonwoven layer or combination of nonwoven layers) are collected from the inner inelastic region. If the nonwoven layers in the inelastic regions are the same and / or inseparable, the calculated basis weight of the specimen is divided by the number of nonwoven layers to obtain the individual nonwoven basis weights.

[0120] Hysteresis Test Method Hysteresis testing can be used for a variety of specified strain values. Hysteresis testing utilizes a commercially available tensile testing machine (e.g., from Instron Engineering Corp., Canton, MA, SINTECH-MTS Systems Corporation, Eden Prairie, MN, or equivalent) interfaced with a computer. The computer is used to control the test speed and other test parameters and to collect, calculate, and report the data. Testing is performed under laboratory conditions at 23° C.±2° C. and 50%±2% relative humidity. Specimens are conditioned for 24 hours prior to testing.

[0121] Specimens are cut with dimensions of 10 mm in the direction of the intended stretch of the ears by 25.4 mm perpendicular to the direction of the intended stretch of the ears. Specimens are collected from either the inelastic or elastic areas.

[0122] Testing Protocol 1. Select the appropriate grips and load cell. The grips must have a flat surface and be wide enough to grip the specimen along its entire width. The grips must also provide adequate force and a suitable surface area to ensure that the specimen does not slip during testing. The load cell is selected so that the tensile response from the specimen to be tested is between 25% and 75% of the load cell capacity. 2. Calibrate the tester according to the manufacturer's instructions. 3. Set the distance between the grips (gauge length) to 7 mm. 4. Place the specimen in the flat of the grips so that the uniform width lies along a direction perpendicular to the gauge length. Clamp the specimen in the upper grip, allow the specimen to hang slack, then close the lower grip. Strain the preloaded slack with 5 grams / force. This means that data collection begins when the slack has been removed with a force of 5 grams force (at a constant crosshead speed of 13 mm / min). The strain is measured as a function of the adjusted gauge length (l ini ) The adjusted gage length is the length of the specimen between the grips of the tensile tester at a force of 5 grams force. This adjusted gage length is taken as the initial specimen length, which corresponds to 0% strain. The percent strain at any point in the test is defined as the change in length relative to the adjusted gage length divided by the adjusted gage length multiplied by 100. 5(a) First cycle load: The specimen is pulled to 100% strain at a constant crosshead speed of 70 mm / min. The specimen length extended between the grips is l max Report as. 5(b) First cycle unloading: The specimen is held at 100% strain for 30 seconds, then the crosshead is moved to its starting position (0% strain or initial specimen length, l) at a constant crosshead speed of 70 mm / min. ini ) and hold the specimen in the relaxed state for 1 minute. 5(c) Second cycle loading: Pull the specimen to 100% strain at a constant crosshead speed of 70 mm / min. 5(d) Second Cycle Unloading: The specimen is then held at 100% strain for 30 seconds, after which the crosshead is returned to its starting position (ie, 0% strain) at a constant crosshead speed of 70 mm / min.

[0123] A computer data system records the force applied to the specimen during the test as a function of the applied strain. The following quantities are reported from the resulting data generated: i. Preloaded slack 5 grams (l ini ) specimen length between grips in increments of 0.001 mm. ii. 100% distortion (l max ) specimen length between grips in the first cycle to the nearest 0.001 mm. iii. Second cycle load force 7 grams (l ext ) specimen length between grips in increments of 0.001 mm. iv. 0.01% unit, (l ext -l ini ) / (l max -l ini ) * % cure, defined as 100%.

[0124] The test was repeated on six separate specimens and the mean and standard deviation are reported.

[0125] Air Permeability Test It measures the air permeability of an ear laminate or substrate (e.g., a film, nonwoven, or article component) by measuring the flow rate of normal conditioned air through a test specimen that is subjected to a specified pressure drop. This test is particularly suitable for materials that have relatively high air permeability, such as nonwovens, perforated ear laminates, etc. ASTM D737 was used with the following modifications:

[0126] A TexTest FX3300 instrument or equivalent, available from Textest AG, Switzerland, or Advanced Testing Instruments ATI, Spartanburg SC, USA, is used. The procedures described in the TEXTEST FX3300 Air Permeability Tester manual, operating instructions, under Airtightness Test and Function and Calibration Check, are carried out. If a different instrument is used, follow the same regulations regarding airtightness and calibration according to the manufacturer's instructions.

[0127] Specimens are tested while in a relaxed state.

[0128] The test pressure drop was set at 125 Pa and the pressure drop was 38.3 cm 2 A test head with an area of ​​100 mm (FX3300-5 model) or equivalent is used. The results are recorded to three significant figures. The average of the five specimens is calculated and the air permeability value (m 3 / m 2 / min).

[0129] Bag stack height test The in-bag stack height of a package of absorbent articles is determined as follows. device A thickness tester is used that has a flat rigid horizontal sliding plate. The thickness tester is configured such that the horizontal sliding plate is free to move vertically while always being maintained in a horizontal orientation directly above a flat rigid horizontal base plate. The thickness tester includes a device suitable for measuring the gap between the horizontal sliding plate and the horizontal base plate to within ±0.5 mm. The horizontal sliding 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 beyond the contact surface of the absorbent article package in all directions). The horizontal sliding plate exerts a downward force of 850±1 grams force (8.34 N) on the absorbent article package, which may be achieved by placing a suitable weight in the center of the top surface of the horizontal sliding plate that does not contact the package, such that the total mass of the sliding plate plus the additional weight is 850±1 grams.

[0130] Test procedure The absorbent article packages are equilibrated at 23±2° C. and 50±5% relative humidity prior to measurement.

[0131] Raise the horizontal sliding plate and center the absorbent article package under it with the absorbent articles in the package oriented horizontally (see Figure 11). Any handles or other packaging features on the surface of the package that would contact either of the plates are folded flat against the surface of the package to minimize their effect on the measurement. Slowly lower the horizontal sliding plate until it touches the top surface of the package and then release it. 10 seconds after releasing the horizontal sliding plate, measure the gap between the horizontal plates to within ±0.5mm. Five identical packages (same size package and same number of absorbent articles) are measured and the arithmetic average is reported as the package width. Calculate "Stack Height in Bag" = (Package Width / Number of Absorbent Articles per Stack) x 10 and report within ±0.5mm.

[0132] The dimensions and values ​​disclosed herein should not be understood to be strictly limited to the exact numerical values ​​recited. Rather, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0133] All documents cited in this application, including all cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document is not admitted to be prior art with respect to any invention disclosed or claimed herein, or that such citation, alone or in combination with any other reference(s), teaches, suggests or discloses any such invention. Furthermore, if any meaning or definition of a term in this document conflicts with a meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0134] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. a first waist region (14), a second waist region (18), and a crotch region (16) disposed between the first waist region and the second waist region; a chassis (20) including a topsheet (24), a backsheet (26), and an absorbent core (28) disposed between the topsheet and the backsheet; a separate ear (30) joined to the chassis and comprising a gathered laminate comprising a first nonwoven (300) and a second nonwoven (302) and an elastomeric film (304) sandwiched between the first nonwoven and the second nonwoven; The gathered laminate further comprises a plurality of ultrasonic bonds (46); the first nonwoven and the second nonwoven are ultrasonically bonded to the elastomeric film when the elastomeric film is in an elongated state to form the gathered laminate; each of the first and second nonwoven fabrics having a basis weight of 17 gsm or less; a fastening system (48) is joined to the ears at a fastener attachment joint (52), the ears including a length ratio of 1 to 3, the length ratio being the ratio of a length (L2) of the ears (30) to a maximum length (L1) of the fastener attachment joint (52); The ears (30) are joined to the chassis (20) at chassis mounting joints (35); The length (L2) of the ear (30) is the length at the outer edge (35b) of the chassis mounting joint (35); the ear includes a first inelastic region (308), an elastic region (306), and a second inelastic region (310) substantially opposite the first inelastic region, the ear is joined to the chassis at the first inelastic region, and the fastening system is disposed in both the second inelastic region and the elastic region; the fastening system (48) is joined to ears in the elastic region (306); the fastening system (48) is joined to the ears such that it overlaps the elastic region by a maximum lateral overlap distance (D); The absorbent article, wherein said maximum lateral overlap distance (D) is between 1% and 5% of the maximum width (Y) of said elastic region.

2. 2. The absorbent article of claim 1, wherein said fastening system (48) comprises fastening elements (50), said fastening elements comprising an average load at break of 22N or greater.

3. The absorbent article of claim 1 or 2, wherein the first nonwoven and / or the second nonwoven have a basis weight of 14 gsm or less.

4. The absorbent article according to any one of claims 1 to 3, wherein the first nonwoven fabric and / or the second nonwoven fabric is a spunbond layer.

5. The absorbent article according to any one of claims 1 to 4, wherein the ear portion is disposed within the second waist region.

6. The ears are at least 1.0 m long. ３ / m ２ The absorbent article according to any one of claims 1 to 5, having an air permeability value of 1 / min.

7. The absorbent article according to any one of claims 1 to 6, wherein the ear has a total ear area and an elastic region having an elastic region area, the elastic region area being 80% or less of the total ear area.

8. The absorbent article according to any one of claims 1 to 7, wherein the ear portions are stretchable by 20 mm or more at 5 N and by 50 mm or more at 10 N.

9. The absorbent article according to any one of claims 1 to 8, wherein the basis weight of the first and / or second nonwoven is 12 gsm or less.

10. The absorbent article of any one of the preceding claims, wherein said fastening system (48) comprises fastening elements (50), said fastening elements comprising an average load at break of 24N or greater.

11. The absorbent article according to any one of claims 1 to 10, wherein the basis weight of the first nonwoven fabric is different from the basis weight of the second nonwoven fabric.

12. The absorbent article according to any one of claims 1 to 11, wherein the basis weight of the first and / or second nonwoven is 10 gsm or less.

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