Extensible absorbent layer and absorbent article

Abstract

The present invention provides an absorbent layer prepared from an absorbent nonwoven web having a first plurality of slits with a first orientation and a second plurality of slits with a second orientation, wherein the first orientation is different from the second orientation. The first plurality of slits and the second plurality of slits are at least partially through the absorbent nonwoven web, and the second plurality of slits at least partially intersects the first plurality of slits in a manner such that where the first and second plurality of slits intersect the first and second plurality of slits combine to form apertures in the absorbent nonwoven web. The present invention also provides an absorbent article having a liquid-permeable top layer, a liquid-impermeable backing layer, and the absorbent layer of the present invention positioned between the top layer and the backing layer. Also disclosed is a method of preparing the absorbent layer.

Description

FIELD OF THE INVENTION [0001] The present invention relates to disposable absorbent articles such as sanitary napkins, pantiliners or incontinence pads and absorbent layers used therein. The present invention further relates to a process of manufacturing an absorbent layer or absorbent article. BACKGROUND OF THE INVENTION [0002] Disposable absorbent articles, such as sanitary napkins worn by women, must fulfill numerous requirements in order to be considered satisfactory for use. From the standpoint of the consumer using the disposable absorbent article, efficient absorption and retention of liquid and other discharges from the human body must be provided, and possible soiling of the wearer's body or the wearer's garment should be avoided. In addition, the absorbent article should be comfortable for a user to wear. The absorbent article should therefore be able to individually conform to the shape of the wearer's body, so that the wearer is not hindered by the absorbent article. Ide...

AI Technical Summary

Benefits of technology

[0011] In another embodiment of the present invention, provided is a process for preparing a web, in particular the absorbent nonwoven web of the absorbent layer of the present invention. In this embodiment, the process has the steps of a) providing a web; b) providing a slitting apparatus having anvil roll, a first cutting roll and a second cutting roll; c) passing the web between the first cutting roll and the anvil to form a first plurality of slits in the absorbent nonwoven web; and d) passing the web between the second cutting roll and the anvil to form a second plurality of slits in the absorbent nonwoven web, wherein at least one slit in the second plurality of slits intersects at least one slit from the first plurality of slits such that an aperture is formed in the web. In the process of the present invention, both the first and second cutting rolls are positioned adjacent the same anvil roll. That is, the first cutting roll and the second cutting roll place slits in the absorbent nonwoven web against the same anvil roll. The absorbent nonwoven web of the present invention is brought into contact with the anvil roll, cut with the first cutting roll. Once cut or slitted with the first cutting roll, the web remains in contact with the anv

Problems solved by technology

This would seriously deteriorate the performance of the absorbent article and influence negatively the wearing comfort.

Furthermore, the materials must be easily processed at high speeds, which often include considerable forces and tensions being applied to the material, especially in the machine direction.

Excessive extensibility of an absorbent layer in the longitudinal direction, which is generally the machine direction, will make it very difficult to prepare such an absorbent layer on a production line designed for very high production rates (high speeds).

If the flexural resistance is reduced too much, the absorbent article will bunch, twist or rope or form lumps when the article is worn.

Additionally, the articles might not be accepted by the consumer if the absorbent article feels too flexible, i.e. flimsy or flabby, thereby creating the impression that the article will not provide sufficient protection against the soiling of the garment to be protected.

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