Forming belts for forming nonwovens

Abstract

The present invention discloses a forming belt for preparing a nonwoven substrate. The forming belt includes a first surface, which, when in use, defines a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction. A plurality of discrete belt patterns may be arranged in a sequential relationship relative to the longitudinal direction. At least most of the plurality of discrete belt patterns may include a total area of ​​discrete belt patterns, a first forming area having a three-dimensional raised element of a first pattern extending outward from the plane of the first surface, and a second forming area having a three-dimensional raised element of a second pattern extending outward from the plane of the first surface. The first forming area may have a first air permeability value, and the second forming area may have a second air permeability value. The first air permeability value may be different from the second air permeability value.

Description

Technical Field

[0001] The present invention relates to formed three-dimensional nonwoven fabrics and articles made using formed three-dimensional nonwoven fabrics. Background Art

[0002] Nonwoven fabrics can be used for a variety of applications, including absorbent personal care products, clothing, medical applications and cleaning applications. Nonwoven personal care products include baby care products such as diapers, child care products such as training pants, feminine care products such as sanitary napkins and adult care products such as incontinence products, pads and pants. Nonwoven clothing includes protective work clothes and medical clothing such as surgical gowns. Other nonwoven medical applications include nonwoven wound dressings and surgical dressings. Nonwoven cleaning applications include towels and wipes. Other uses of nonwoven fabrics are well known. The aforementioned list is not considered to be exhaustive.

[0003] The various properties of nonwoven fabrics determine the adaptability of nonwoven fabrics for different applications. Nonwoven fabrics can be processed to have different combinations of properties to meet different needs. The variable properties of nonwoven fabrics include liquid handling properties such as wettability, dispensability, and absorbency, strength properties such as tensile strength and tear strength, soft properties, durable properties such as abrasion resistance and aesthetic properties. The physical shape of the nonwoven fabric also affects the functionality and aesthetic properties of the nonwoven fabric. Nonwoven fabrics are initially prepared into sheets that can have a substantially planar surface without feature structures when placed on a flat surface, or can have a series of surface feature structures such as holes or protrusions or both. Nonwoven fabrics with holes or protrusions are often referred to as three-dimensional shaped nonwoven fabrics. The present disclosure relates to three-dimensional shaped nonwoven fabrics.

[0004] Despite advances in the nonwoven fabric art, there remains a need for improved nonwoven fabrics having three-dimensional surface features.

[0005] Additionally, there remains a need for processes and apparatus for making improved nonwoven fabrics having three-dimensional surface features.

[0006] Additionally, there remains a need for articles, including absorbent articles, that utilize improved nonwoven fabrics having three-dimensional surface features.

[0007] Additionally, there remains a need for absorbent articles that utilize nonwoven fabrics having three-dimensional surface features and that can be packaged in a compressed form while minimizing the loss of the three-dimensional surface features when opened from the package.

[0008] Additionally, there remains a need for absorbent articles that utilize soft spunbond nonwoven fabrics having three-dimensional surface features that have reduced linting characteristics during use.

[0009] Additionally, there remains a need for absorbent article packaging that includes soft nonwoven materials having reduced in-bag stacking height compared to conventional absorbent article packaging, thereby making the package easier for caregivers to hold and store, and allowing manufacturers to enjoy low distribution costs without sacrificing the aesthetic clarity, absorbency or softness of the ready-made absorbent articles. Summary of the invention

[0010] The present invention discloses a forming belt for preparing a nonwoven substrate. The forming belt includes a first surface, which, when in use, defines a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction. A plurality of discrete belt patterns may be arranged in a sequential relationship relative to the longitudinal direction. At least most of the plurality of discrete belt patterns may include a total area of ​​discrete belt patterns, a first forming area having a three-dimensional raised element of a first pattern extending outward from the plane of the first surface, and a second forming area having a three-dimensional raised element of a second pattern extending outward from the plane of the first surface. The first forming area may have a first air permeability value, and the second forming area may have a second air permeability value. The first air permeability value may be different from the second air permeability value. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a photograph of one embodiment of the present disclosure.

[0012] Figure 2 is a photograph of one embodiment of the present disclosure.

[0013] Figure 3 is a photograph of one embodiment of the present disclosure.

[0014] Figure 4 For Figure 1 A cross-section of a portion of a fabric of the present disclosure is shown.

[0015] Figure 5A Schematically, a cross section of a filament produced from a primary component A and a secondary component B arranged side by side is shown.

[0016] Figure 5B As a schematic diagram, a cross section of a filament produced with a primary component A and a secondary component B in an eccentric sheath / core arrangement is shown.

[0017] Figure 5C As a schematic diagram, a cross section of a filament made with a primary component A and a secondary component B in a concentric sheath / core arrangement is shown.

[0018] Figure 6 A perspective photograph of a trilobal bicomponent fiber.

[0019] Figure 7is a schematic diagram of an apparatus for preparing the fabric of the present disclosure.

[0020] Figure 8 Detail of a portion of an apparatus for bonding a portion of a fabric of the present disclosure.

[0021] Fig. 9 Additional details of a portion of an apparatus for bonding a portion of a fabric of the present disclosure.

[0022] Fig.10 Detail of a portion of an apparatus for optionally additionally bonding a portion of a fabric of the present disclosure.

[0023] Fig.11 is a photograph of one embodiment of the present disclosure.

[0024] Fig.12 is a photograph of a portion of a forming belt that may be used in the present disclosure.

[0025] Fig.13 for Fig.12 A cross-sectional view of a portion of the forming belt is shown.

[0026] Fig.14 For the preparation Fig.12 An image of a portion of a mask forming a strip is shown.

[0027] Fig.15 For the preparation Fig.16 An image of a portion of a mask forming a strip is shown.

[0028] Fig.16 is a photograph of a portion of a forming belt that may be used in the present disclosure.

[0029] Fig.17 For the preparation Fig.18 An image of a portion of a mask forming a strip is shown.

[0030] Fig.18 is a photograph of a portion of a forming belt that may be used in the present disclosure.

[0031] Fig.19 is a photograph of a portion of a forming belt that may be used in the present disclosure.

[0032] Fig. 20 For the preparation Fig.19 Image of mask showing forming tape.

[0033] Fig.21 For Fig.19 A photograph of a fabric of the present disclosure produced on a forming belt is shown.

[0034] Fig. 22 is a schematic perspective view of a forming belt of the present disclosure.

[0035] Fig.23 is a plan view of a nonwoven substrate comprising a nonwoven fabric of the present disclosure.

[0036] Fig.24 is a plan view of a nonwoven substrate comprising a nonwoven fabric of the present disclosure.

[0037] Fig.25A is a plan view of a fabric of the present disclosure with portions removed to allow for measurement of local basis weight.

[0038] Fig.25B is a plan view of a fabric of the present disclosure with portions removed to allow for measurement of local basis weight.

[0039] Fig.26 is a graphical representation of the cross-directional variation in basis weight of the fabrics of the present disclosure.

[0040] Fig. 27 A schematic diagram of a package disclosed herein.

[0041] Fig.28 is a plan view of an absorbent article of the present disclosure.

[0042] Fig.29 is a plan view of an absorbent article of the present disclosure.

[0043] Fig.30 for Fig.28 A cross-sectional view of section 29-29.

[0044] Fig.31 is a plan view of an absorbent article of the present disclosure.

[0045] Fig.32 for Fig.31 A cross-sectional view of section 32-32.

[0046] Fig.33 is a plan view of an absorbent article of the present disclosure.

[0047] Fig.34 for Fig.33 A cross-sectional view of section 34-34.

[0048] Fig.35 for Fig.33 A cross-sectional view of section 35-35.

[0049] Fig.36 is a photograph of one embodiment of the present disclosure.

[0050] Fig.37 is a photograph of one embodiment of the present disclosure. DETAILED DESCRIPTION

[0051] The present disclosure provides a formed nonwoven fabric formed directly on a formed forming belt with continuous spunbond filaments in a single forming process. The fabric of the present disclosure can take on a shape corresponding to the shape of the forming belt. The fabric of the present disclosure made on the forming belt of the present disclosure by the method of the present disclosure can be particularly beneficially used in personal care products, clothing, medical products, and cleaning products.

[0052] In some embodiments herein, the beneficial characteristic structures of nonwoven fabrics will be described in the context of the total area of ​​the nonwoven fabric. The total area can be the area determined by the size suitable for certain uses, and the various characteristic structures of the present invention provide beneficial properties for the certain uses. For example, the total area of ​​a fabric can be the total area of ​​a fabric, and the size of the fabric makes it suitable for use as the top sheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of a diaper, or the top sheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of a sanitary napkin, the top sheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of an adult incontinence pad or pants, or the pad of a floor cleaning tool. Therefore, the total area can be based on a width dimension and a length dimension ranging from 10 cm wide to 50 cm wide and 15 cm long to 100 cm long, thereby producing a 150 cm 2 Up to 500cm 2 The foregoing ranges include every integer size between the range boundaries as if explicitly stated. By way of example, a 176 cm 2 The total area of ​​the formed nonwoven fabric is disclosed in the above ranges. As will be understood from the description herein, the total area of ​​the formed nonwoven fabric can be an area less than the area of ​​the web of the nonwoven fabric, which is a part of the web when the formed nonwoven fabric is commercially prepared. That is, in a given commercially prepared web of nonwoven fabric, there can be a plurality of formed nonwoven fabrics of the present invention, each of which has a total area less than the area of ​​the web (on which it is prepared).

[0053] A photograph of a representative embodiment of a formed nonwoven fabric 10 is shown in Figure 1-3 The formed nonwoven fabric 10 may be a spunbond nonwoven substrate having a first surface 12 and a second surface 14. Figure 1-3 In the embodiment, the second surface 14 faces the viewer and is opposite to the first surface 12, which is not visible but is shown in FIG. Figure 4The term "surface" is used broadly for descriptive purposes to refer to both sides of the web and is not intended to infer any necessary flatness or smoothness. Although the formed nonwoven fabric 10 is soft and flexible, it will be described in the flattened state, that is, in the context of one or more XY planes parallel to the flattened state, and the planes correspond to the planes of the cross direction CD and the planes of the machine direction MD, respectively, in web preparation technology, as shown in FIG. Figure 1-3 The length L along MD and the width W along CD determine the total area A of the fabric 10. Figure 4 (It is Figure 1 For descriptive purposes, the three-dimensional features of the formed nonwoven fabric are described as extending outwardly from the XY plane of the first plane 16 in the Z direction (see FIG. Figure 4 ). In one embodiment, the maximum dimension of the three-dimensional features along the Z direction may define the maximum distance between the plane of the first plane 16 and the XY plane of the second plane 18, which can be measured as the average thickness AC of the formed nonwoven fabric 10. The average thickness can be determined via an optical non-contact device, or it can be determined by an instrument involving spaced apart plates that measure the thickness of the nonwoven fabric placed between them under a predetermined pressure. It is not necessary for all three-dimensional features to have the same maximum dimension in the Z direction, but multiple three-dimensional features can have substantially the same maximum dimension in the Z direction determined by the spinning process and the characteristics of the forming belt described below.

[0054] like Figure 1-4 As shown, the fabric 10 may have a plurality of discrete identifiably different three-dimensional features in a regularly repeating pattern, including a first three-dimensional feature 20, a second three-dimensional feature 22, and a third three-dimensional feature 24, such as Figure 2 and 3 For example, in Figure 1 , the heart-shaped first three-dimensional feature 20 is identifiably different from the smaller, generally triangular-shaped second three-dimensional feature 22. The identifiable difference may be visual, such as a identifiably different size and / or shape.

[0055] The three-dimensional features of fabric 10 are formed directly from spun fibers onto a forming belt having corresponding three-dimensional features in a pattern. In one sense, fabric 10 is molded onto a forming belt that determines the shape of the three-dimensional features of fabric 10. Importantly, however, as described herein, the apparatus and method of the present invention produce fabric 10 such that, in addition to taking on the shape of the forming belt due to the properties of the forming belt and the properties of the apparatus used to form the fabric, the fabric is also endowed with beneficial properties for use in personal care products, garments, medical products, and cleaning products. Specifically, due to the properties of the forming belt and other equipment elements, as described below, the three-dimensional features of fabric 10 have strength properties that can vary from feature to feature in the following manner: providing beneficial properties of fabric 10 when used in personal care products, garments, medical products, and cleaning products. For example, the first three-dimensional feature structure 20 may have a basis weight or density that is different from the basis weight or density of the second three-dimensional feature structure 22, and both may have a basis weight or density that is different from the basis weight or density of the third three-dimensional feature structure 24, thereby providing beneficial aesthetic and functional properties related to fluid acquisition, distribution and / or absorption in a diaper or sanitary napkin.

[0056] It is believed that the differences in strength properties between the various three-dimensional features of fabric 10 are due to fiber distribution and compaction resulting from the apparatus and method described below. Fiber distribution occurs during the fiber spinning process, rather than during, for example, a post-manufacturing process such as a hydroentanglement process or an embossing process. Since the fibers are free to move during the spinning process, with the motion determined by the nature of the features and the air permeability of the forming belt and other processing parameters, it is believed that the fibers will be more stably and permanently formed in fabric 10.

[0057] As can be seen in Figure 1-3 , and as can be understood from the description herein, different three-dimensional feature structures can be defined by a relatively high density (relative to the interior of the three-dimensional feature structure) area, which can be in the form of a closed figure (such as Figure 1 and 3 The heart shape in the Figure 2 and 3 The closed figure may be a curved closed figure, such as Figure 1 and 3 The relatively high density regions may be regions of the fabric 10 that are most closely adjacent to the first surface 12 in the Z direction, such as Figure 4 The regions 21 shown in the drawings may be located at least partially in or on the first plane 16 when in the flattened state. Figure 1As shown, the first three-dimensional feature structure 20 is heart-shaped and, as shown in an exemplary first three-dimensional feature structure 20A, is defined by curved closed heart-shaped elements. A curved element can be understood as a linear element that has a tangent vector V at any point along its length (in the presence of a closed shape) such that the tangent vector V has both an MD component and a CD component that change value over more than 50% of the length of the linear element of the closed figure. Of course, the figure does not need to be completely 100% closed, but the linear element may have breaks that do not deviate from the overall impression of the closed figure. As discussed below in the context of a forming belt, a relatively high density of curved closed heart-shaped elements is formed by corresponding closed heart-shaped raised elements on the forming belt, thereby preparing a heart-shaped closed figure on the fabric 10. In a repeating pattern, the individual shapes (in Figure 1 In the case of the first three-dimensional features in the fabric 10, a heart shape) can result in an aesthetically pleasing soft pillow-like features over the total area OA of the second surface 14 of the fabric 10. In an embodiment where the fabric 10 is used as a topsheet for a diaper or sanitary napkin, the second surface 14 of the fabric 10 can face the body to deliver excellent aesthetic and performance benefits related to softness, compression resistance, and fluid absorption.

[0058] Specifically, in Figure 1-3 In the closed three-dimensional features of the regularly repeating pattern shown, without being bound by theory, it is believed that the size of the various features, the average basis weight of the entire fabric 10 over its total area, and the other processing parameters described below (which define different strength properties) contribute to the beneficial improvement of compression recovery. It is believed that multiple relatively closely spaced, relatively small and relatively pillow-like three-dimensional features act as springs to resist compression and recover once the compressive force is removed. Compression recovery is important in personal care products such as diapers, sanitary napkins, or adult incontinence pads, diapers or pants topsheets, backsheet nonwovens, collection layers, distribution layers, or other component layers because such products are typically packaged and folded in a compressed state. For aesthetic and performance purposes, manufacturers of personal care products wish to retain most, if not all, of the existing thickness. Due to the soft look and feel and the pleasing crisp appearance, well-defined shapes, including very small shapes such as Figure 2The three-dimensionality of the features formed, as shown in the small heart shape, provides important aesthetic benefits. The three-dimensional features also provide softness, improved absorbency, less leakage, and an overall improved user experience during use. However, during the folding, packaging, shipping, and storage of personal care products, the necessary compression can cause the top sheet, backsheet nonwoven fabric, acquisition layer, distribution layer, or other component layers of the absorbent article to permanently lose thickness, thereby degrading the functional benefits of the existing product. We have unexpectedly discovered that the nonwoven fabrics of the present disclosure retain their existing three-dimensional features to a significant extent, even after undergoing compression packaging and distribution in the compressed packaging state.

[0059] Table 1 below shows the compression recovery data of two embodiments of the present disclosure. Example 1 corresponds to Figure 1 The fabric 10 shown is as shown in reference Fig.12 and 14 Example 2 corresponds to Figure 2 The fabric 10 shown is as shown in reference Fig.15 and 16 As can be seen from the data, the fabric 10 of the present invention exhibits significant benefits in compression recovery when measured by the "Compression Aging Test". In one form, an absorbent article package having the compression recovery feature of the present disclosure may have a reduced in-bag stack height, but still deliver the aesthetic, absorbency, and softness benefits of a ready-made diaper. Or as if it had never been compressed and packaged. The present invention provides packages with reduced in-bag stack heights that allow caregivers to easily grasp and store the packages, while also providing manufacturers with reduced distribution costs, both while maintaining the ready-made aesthetic clarity, absorbency, or softness performance of the absorbent article.

[0060] Example 1 :

[0061] A bicomponent spunbond nonwoven fabric was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration, such as Figure 6 , which is a scanning electron microscope photo showing a cross-section of a bicomponent trilobal fiber. The nonwoven fabric is spun on a forming belt having a Fig.12 The repeating pattern is as follows Figure 7 and 8 As described, it moves at a line speed of about 25 meters / minute to an average basis weight of 30 grams / square meter with a repeating pattern of heart shapes, such as Figure 1The fibers of the fabric are further bonded on the first side 12 by heated compaction rolls 70 , 72 (described below) at 130° C. and wound onto a reel at a winder 75 .

[0062] Example 2 :

[0063] A bicomponent spunbond nonwoven fabric was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration, such as Figure 6 , which is a scanning electron microscope photo showing a cross-section of a bicomponent trilobal fiber. The nonwoven fabric is spun on a forming belt having a Fig.16 The repeating pattern is as follows Figure 7 and 8 As described, it moves at a line speed of about 25 meters / minute to form a fabric 10 having an average basis weight of 30 grams / square meter with diamond shapes in a repeating pattern, such as Figure 2 The fibers of the fabric are further bonded on the first side 12 by heated compaction rolls 70, 72 (described below) at 130°C.

[0064] Table 1: Compression recovery

[0065]

[0066] As can be seen from Table 1, the fabric 10 of the present invention retains a significant amount of thickness after being compressed under relatively high pressure. For example, the samples of Example 1 and Example 2 retained greater than 70% of their initial average thickness after being tested under a pressure of 35 KPa by the "Compression Aging Test." The "Compression Aging Test" is a simulation of the following conditions that a nonwoven fabric will encounter: packaged in a high compression packaging diaper, and then maintained in this state during distribution to be distributed to a consumer, and then the package is ultimately opened by the consumer.

[0067] The present disclosure may utilize a melt spinning process. In melt spinning, there is no mass loss in the extrudate. Melt spinning is different from other spinning, such as wet spinning or dry spinning from a solution, in which the solvent is removed by volatilization or diffusion from the extrudate, resulting in mass loss.

[0068] Spinning can be carried out at about 150°C to about 280°, or in some embodiments, at about 190° to about 230°. The fiber spinning speed can be greater than 100 meters per minute, and can be about 1,000 to about 10,000 meters per minute, and can be about 2,000 to about 7,000 meters per minute, and can be about 2,500 to about 5,000 meters per minute. The spinning speed can affect the brittleness of the spun fiber, and generally speaking, the higher the spinning speed, the less brittle the fiber. Continuous fibers can be produced by a spunbond process or a meltblown process.

[0069] The fabric of the present disclosure may include continuous multi-component polymer filaments, including a primary polymer component and a secondary polymer component. The filaments may be continuous bicomponent filaments, including a primary polymer component A and a secondary polymer component B. The bicomponent filaments have a cross section, a length, and a circumferential surface. Component A and component B may be arranged in substantially different zones across the cross section of the bicomponent filaments, and may extend continuously along the length of the bicomponent filaments. Secondary component B continuously forms at least a portion of the circumferential surface of the bicomponent filaments along the length of the bicomponent filaments. Polymer component A and polymer component B may be melt-spun into multi-component fibers on conventional melt spinning equipment. Equipment will be selected based on the desired multi-component configuration. Commercially available melt spinning equipment is purchased from Hills, Inc., located in Melbourne, Florida. The spinning temperature ranges from about 180°C to about 230°C. The processing temperature is determined by the chemical properties, molecular weight, and concentration of each component. The bicomponent spunbond filaments may have an average diameter of about 6 to about 40 microns, and preferably about 12 to about 40 microns.

[0070] Component A and component B can be arranged as follows Figure 5A The parallel arrangement structure shown or Figure 5B The eccentric sheath / core arrangement shown in the embodiment of the present invention is used to obtain a filament exhibiting a natural helical crimp. Alternatively, component A and component B may be arranged as shown in the embodiment of the present invention. Figure 5C In addition, component A and component B can also be arranged as shown in FIG. Figure 6 The multi-lobed sheath-core arrangement shown. Other multi-component fibers can be produced by using the compositions and methods of the present disclosure. The bi-component fibers and multi-component fibers can be in a segmented, ribbon, island-in-the-sea configuration, or any combination thereof. The sheath can be continuous or discontinuous around the core. The weight ratio of the sheath to the core is about 5:95 to about 95:5. The fibers of the present disclosure can have different geometric shapes, including circular, elliptical, star-shaped, rectangular, and other various eccentricities.

[0071] Methods for extruding multicomponent polymer filaments into such arrangements are well known to those of ordinary skill in the art.

[0072] A wide variety of polymers are suitable for practicing the present disclosure, including polyolefins (such as polyethylene, polypropylene, and polybutylene), polyesters, polyamides, polyurethanes, elastomeric materials, etc. Non-limiting examples of polymer materials that can be spun into filaments include natural polymers such as starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, chitin, chitosan, polyisoprene (cis and trans), peptides, polyhydroxyalkanoates; and synthetic polymers, including but not limited to thermoplastic polymers such as polyesters, nylons, polyolefins such as polypropylene, polyethylene, polyvinyl alcohol and polyvinyl alcohol derivatives, sodium polyacrylate (absorbent gelling material); and copolymers of polyolefins such as polyethylene-octene or polymers comprising a monomer blend of propylene and ethylene; and biodegradable or compostable thermoplastic polymers such as polylactic acid filaments, polyvinyl alcohol filaments, and polycaprolactone filaments. In one example, the thermoplastic polymer is selected from the group consisting of polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, styrene-butadiene-styrene block copolymer, styrene-isoprene-styrene block copolymer, polyurethane, and mixtures thereof. In another example, the thermoplastic polymer is selected from the group consisting of polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, and mixtures thereof. Alternatively, the polymer may include a polymer derived from a bio-based monomer such as bio-polyethylene or bio-polypropylene.

[0073] The primary component A and the secondary component B may be selected so that the resulting bicomponent filaments provide improved nonwoven bonding and substrate softness.Primary polymer component A has a melting temperature that is lower than the melting temperature of secondary polymer component B.

[0074] The primary polymer component A may comprise a random copolymer of polyethylene or propylene and ethylene. The secondary polymer component B may comprise a random copolymer of polypropylene or propylene and ethylene. Polyethylene comprises linear low density polyethylene and high density polyethylene. In addition, the secondary polymer component B may also comprise an additive to enhance the natural spiral curl of the filaments, reduce the bonding temperature of the filaments and enhance the abrasion resistance, strength and flexibility of the resulting fabric.

[0075] Inorganic fillers such as oxides of magnesium, aluminum, silicon, and titanium may be added as inexpensive fillers or processing aids. Other inorganic materials include hydrated magnesium silicate, titanium dioxide, calcium carbonate, clay, chalk, boron nitride, limestone, diatomaceous earth, mica, glass, quartz, and ceramics.

[0076] The filaments of the present invention also contain a slip additive in an amount sufficient to impart the desired tactile properties to the fiber. As used herein, "slip additive" or "slip agent" refers to an external lubricant. When melt blended with the resin, the slip agent gradually seeps out or migrates to the surface during cooling or after manufacture, thereby forming a uniform, invisibly thin coating, thereby producing a permanent lubricating effect. The slip agent is preferably a fast-acting full-bodied slip agent and can be a hydrocarbon with one or more functional groups selected from hydroxides, aryls and substituted aryls, halogens, alkoxyls, carboxylates, esters, carbon unsaturated substances, acrylates, oxygen, nitrogen, carboxyls, sulfates and phosphates.

[0077] During preparation or in post-processing process or even in both, three-dimensional nonwoven fabric of the present invention can be processed with surfactant or other reagent to hydrophilize the fiber web or make it hydrophobic. This is the standard practice for nonwoven fabrics used for absorbent articles. For example, the fiber web used for top sheet can be processed with hydrophilizing material or surfactant to make it permeable for body effluent such as urine. For other absorbent articles, top sheet can remain on its natural hydrophobic state or make it more hydrophobic by adding hydrophobizing material or surfactant.

[0078] Suitable materials for making the multicomponent filaments of the fabrics of the present disclosure include PH-835 polypropylene available from LyondellBasell and Aspun-6850-A polyethylene available from Dow chemical company.

[0079] When polyethylene is component A (sheath) and polypropylene is component B (core), the bicomponent filaments may comprise polyethylene from about 5 to about 95% by weight and polypropylene from about 95 to about 5%. The filaments may comprise polyethylene from about 40 to about 60% by weight and polypropylene from about 60 to about 40% by weight.

[0080] Go to Figure 7 , discloses a representative production line for making the fabric 10 of the present disclosure. The production line is arranged to produce a fabric of bicomponent continuous filaments, but it should be understood that the present disclosure includes nonwoven fabrics made with monocomponent filaments or multicomponent filaments having more than two components. The bicomponent filaments may be trilobal.

[0081] The production line includes a pair of extruders 32 and 34 for separately extruding a primary polymer component A and a secondary polymer component B. Polymer component A is fed into the corresponding extruder 32 from a first hopper 36, and polymer component B is fed into the corresponding extruder 34 from a second hopper 38. Polymer component A and polymer component B can be fed from the extruders 32 and 34 through corresponding polymer conduits 40 and 42 to filters 44 and 45 and melt pumps 46 and 47, which pump the polymers into a spinning pack 48. Spinnerets for extruding bicomponent filaments are well known to those of ordinary skill in the art and are therefore not described in detail herein.

[0082] Generally described, the spin pack 48 includes a housing including a plurality of plates stacked one on top of another with patterned openings arranged to create flow paths for individually directing polymer component A and polymer component B through a spinneret. The spin pack 48 has openings arranged in one or more rows. When the polymer is extruded through the spinneret, the spinneret openings form a curtain of filaments extending downwardly. For purposes of this disclosure, the spinneret may be arranged to form a plurality of plates stacked one on top of another with patterned openings arranged to create flow paths for individually directing polymer component A and polymer component B through a spinneret. Figure 5A , 5B and sheath / core or side-by-side bicomponent filaments as shown in 5C, and non-circular fibers such as trilobal fibers, such as Figure 6 In addition, the fibers may also be monocomponent comprising one polymer component such as polypropylene.

[0083] The production line also includes a quench blower 50 positioned adjacent to the filament curtain extending from the spinneret. The air from the quench blower 50 quenches the filaments extending from the spinneret. The quenching air may be directed from one side of the filament curtain or from both sides of the filament curtain.

[0084] Attenuator 52 is positioned below the spinneret and receives the quenched filaments. Fiber suction units or aspirators used as attenuators in the process of melt spinning polymers are well known. Suitable fiber suction units for the process of the present disclosure include linear fiber attenuators of the type shown in U.S. Patent 3,802,817 and extraction guns of the type described in U.S. Patent 3,692,618 and U.S. Patent 3,423,266, the disclosures of which are incorporated herein by reference.

[0085] Generally described, the attenuator 52 includes an elongated vertical channel through which the filaments are drawn by suction air, which enters from the side of the channel and flows downwardly through the channel. A shaped, annular and at least partially perforated forming belt 60 is positioned below the attenuator 52 and receives the continuous filaments from the outlet opening of the attenuator 52. The forming belt 60 is a belt and travels around a guide roller 62. A vacuum 64 positioned below the forming belt 60 (where the filaments are deposited) draws the filaments against the forming surface. Although the forming belt 60 is in the Figure 8 It is shown as a belt in the figure, but it should be understood that the forming belt can also be in other forms, such as a rotating drum. The details of the forming belt of a specific shape are described below.

[0086] In the operation of the production line, hoppers 36 and 38 are filled with respective polymer components A and B. Polymer components A and B are molten and extruded by respective extruders 32 and 34 through polymer conduits 40 and 42 and a spinning pack 48. Although the temperature of the molten polymer varies depending on the polymer used, when polyethylene and polypropylene are used as primary component A and secondary component B, respectively, the temperature of the polymer may be in the range of about 190° C. to about 240° C.

[0087] Along with the long filaments that are extruded extending below the spinneret, the air stream from the quenching blower 50 quenches the long filaments at least in part, and for some long filaments, induces the crystallization of the molten long filaments. The quenching air can flow at a speed of about 100 feet per minute to about 400 feet per minute at a temperature of about 0 ℃ to about 35 ℃ along the direction that is substantially perpendicular to the length of the long filaments. The long filaments can be fully quenched before being collected on the forming belt 60 so that the long filaments can be arranged by the forced air passing through the long filaments and the forming surface. Quenching the long filaments reduces the viscosity of the long filaments so that the long filaments are not too closely adhered to each other before being bonded, thereby being collected on the forming belt and forming the fiber web during being moved or arranged on the forming belt.

[0088] After quenching, the filaments are drawn by the air flow of the fiber aspiration unit into the vertical passage of the attenuator 52. The attenuator may be positioned 30 inches to 60 inches below the bottom of the spinneret.

[0089] The filaments may be deposited onto the shaped, traveling forming belt 60 through the outlet holes of the attenuator 52. As the filaments contact the forming surface of the forming belt 60, the vacuum 64 draws air and the filaments against the forming belt 60 to form a nonwoven web of continuous filaments that assumes a shape corresponding to the shape of the forming surface. As described above, since the filaments are quenched, the filaments are not too sticky, and as the filaments are collected on the forming belt 60 and formed into the fabric 10, the vacuum may move the filaments or arrange the filaments on the forming belt 60.

[0090] The production line also includes one or more bonding devices, such as cylindrical compacting rollers 70 and 72, which form a roller gap through which the fabric can be compacted, that is, calendered, and they can also be heated to bond the fibers. One or both of the compacting rollers 70, 72 can be heated to bond some parts of the fabric and provide enhanced properties and benefits to the fabric 10. For example, it is believed that heating sufficient to provide thermal bonding will improve the tensile properties of the fabric 10. The compacting roller can be a pair of stainless steel rollers with a smooth surface with an independent heating controller. The compacting roller can be heated by an electrical component or a hot oil cycle. The gap between the compacting rollers can be controlled hydraulically to apply a desired pressure to the fabric as it passes through the compacting rollers on the forming belt. In one embodiment, wherein the forming belt thickness is 1.4 mm, and the spunbonded nonwoven fabric has a basis weight of 30 gsm, the roller gap between the compacting rollers 70 and 72 can be about 1.4 mm.

[0091] In one embodiment, the upper compacting roll 70 may be heated sufficiently to melt bond the fibers on the first surface 12 of the fabric 10, thereby imparting strength to the fabric so that it may be removed from the forming belt 60 without loss of integrity. Figure 8 and 9 As shown, for example, as rollers 70 and 72 rotate in the direction indicated by the arrows, belt 60 (with the spunbond fabric laid thereon) enters the nip formed by rollers 70 and 72. Heated roller 70 can heat the portion of fabric 10 that is pressed against it by the raised resin elements of belt 60 (i.e., in region 21), thereby producing bonded fibers 80 on at least the first surface 12 of fabric 10. As can be understood from the description herein, the bonded areas so formed can present a pattern of raised elements of forming belt 60. For example, the bonded areas so formed can be a substantially continuous network or a substantially semi-continuous network on the first surface 12 of region 21, which forms a bond with the first surface 12 of region 21. Figure 1 and Fig.11 By adjusting the temperature and dwell time, the bonding can be primarily confined to the fibers closest to the first surface 12, or the thermal bonding can reach the second surface 14, such as Fig.11 (This figure also shows point bonds 90 described in more detail below.) The bonds may also be a discontinuous network, such as point bonds 90 described below.

[0092] The raised elements of the forming belt 60 may be selected to establish various network features of the bonding areas of the forming belt and the nonwoven substrate 11 or nonwoven fabric 10. The network corresponds to the resin that constitutes the raised elements of the forming belt 60 and may include options of being substantially continuous, substantially semi-continuous, discontinuous, or a combination thereof. These networks may describe the raised elements of the forming belt 60 as it relates to their appearance or composition within the XY plane of the three-dimensional features of the forming belt 60 or the nonwoven substrate 11 or nonwoven fabric 10 comprising the present invention.

[0093] A "substantially continuous" network is a region within which any two points can be connected by an unbroken line, the entire line length of which extends completely within the region. That is, the substantially continuous network has substantial "continuity" along all directions parallel to the first plane and terminates only at the edges of the region. In conjunction with "continuous", the term "substantially" is intended to indicate that while absolute continuity can be achieved, minor deviations from absolute continuity are tolerable as long as these deviations do not significantly affect the designed and intended performance of the fiber structure (or molded component).

[0094] A "substantially semi-continuous" network refers to a region having "continuity" along all but at least one direction parallel to a first plane, and within said region, no two points can be connected by an unbroken line, the entire line length of which extends entirely within said region. A semi-continuous framework may have continuity in only one direction parallel to the first plane. Similar to the continuous region described above, although absolute continuity in all but at least one direction is preferred, minor deviations from this continuity are tolerable as long as these deviations do not significantly affect the performance of the fiber structure.

[0095] A "discontinuous" network refers to discrete and separated regions that are discontinuous in all directions parallel to the first plane.

[0096] After compaction, the fabric may leave the forming belt 60 and may be calendered through the nip formed by calendering rollers 71, 73, after which the fabric may be wound onto a reel. Fig.10 As shown in the schematic cross-section of , the calender rolls may be stainless steel rolls having an engraved pattern roll 84 and a smooth roll 86. The engraved roll may have raised portions 88 that may provide additional compaction and bonding to the fabric 10. The raised portions 88 may be relatively small, spaced "spikes" in a regular pattern that form patterned, relatively small point bonds 90 in the nip between the calender rolls 71 and 73. The percentage of point bonds in the fabric 10 may be 3% to 30% or 7% to 20%. The engraved pattern may be a plurality of densely spaced, regular, generally cylindrical, generally flat-topped spike shapes, wherein the spike height is in the range of 0.5 mm to 5 mm and preferably 1 mm to 3 mm. The spikes of the bonding calender roll may form densely spaced, regular point bonds 90 in the fabric 10, such as Fig.11 Further bonding can be achieved by, for example, heat-through-air bonding.

[0097] like Fig.11As shown, in one embodiment, the heated compaction roller 70 can form a bond pattern that can be a substantially continuous network bond pattern 80 (e.g., interconnected heart-shaped bonds) on the first surface 12 of the fabric 10 (not shown in FIG. Fig.11 The first surface 12 of the fabric 10 is relatively flat (relative to the second surface 14) and has a relatively large amount of bonding due to the heated compacting rollers, thereby forming bonding portions 80 at the area of ​​the fabric pressed by the raised elements of the forming belt 60. This bonding gives the fabric 10 structural integrity, but may be relatively hard or rough for the user's skin. Therefore, the first surface 12 of the fabric 10 can be oriented in a diaper or sanitary napkin to face the inside of the product, that is, away from the wearer's body. Similarly, the second surface 14 can face the body in use and contact the body. The relatively small point bonds 90 are less likely to be visually or tactilely perceived by the user, and the relatively soft three-dimensional features remain visually free of linting and pilling while feeling soft to the body during use. Further bonds may be used in lieu of or in addition to the above bonds.

[0098] Forming belt 60 may be prepared according to the methods and processes described in U.S. Pat. No. 6,610,173, issued to Lindsay et al. on August 26, 2003; or U.S. Pat. No. 5,514,523, issued to Trokhan et al. on May 7, 1996; or U.S. Pat. No. 6,398,910, issued to Burazin et al. on June 4, 2002; or U.S. Publication No. 2013 / 0199741, issued on August 8, 2013 in the name of Stage et al., each with the improved features and patterns disclosed herein for making spunbond nonwoven webs. The disclosures of Lindsay, Trokhan, Burazin, and Stage describe belts that represent papermaking belts made with cured resin on woven reinforcement members with improvements that can be used in the present disclosure as described herein.

[0099] The forming belt 60 having improved three-dimensional features and patterns for making spunbond nonwoven webs can also be made by following the following methods and processes and / or on the following equipment, including (with modifications as required by the structure taught herein): a rotary screen process, such as taught in US 7,799,382, issued to Payne et al. on September 21, 2010; polymer extrusion, such as taught in US2007-0170610, issued to Payne et al. on July 26, or US20072005-028018, issued to Sayers et al. on December 22, 2005; resin system grafting, such as taught in US 2006, issued to Patel et al. on September 12, 2006; 7,105,465; perforated membranes as taught in US 8,815,057 issued to Eberhardt et al. on August 26, 2014; continuous processing as taught in US 2006-0019567 to Sayers published on January 26, 2006; polymer droplet deposition as taught in US 7,005,044 issued to Kramer et al. on February 28, 2006; polymer droplet deposition with sacrificial material as taught in US 7,014,735 issued to Kramer et al. on March 21, 2006; breathable membrane technology as taught in US 8,454,800 issued to Mourad et al. on June 4, 2013 or US 2003,079 issued to Riviere et al. on September 9, 2014 8,822,009; multilayer tape structures, as taught in US 2016-0090692 issued to Eagles et al. on March 31, 2016; laser etching, as taught in US 8,758,569 issued to Aberg et al. on June 24, 2014 or US 8,758,569 issued to Klerelid et al. on February 5, 2013 8,366,878; extruded mesh technology as taught in US2014-0272269 to Hansen, published on September 18, 2014; nonwoven tapes as described in US2008-0199655 to Monnerie et al., published on August 21, 2008; and additive manufacturing methods and processes as taught in US2015-0102526A1 to Ward et al., published on April 16, 2015, or US2016-0159007 to Miller et al., published on June 9, 2016, or WO 2016-085704 to Burazin et al., published on November 17, 2016, or US2016-0185041 to Lisagor et al., published on June 30, 2016.

[0100] An example of a forming belt 60 of the type useful in the present disclosure and which may be prepared in accordance with the disclosure of U.S. Pat. No. 5,514,523 is shown at Fig.12 As taught herein, the reinforcing member 94 (such as a woven tape of filaments 96) is fully coated with a liquid photopolymer resin to a preselected thickness. Incorporating a desired raised element pattern repeating element (e.g., Fig.14 ) is juxtaposed over the liquid photosensitive resin. The resin is then exposed to light of an appropriate wavelength, such as UV light (for UV curable resins), passing through the film. This exposure to light results in curing of the resin in the exposed areas (i.e., the white or non-printed portions of the mask). The uncured resin (resin under the opaque portions of the mask) is removed from the system, leaving behind the cured resin that forms a pattern, such as that formed by the Fig.12 The cured resin element is shown as 92. Other patterns may also be formed, as described herein.

[0101] Fig.12 It shows that it can be used to prepare Figure 1 A portion of a forming belt 60 of a fabric 10 is shown. As shown, the forming belt 60 may include a cured resin element 92 on a woven reinforcing member 94. The reinforcing member 94 may be made of woven filaments 96, as is known in the papermaking belt art, including resin-coated papermaking belts. The cured resin element may have Fig.12 The general structure shown in FIG. 1 and by using Fig.14 The mask 97 of the size shown is prepared. Fig.13 As shown in the schematic cross-section in FIG, the cured resin element 92 flows around and is cured to "lock" to the reinforcing member 94, and may have a width DW at the distal end of about 0.020 inches to about 0.060 inches, or about 0.025 inches to about 0.030 inches, and an overall height above the reinforcing member 94 (referred to as overload OB) of about 0.030 inches to about 0.120 inches, or about 0.50 inches to about 0.80 inches, or about 0.060 inches. Fig.14 A portion of mask 97 is shown, showing the Figure 1 The design and representative dimensions of one repeating unit of the repeating heart-shaped design in the fabric 10 are shown. The white portion 98 is transparent to UV light and, in the process of making the tape, as described in U.S. Pat. No. 5,514,523, allows the UV light to cure the underlying resin layer, which is cured to form raised elements 92 on the reinforcing member 94. After the uncured resin is washed away, the ends of the tape length are seamed to produce a tape having a shape such as Fig.12 The curing resin is designed to form a belt 60, the length of which may depend on the design of the equipment, such as Figure 7 shown.

[0102] In a similar manner, Fig.15 A portion of mask 97 is shown, showing the Figure 2The white portion 98 is transparent to UV light and allows the UV light to cure the underlying resin layer, which is cured to the reinforcement members 94, during the process of making the tape. After the uncured resin is washed away, a tape having a shape such as a nylon 20 is produced by seaming the ends of the tape length. Fig.16 The curing resin is designed to form a belt 60, the length of which may depend on the design of the equipment, such as Figure 7 shown.

[0103] Additionally, in another non-limiting example, Fig.17 A portion of a mask is shown, showing the Fig.18 The white portion 98 is transparent to UV light and allows the UV light to cure the underlying resin layer, which is cured to the reinforcement members 94, during the process of making the tape. After the uncured resin is rinsed off, the ends of the lengths of fabric 10 are sewn together to create a tape having a shape similar to that of a repeating unit of the repeating design in the fabric 10 shown. The white portion 98 is transparent to UV light and allows the UV light to cure the underlying resin layer, which is cured to the reinforcement members 94, during the process of making the tape. Fig.18 A forming belt 60 of a cured resin design is shown.

[0104] Another example of a portion of a forming belt 60 of the type that may be used in the present disclosure is shown in Fig.19 middle. Fig.19 The portion of the forming belt 60 shown is a discrete belt pattern 61, which can have a length L and a width W corresponding to the length L and the width W of the total area OA of the nonwoven fabric 10. That is, the forming belt 60 can have a discrete belt pattern 61 (as described below with reference to Fig. 22 ), each of which has a discrete patterned total area DPOA corresponding to the total area OA of the nonwoven fabric 10. Fig. 20 represents a portion of the mask, showing Fig.21 The white portion 98 is transparent to UV light and allows the UV light to cure the underlying resin layer, which is cured to the reinforcement members 94, during the process of making the tape. After the uncured resin is washed away, the tape is produced by seaming the ends of the length of tape. Fig.19 A forming belt 60 of a cured resin design is shown.

[0105] Fig.19 The portion of the forming belt shown illustrates another beneficial effect of the present disclosure. Fig.19 The portion of the forming belt 60 shown can be prepared Fig.21 The fabric 10 is shown. Fig.21 The fabric 10 shown may have a width W dimension and a length L dimension and an overall area OA, making it suitable for use as a top sheet in, for example, a disposable diaper. Fig.19 The fabric 10 formed on the illustrated forming belt 60 is different from Figure 1-3The fabric shown in FIG. 1 is a fabric that is not formed by the patterned three-dimensional features formed by the discrete resin elements 92 on the forming belt 60, because the patterned three-dimensional features formed by the discrete resin elements 92 on the forming belt 60 are not in a regular repeating pattern over the entire total area. Instead, the patterned three-dimensional raised elements in the discrete pattern total area DPOA can be described as an irregular pattern that includes different parts called zones. The differences between the zones can be visual, that is, visually discernible differences, or in the fabric 10, the differences can produce differences in strength properties such as basis weight or density, or differences in a combination of visual properties and strength properties. If an observer can visually discern the pattern differences between the zones, such as the first zone 112 and the second zone 122, under normal conditions (e.g., 20 / 20 vision, sufficient lighting for reading), then there is a visually discernible difference.

[0106] The fabric 10 may also have visually discernible areas corresponding to areas of the forming belt. Fig.21 As shown, for example, the fabric 10 may have at least two, three, or four visually distinguishable zones. A first zone 110 having three-dimensional features in a first pattern and a first average strength characteristic may have a first area that is approximately centrally located within the total area OA. A second zone 120 having three-dimensional features in a second pattern and a second average strength characteristic may have a second area that is approximately distributed around, and in one embodiment completely surrounds the first zone 110 within the total area OA. A third zone 130 having three-dimensional features in a third pattern and a third average strength characteristic may have a third area that is approximately distributed around, and in one embodiment completely surrounds the second zone 120 within the total area OA. A fourth zone 140 having a fourth three-dimensional feature and a fourth average strength characteristic may have a fourth area that is located in any position within the total area OA, such as at the front area of ​​the top sheet, such as Fig.21 The heart-shaped design shown. Generally speaking, there can be n regions, where n is a positive integer. Each of the n regions can have a three-dimensional feature structure in an nth pattern and an nth area and an nth average intensity characteristic.

[0107] like Fig.21 As shown, the visually discernible regions may include visually discernible three-dimensional features. These different three-dimensional features may be defined by regions of relatively high density (relative to the interior of the three-dimensional features), which may be in the form of closed figures, such as Figure 1 and 3 The heart shape in the Figure 2 and 3 Rhombus shape.

[0108] As can be appreciated, instead of having a constant repeating pattern that is uniform across the entire forming belt, the forming belt 60 of the present disclosure allows for the production of a nonwoven web that can have a repeating irregular pattern of discrete bands 61, each of which is similar to Fig.19 The discrete band patterns 61 are shown in Figure 6. Each of the discrete band patterns 61 can be used to form a fabric 10 having a total area OA suitable for a disposable absorbent article such as a diaper or sanitary napkin. The fabric 10 can be produced sequentially, that is, produced online, and optionally produced in parallel lanes in a sequential manner, each lane being a sequential line of the fabric 10. The sequential lines of the fabric 10 can be produced in the machine direction along an axis parallel to the machine direction. The nonwoven web can then be cut or otherwise cut to size to produce a fabric 10 for use as a top sheet in a disposable absorbent article such as a diaper or sanitary napkin.

[0109] In one embodiment, the patterns within each discrete patterned total area DPOA may be the same or different. That is, sequentially spaced discrete patterned strips may be substantially the same, or they may differ in visual appearance and / or in strength properties (resulting in the nonwoven substrate produced thereon). For example, Fig. 22 As shown schematically, the patterned three-dimensional raised elements in the first forming area 112 of the discrete band pattern 61A may be different from the patterned three-dimensional raised elements in the first forming area 112 of the discrete band pattern 61B. The forming band 60 therefore provides flexibility in the process of producing the nonwoven web 10 suitable for consumer goods, and the consumer goods include disposable absorbent articles. For example, in a package of diapers, the top sheets of at least two diapers may be different because they are sequentially produced in the spunbond process as described herein, with sequential discrete band patterns with zones having different patterns. In one embodiment, the top sheet or back sheet nonwoven fabric pattern for a diaper of one size may be different from the top sheet or back sheet nonwoven fabric of a diaper of another size, thereby giving the caregiver a visual reminder about the diaper size. Similarly, fabric 10 can be used for top sheets in sanitary napkins, wherein the visual pattern of the three-dimensional feature structure represents the absorbency of the sanitary napkin. In any case, the various patterns of fabric 10 can be produced on a single band by preparing different discrete band patterns as required.

[0110] Therefore, reference Fig. 22, the present invention can be described as a forming belt having an axis A parallel to the longitudinal direction, which is the processing direction. The forming belt 60 may have a plurality of discrete band patterns 61 that are arranged in at least one sequential relationship relative to the longitudinal direction. Each discrete band pattern 61 may have a discrete band pattern total area DPOA, which is limited to a rectangular pattern by the length L and width W as shown in the discrete band pattern 61A. Each discrete band pattern within its total area DPOA may have a first forming area 112 and a second forming area 122, the first forming area having a three-dimensional raised element extending outward from the plane of the first surface into a first pattern, and the second forming area having a second three-dimensional raised element extending outward from the plane of the first surface. The first forming area may have a first permeability value, and the second forming area may have a second permeability value, and the first permeability value may be different from the second permeability value. In one embodiment, the first permeability value differs from the second permeability value by a factor of 1.2. In one embodiment, the first permeability value differs from the second permeability value by a factor of 2. The pattern within each sequentially ordered discrete patterned total area DPOA may be the same or different.

[0111] By way of example, and with reference to Fig.19 The discrete belt pattern 61 and Fig.21 For the fabric 10 shown, the following properties are determined. The first region 110 of the fabric 10 may have an average basis weight of about 5 gsm to about 30 gsm; the second region 120 may have an average basis weight of about 50 gsm to about 70 gsm; and the third region 130 may have an average basis weight of about 25 gsm to about 60 gsm. The difference in basis weight from one region to another may be attributed to the difference in air permeability of the forming belt 60. In the process used to prepare the Fig. 20 In the illustrated embodiment of fabric 10, where the basis weights of zones 110, 120, and 130 are 15 gsm, 53 gsm, and 25 gsm, respectively, the air permeabilities of corresponding zones 112, 122, and 132 of forming belt 60 are 379 cfm, 805 cfm, and 625 cfm, respectively. Thus, by varying the air permeability of each zone in forming belt 60, the strength properties of average basis weight and average density in each zone can be facilitated over the total area of ​​fabric 10.

[0112] If you can Fig. 22 The description of the forming belt 60 is to be understood and referred to Fig.23 In one embodiment, the nonwoven substrate 11 prepared on the belt 60 can be described as a nonwoven substrate 11 having multiple parts, which are described herein as fabrics 10 that are arranged in at least one sequential relationship relative to the longitudinal direction, i.e., the processing direction, when prepared on the forming belt 60. Fig.23is a schematic diagram of a spunbond nonwoven substrate 11, showing sequentially arranged fabrics 10, each fabric 10 having different patterns in various zones. Each fabric 10 may have a total area OA, which is defined by a length L and a width W in a rectangular-shaped pattern. Each sequentially arranged fabric 10 may have at least a first zone 110 within its total area OA, the first zone having a three-dimensional feature structure in a first pattern and a first average strength characteristic, and a first area within the total area OA; a second zone 120, the second zone having a three-dimensional feature structure in a second pattern and a second average strength characteristic, and having a second area within the total area OA. Optionally, there may be more zones, such as a third zone 130, the third zone having a three-dimensional feature structure in a third pattern and a third average strength characteristic, and having a third area within the total area OA. As Fig.23 As shown in the exemplary schematic diagram of , the first pattern 110A of fabric 10A may be different from the first pattern 110B of fabric 10B, and may be different from the first pattern 110C of fabric 10C. The same situation may also be true for the second areas 120A, 120B and 120C.

[0113] Generally speaking, the sequentially ordered fabrics 10 of the nonwoven substrate 11 produced on the forming belt 60 may vary in their respective total area, strength characteristics, and visual appearance. A common strength characteristic is more than one zone (as opposed to a zoned pattern, such as Fig.21 ) as shown in the partition pattern) or area (for a regularly repeating pattern, such as Figure 1 The intensive properties of the fibrous structure may be average values ​​and may include, but are not limited to, density, basis weight, height, and opacity. For example, if density is a common intensive property of two different zones or regions, the density value in one zone or region may be different from the density value in another zone or region. Zones (e.g., a first zone and a second zone) are identifiable areas that can be distinguished from each other by different intensive properties averaged within the zones.

[0114] Once produced, the individual fabrics 10 can be cut to size and used for their intended use, such as for use as a top sheet in a disposable absorbent article. For example, a disposable diaper 1006 is shown in a flattened orientation. Fig.24 A fabric 10 is cut to the appropriate total area and attached to the diaper 1006 by methods known in the art. The fabric 10 can be cut before being assembled into the diaper 1006, or during the diaper manufacturing process, the nonwoven substrate 11 can be placed together with other diaper components in the form of a fiber web and cut to size after assembly.

[0115] If you can refer to Fig.24To understand, in one embodiment, the nonwoven substrate 11 made on the belt 60 can be described as a nonwoven fabric 10 having multiple parts, and the multiple parts are described herein as a fabric 10 that is arranged in at least one sequential relationship relative to the longitudinal direction, i.e., the processing direction, when prepared on the forming belt 60, and in at least one parallel relationship when prepared on the forming belt 60, that is, in at least one parallel relationship in the transverse direction. Fig.24 is a schematic diagram of a spunbond nonwoven substrate 11 showing sequentially arranged fabrics 10 in adjacent machine direction lanes 13, with adjacent lanes having each fabric 10 next to them. Fig.24 In the embodiment of the present invention, the fabric 10 is marked as 10D, 10E and 10F. Each fabric 10 may have a total area OA, which is limited in a rectangular pattern by a length L and a width W. Each sequentially arranged fabric 10 may have at least a first zone 110 in its total area OA, the first zone having a three-dimensional characteristic structure and a first average strength characteristic in a first pattern, and a first area in the total area OA; a second zone 120, the second zone having a three-dimensional characteristic structure and a second average strength characteristic in a second pattern, and having a second area in the total area OA. Optionally, there may be more zones, such as a third zone 130, the third zone having a three-dimensional characteristic structure and a third average strength characteristic in a third pattern, and having a third area in the total area OA. Each fabric 10 in the parallel lanes may be substantially the same, or they may be different in size, visual appearance, and strength characteristics. Once produced, the nonwoven substrate 11 may be wound onto a reel so as to be cut into the lanes to be processed into consumer products, or cut and then wound onto a reel.

[0116] The fabric 10 of Example 1 was compared to a fabric 10 having a similar pattern to that of Example 1 by comparing the basis weight difference of the fabric 10 made with a regularly repeating uniform pattern and the fabric 10 made with a non-uniform zoned pattern using representative samples. Fig.21 The fabrics having the pattern shown in FIG. 1 and the pattern shown in FIG. 2 (and referred to as Example 3) were compared. Example 3 is a bicomponent spunbond nonwoven web produced on the apparatus disclosed herein by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration. The spunbond bicomponent trilobal fibers were laid on a forming belt 60 which was moved at a line speed of about 25 m / min to a position on a belt having a pattern shown in FIG. Fig.19 The second substrate is formed under the same conditions, but has at least one cross-section that is formed in the following manner: Fig.16The forming belt shown has a regularly repeating uniform pattern on it from which the basis weight was determined. The fiber spinning conditions, throughput, forming belt line speed, and compacting roll bonding temperature were identical for both substrates.

[0117] Example 3

[0118] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration to an average basis weight of 30 g / m2. A nonwoven fabric is as described herein Figure 7 and 8 The produced surface is moved at a forming belt line speed of about 25 m / min to form a Fig. 20 The fibers of the fabric are further bonded on the first side 12 by heated compaction rollers 70 , 72 at 130° C. and the fabric is wound onto a reel at a winder 75 .

[0119] Example 4

[0120] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration to an average basis weight of 30 g / m2. A nonwoven fabric is as described herein Figure 7 and 8 The above-mentioned belt is produced at a speed of about 25 m / min to form a forming belt having a Figure 2 The fabric is shown with a repeating (non-zonal) pattern. The fibers of the fabric are further bonded on the first side 12 by heated compaction rollers 70 , 72 at 130° C. and wound onto a reel at a winder 75 .

[0121] Table 2 below shows the average local basis weight measured according to the "Local Basis Weight" test method herein and averaged using 10 samples. The samples used for the measurements were taken from Fig.25A and 25B The fabric shown, with the dark rectangle showing the 3cm 2 As can be seen, these fabrics are labeled A-E in the cross direction (CD). The measurements show not only the significant basis weight differences between the zones of the zoned fabrics, but also Fig.26 CD distribution shown.

[0122] Table 2: Average basis weight distribution in fabric 10 measured in grams per square meter (gsm)

[0123]

[0124] As can be seen in Table 2, fabrics 10 made on a forming belt 60 having zones of varying air permeability exhibit substantial variation in fiber layup and, therefore, basis weight across the CD of the fabric 10 suggesting that the fibers are able to travel with the air into the high permeability zones. The non-zonal regular repeat pattern fabric 10 exhibits approximately the same basis weight across the CD of the fabric.

[0125] In addition to the air permeability differences of the various zones of the forming belt 60, the structure of the forming belt 60 may also affect other strength characteristics of the zones in the fabric 10, such as average thickness, average softness, average resistance to compression, and fluid absorption characteristics.

[0126] Another aspect of the invention relates to a spunbond commercial line where multiple beams are used for improved laydown opacity and uniformity of the fabric. In some cases, the equipment may include a triple spunbond beam (referred to in the art as "SSS") and may be combined with meltblowing (M), for example, in equipment referred to as a "SSMMS" spunbond line.

[0127] By calendering fabric 10 to have point bonding 90, this can reduce fuzzing. Fuzzing refers to the trend that fibers become loose and are removed from fabric 10. Looseness and removal can be attributed to the frictional engagement with manufacturing equipment during the production of disposable absorbent articles, or the interaction of another surface such as human skin and fabric 10. In some applications, such as the top sheet used in disposable absorbent articles, fuzzing is a negative consumer phenomenon. But fiber bonding in a fixed position can also be negative for consumption, because it can produce roughness on the surface of otherwise soft nonwoven substrate. As expected, we have found that nonwoven fabric substrate and nonwoven fabric of the present disclosure can ensure the increase of bonding (and the reduction of fuzzing thus occurring) with minimal softness loss. Bonding can be achieved by relatively closely spaced point bonding 90, wherein the spacing depends on the desired fuzzing reduction degree. Bonding can also be achieved by known methods for chemical bonding or thermal bonding nonwoven fibers, such as thermal bonding, ultrasonic bonding, pressure bonding, latex adhesive bonding and the combination of such methods. The fuzz reduction achieved by bonding is shown in relation to embodiments 5 and 6 below.

[0128] Example 5

[0129] A bicomponent spunbond nonwoven fabric is produced by: Figure 7 and 8The forming belt is spun with a polyethylene sheath (Aspun-6850-A from Dow Chemical Company) and a polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration in a 50:50 ratio to an average basis weight of about 30 g / m2 and is moved at a line speed of about 25 m / min to form a forming belt having a fiber structure as shown in FIG. Fig.36 The fibers of the fabric are further bonded on the first side 12 by compaction rollers 70 , 72 , wherein compaction roller 70 is heated to 130° C. to form a substantially continuous bond 80 .

[0130] Example 6

[0131] A bicomponent spunbond nonwoven fabric is produced by: Figure 7 and 8 The forming belt is spun with a polyethylene sheath (Aspun-6850-A from Dow Chemical Company) and a polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration in a 50:50 ratio to an average basis weight of about 30 g / m2 and is moved at a line speed of about 25 m / min to form a forming belt having about Fig.37 The fibers of the fabric are further bonded on the first side 12 by compacting rollers 70, 72, wherein compacting roller 70 is heated to 130°C to form substantially continuous bonds 80. The fibers of the fabric are further calendared and bonded at calendaring rollers 71, 73, wherein roller 73 is an engraved roller having raised portions 88 in the form of spikes with a spike height of 1.25 mm and an open gap of 0.62 mm in a 10% point bond pattern. Roller 73 is heated to 135°C to form point bonds 90 on the second side 14 of the fabric 10, as shown. Fig.11 shown.

[0132] The fabrics 10 of Examples 5 and 6 differ only in the absence or presence of point bonds 90. The second side 14 of the fabric 10 was subjected to a fuzz test according to the "Fuzz Content Test" to determine the effectiveness of the point bonds in securing the fibers to the fabric surface. The results of the fuzz test for Examples 5 and 6 are shown in Table 3.

[0133] Table 3: MD villus results

[0134] Sample No. <![CDATA[MD fluff value (mg / cm 2 )]]> Example 5 0.36 Example 6 0.19

[0135] As shown above, the point bonds 90 result in a significant reduction in the MD fuzz value. Despite the bonding process, it unexpectedly maintains its softness, absorbency, and aesthetic benefits, and now also has the desired fuzz resistance for consumers.

[0136] Packaging

[0137] The absorbent articles of the present disclosure may be placed in a package. The package may comprise a polymer film and / or other material. Graphics and / or markings associated with the characteristics of the absorbent articles may be formed, printed, positioned, and / or placed on an outer portion of the package. Each package may comprise a plurality of absorbent articles. The absorbent articles may be stacked under compression to reduce the size of the package while still providing a sufficient amount of absorbent articles for each package. By packaging the absorbent articles under compression, the caregiver can easily handle and store the package while also providing savings in distribution for the manufacturer due to the size of the package.

[0138] Thus, according to the "In-Bag Stacking Height Test" described herein, the packaging of the absorbent articles of the present disclosure may have an "In-Bag Stacking Height" of 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 reciting all 0.1 mm increments within the specified range and all ranges formed therein or thereby. Alternatively, according to the "In-Bag Stacking Height Test" described herein, the packaging of the absorbent articles of the present disclosure may have an "In-Bag Stacking Height" of about 70 mm to about 110 mm, about 70 mm to about 105 mm, about 70 mm to about 100 mm, about 70 mm to about 95 mm, about 70 mm to about 90 mm, about 70 mm to about 85 mm, about 72 mm to about 80 mm, or about 74 mm to about 78 mm, specifically reciting all 0.1 mm increments within the specified range and all ranges formed therein or thereby.

[0139] Fig. 27 An exemplary package 1000 is shown that includes a plurality of absorbent articles 1004. The package 1000 defines an interior space 1002 in which the plurality of absorbent articles 1004 are located. The plurality of absorbent articles 1004 are arranged into one or more stacks 1006.

[0140] General description of absorbent articles

[0141] The three-dimensional nonwoven fabric 10 of the present disclosure can be used as a component of absorbent articles such as diapers, child care articles such as training pants, feminine care articles such as sanitary napkins, and adult care articles such as incontinence products, pads, and pants. An exemplary absorbent article in the form of a diaper 220 is shown in FIG. Figure 28-30 middle. Fig.282 is a plan view of an exemplary diaper 220 in a flattened state with portions of the structure cut away to more clearly illustrate the construction of the diaper 220. Fig.28 The wearer-facing surface of the diaper 220 faces the viewer. The diaper 220 is shown for illustration purposes only, as the three-dimensional nonwoven material of the present disclosure may be used as one or more components of an absorbent article, such as a top sheet, an acquisition layer, a top sheet and an acquisition layer, or a top sheet and an acquisition and / or distribution system ("ADS"). In any case, the three-dimensional nonwoven material of the present disclosure may be liquid permeable.

[0142] The absorbent article 220 may include a liquid permeable material or topsheet 224, a liquid impermeable material or backsheet 225, and an absorbent core 228 positioned at least partially intermediate the topsheet 224 and the backsheet 225, and barrier leg cuffs 234. The absorbent article may also include an ADS 250, which in the example shown includes a distribution layer 254 and an acquisition layer 252, which will be discussed further below. The absorbent article 220 may also include an elasticized gasketing cuff 232, which includes an elastic component 233 that is typically joined to the chassis of the absorbent article via the topsheet and / or the backsheet and is substantially in-plane with the chassis of the diaper.

[0143] Fig.28 and Fig.31 Also shown are typical taped diaper components such as a fastening system including a tab 242 attached toward the rear edge of the article and cooperating with a landing zone 244 on the front of the absorbent article. The absorbent article may also include other typical elements not shown, such as, for example, a rear elastic waist feature, a front elastic waist feature, one or more transverse barrier cuffs, and / or a lotion application.

[0144] The absorbent article 220 includes a front waist edge 210, a back waist edge 212 longitudinally opposite the front waist edge 210, a first side edge 203, and a second side edge 204 laterally opposite the first side edge 203. The front waist edge 210 is the edge of the article that is intended to be placed toward the front of the user when worn, and the back waist edge 212 is the opposite edge. The absorbent article 220 may have a longitudinal axis 280 that extends from the lateral midpoint of the front waist edge 210 of the article to the lateral midpoint of the back waist edge 212 and divides the article into two halves that are substantially symmetrical relative to the longitudinal axis 280, wherein the article is laid flat, unfolded, and viewed from above, as shown. Fig.28As shown. The absorbent article 220 may also have a lateral axis 290 extending from the longitudinal midpoint of the first side edge 203 to the longitudinal midpoint of the second side edge 204. The length L of the article may be measured along the longitudinal axis 280 from the front waist edge 210 to the back waist edge 212. The width W of the absorbent article may be measured along the lateral axis 290 from the first side edge 203 to the second side edge 204. The absorbent article may include a crotch point C, which is defined herein as a point disposed on the longitudinal axis at a distance of two-fifths (2 / 5) L from the front edge 210 of the article 220. The article may include a front waist region 205, a back waist region 206, and a crotch region 207. The front waist region 205, the back waist region 206, and the crotch region 207 may each define 1 / 3 of the longitudinal length L of the absorbent article.

[0145] The topsheet 224, backsheet 225, absorbent core 228 and other article components may be assembled in a variety of configurations, particularly by, for example, gluing or heat embossing.

[0146] The absorbent core 228 may include an absorbent material including at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight superabsorbent polymer; and a core wrap encapsulating the superabsorbent polymer. The core wrap may typically include two materials, substrates, or nonwoven materials 216 and 216' for the top and bottom sides of the core. These types of cores are referred to as air-felt-free cores. The core may include one or more grooves, between which the core may be formed. Fig.28 Four grooves 226, 226' and 227, 227' are shown in FIG. Grooves 226, 226', 227 and 227' are optional features. Conversely, the core may not have any grooves or may have any number of grooves.

[0147] These and other components of exemplary absorbent articles will now be discussed in greater detail.

[0148] Top sheet

[0149] In the present disclosure, top sheet (the part that contacts the skin of the wearer and receives fluid of absorbent article) can be formed by a part or all of one or more of three-dimensional nonwoven material as described herein, and / or have one or more of the nonwoven material that is positioned thereon and / or is joined thereto, so that one or more nonwoven materials contact the skin of the wearer. Other parts of top sheet (part except the three-dimensional nonwoven material) also can contact the skin of the wearer. The three-dimensional nonwoven material can be positioned on the top of typical top sheet 224 as strip or patch. Alternatively, the three-dimensional nonwoven material can only form the center CD area of ​​top sheet. The center CD area can extend the full MD length of top sheet or be less than the full MD length of top sheet.

[0150] As is well known to those skilled in the art, the top sheet 224 may be joined to the back sheet 225, the absorbent core 228, and / or any other layer. Typically, the top sheet 224 and the back sheet 225 are directly joined to each other at some locations (e.g., at or near the periphery of the absorbent article), and are indirectly joined together by directly joining them to one or more other elements of the article 220 at other locations.

[0151] Top sheet 224 can be compliant, feel soft, and non-irritating to the wearer's skin. In addition, a part or all of top sheet 224 can be liquid permeable, allowing liquid to easily seep through its thickness. In addition, a part or all of top sheet 224 can be processed with a surfactant or other reagent to hydrophilize the fiber web or make it hydrophobic. As generally disclosed in the art, any part of top sheet 224 can be coated with lotion and / or skin care composition. Top sheet 224 also can include antimicrobial agent or handle with antimicrobial agent.

[0152] Negatives

[0153] Backsheet 225 is normally that part of the surface positioning facing clothes of absorbent article 220 adjacent to absorbent core 228 and it prevents or at least suppresses the fluid and body exudates absorbed and contained therein to soil articles such as sheets and underwear. Backsheet 225 is normally impermeable to fluid (for example, urine), or at least basically impermeable. Backsheet can be for example or include thin plastic film such as thermoplastic film, and it has the thickness of about 0.012mm to about 0.051mm. Other suitable backsheet materials can include breathable material, and it allows steam to escape from absorbent article 220, while still preventing or at least suppressing fluid from penetrating backsheet 225.

[0154] The backsheet 225 may be joined to the topsheet 224, the absorbent core 228, and / or any other element of the absorbent article 220 by any attachment method known to those skilled in the art.

[0155] The absorbent article may include a backsheet including an outer cover or an outer cover nonwoven. The outer cover or outer cover nonwoven of the absorbent article 220 may cover at least a portion or all of the backsheet 225 to form a soft, garment-facing surface of the absorbent article. The outer cover or outer cover nonwoven may be formed by a high-loft three-dimensional nonwoven material as described herein. Alternatively, the outer cover or outer cover nonwoven may include one or more known outer cover materials. If the outer cover includes one of the three-dimensional nonwoven materials disclosed herein, the three-dimensional nonwoven material of the outer cover may or may not match (e.g., the same material, the same pattern) the top sheet or the top sheet and the three-dimensional nonwoven material of the acquisition layer used as the absorbent article. In other examples, the outer cover may have a printed or otherwise applied pattern that matches or is visually similar to the pattern of the three-dimensional nonwoven material used as the top sheet or the top sheet and the acquisition layer laminate of the absorbent article. The outer cover may be joined to at least a portion of the backsheet 225 by mechanical bonding, ultrasonic bonding, thermal bonding, adhesive bonding, or other suitable attachment methods.

[0156] Absorbent core

[0157] The absorbent core is the following component of the absorbent article, which has the maximum absorption capacity and includes the absorbent material and the core wrap or core bag that encapsulates the absorbent material. The absorbent core does not include any other components of the absorbent article that are not an integral part of the core wrap or core bag or are not placed in the core wrap or core bag of the acquisition and / or distribution system. The absorbent core may include, consist essentially of, or consist of the core wrap, the absorbent material in question (e.g., superabsorbent polymer and little or no cellulose fiber), and glue.

[0158] The absorbent core 228 may include an absorbent material having a high content of superabsorbent polymer (abbreviated herein as "SAP") encapsulated in a core wrap. The SAP content may represent 70%-100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99% or 100% by weight of the absorbent material contained in the core wrap. For the purpose of evaluating the percentage of SAP in the absorbent core, the core wrap is not considered to be an absorbent material. The absorbent core may include air felt with or without superabsorbent polymer.

[0159] So-called "absorbent material" refers to a material with some absorption properties or liquid retention properties, such as SAP, cellulose fiber and synthetic fiber. Typically, the glue used to prepare the absorbent core does not have or has very little absorption properties, and is not considered to be an absorbent material. SAP content can be higher than 80% of the weight of the absorbent material contained in the core wrap, for example at least 85%, at least 90%, at least 95%, at least 99%, and even up to and including 100%. Compared to the conventional core that usually comprises SAP between 40%-60% by weight and high-content cellulose fiber, the core that does not contain air-permeable felt is relatively thin. Absorbent material can especially comprise less than 15% weight percent or less than 10% weight percent of natural fiber, cellulose fiber or synthetic fiber, less than 5% weight percent, less than 3% weight percent, less than 2% weight percent, less than 1% weight percent, or even can be substantially free of natural fiber, cellulose fiber and / or synthetic fiber.

[0160] As described above, compared to conventional cores, cores without air felt with very little or no natural fibers, cellulose fibers and / or synthetic fibers are quite thin, making the overall absorbent article thinner than absorbent articles with cores containing mixed SAP and cellulose fibers (e.g., 40%-60% cellulose fibers). The core thinness may cause consumers to perceive reduced absorbency and performance, but technically this is not the case. At present, these thin cores are usually used with substantially planar or perforated top sheets. In addition, absorbent articles with these thin cores without air felt also have reduced capillary void spaces because there are very few or no natural fibers, cellulose fibers, or synthetic fibers in the core. Therefore, sometimes there may not be enough capillary void spaces in absorbent articles to fully receive multiple insults or single large insults of body exudates.

[0161] To address such problems, the present disclosure provides absorbent articles with these thin air-felt-free cores, which are combined with one of the high-loft three-dimensional nonwoven materials described herein as a top sheet or a top sheet and a collection layer laminate. In this example, the consumer's perception of absorbency and performance is enhanced, although there is an increased thickness of the absorbent article due to the additional thickness provided by the high-loft three-dimensional nonwoven material. In addition, when used with these thin air-felt-free cores and used as a top sheet or a top sheet and a collection layer laminate, the three-dimensional nonwoven material adds capillary void space back into the absorbent article while still allowing a minimum stack height, thereby passing on cost savings to consumers and manufacturers. Therefore, due to the increased capillary void space, the absorbent article of the present disclosure can easily absorb multiple insults of body exudates or a single large insult. Additionally, absorbent articles comprising nonwoven materials as a topsheet, acquisition layer, or a laminate of a topsheet and acquisition layer also provide consumers with an aesthetically pleasing topsheet relative to a flat topsheet or apertured topsheet having increased thickness and thus enhanced consumer perception of absorbency and performance.

[0162] exist Figure 33-Figure 35 Shown in separate form Figure 31-Figure 32 220 of the absorbent article 220. The absorbent core 228 may include a front side 480, a back side 282, and two longitudinal sides 284, 286 joining the front side 480 and the back side 282. The absorbent core 228 may also include a generally planar top side and a generally planar bottom side. The front side 480 of the core is the side of the core that is intended to be placed toward the front waist edge 210 of the absorbent article. As shown in Fig.28 When viewed from the top in the plan view shown, the core 228 may have a longitudinal axis 280' that substantially corresponds to the longitudinal axis 280 of the absorbent article 220. The absorbent material may be dispensed in higher amounts toward the front side 480 than toward the rear side 282 because greater absorbency may be required at the front of a particular absorbent article. The front and rear sides 480 and 282 of the core may be shorter than the longitudinal sides 284 and 286 of the core. The core wrap may be formed from two nonwoven materials, substrates, laminates, or other materials 216, 216' which may be at least partially sealed along the sides 284, 286 of the absorbent core 228. The core wrap may be at least partially sealed along its front side 480, rear side 282, and both longitudinal sides 284, 286 so that substantially no absorbent material leaks out of the absorbent core wrap. The first material, substrate, or nonwoven material 216 may at least partially surround the second material, substrate, or nonwoven material 216' to form a core wrap, such as Fig.34 The first material 216 may surround a portion of the second material 216' adjacent to the first and second sides 284 and 286.

[0163] The absorbent core may contain, for example, an adhesive to help secure the SAP within the core wrap and / or to ensure the integrity of the core wrap, particularly when the core wrap is made of two or more substrates. The adhesive may be a hot melt adhesive supplied by, for example, HB Fuller. The core wrap may extend to an area larger than the area strictly required to contain the absorbent material therein.

[0164] The absorbent material can be a continuous layer present in the core wrap. Alternatively, the absorbent material can be composed of a bag or strip of a separate absorbent material encapsulated in the core wrap. In the first case, the absorbent material can be obtained, for example, by applying a single continuous layer of absorbent material. The continuous layer of absorbent material, specifically SAP, can also be obtained by combining two absorbent layers with a discontinuous absorbent material application pattern, wherein the resulting layer is substantially continuously distributed on the absorbent granular polymer material area, as disclosed in U.S. Patent Application Publication 2008 / 0312622A1 (Hundorf). The absorbent core 228 can include a first absorbent layer and a second absorbent layer. The first absorbent layer can include a first material 216 and a first layer 261 of an absorbent material, which can be 100% or less SAP. The second absorbent layer can include a second material 216' and a second layer 262 of an absorbent material, which can also be 100% or less SAP. The absorbent core 228 may also include a fibrous thermoplastic adhesive material 251 that at least partially bonds each layer 261, 262 of absorbent material to its respective material 216 or 216'. This is shown, for example, in Figure 34-35 228, wherein the first and second SAP layers have been applied to their respective substrates prior to combination in the form of transverse bands or "landing zones" having the same width as the desired absorbent material deposition area. The bands may contain different amounts of absorbent material (SAP) to provide a basis weight distributed along the longitudinal axis of the core 228. The first material 216 and the second material 216' may form a core wrap.

[0165] The fibrous thermoplastic adhesive material 251 may at least partially contact the absorbent material 261, 262 in the landing area and at least partially contact the material 216 and 216' in the joining area. This gives the fibrous layer of thermoplastic adhesive material 251 a substantially three-dimensional structure, which itself is a substantially two-dimensional structure with a relatively small thickness compared to the dimensions along the length and width directions. Therefore, the fibrous thermoplastic adhesive material can provide a cavity to cover the absorbent material in the landing area, thereby fixing the absorbent material, which can be 100% or less SAP.

[0166] The thermoplastic binder used for the fiber layer may have elastomeric properties so that the fiber web formed by the fibers on the SAP layer can be stretched when the SAP swells.

[0167] Superabsorbent polymer (SAP)

[0168] SAPs useful in the present disclosure may include a variety of water-insoluble but water-swellable polymers capable of absorbing large amounts of fluid.

[0169] The superabsorbent polymer may be in particulate form so as to be flowable in a dry state. The particulate absorbent polymer material may be made of a poly(meth)acrylic acid polymer. However, starch-based particulate absorbent polymer materials may also be used, as well as polyacrylamide copolymers, ethylene maleic anhydride copolymers, cross-linked carboxymethyl cellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and starch-grafted copolymers of polyacrylonitrile.

[0170] SAP can be in various shapes. The term "particle" refers to granules, fibers, flakes, spheres, powders, thin plates and other shapes and forms known to those skilled in the art in the field of superabsorbent polymer particles. SAP particles can be in the shape of fibers, i.e. elongated needle-like superabsorbent polymer particles. Fibers can also be in the form of woven filaments. SAP can be spherical particles. The absorbent core can contain one or more types of SAP.

[0171] For most absorbent articles, liquid discharge from the wearer occurs primarily in the front half of the absorbent article, particularly a diaper. Thus, the front half of the article (as defined by the area between the front edge and a transverse line disposed at a distance of half L from the front waist edge 210 or the back waist edge 212) may include most of the core's absorbent capacity. Thus, at least 60% of the SAP, or at least 65%, 70%, 75%, 80% or 85% of the SAP may be present in the front half of the absorbent article, while the remaining SAP may be disposed in the back half of the absorbent article. Alternatively, the SAP distribution throughout the core may be uniform or may have other suitable distributions.

[0172] The total amount of SAP present in the absorbent core may also vary depending on the desired user. Diapers for newborns may require less SAP than baby diapers, children's diapers, or adult incontinence diapers. The amount of SAP in the core may be about 5 g to 60 g or 5 g to 50 g. The average SAP basis weight in the deposition area 8 of SAP (or if there are several, "at least one") may be at least 50 g / m 2 , 100g / m 2 , 200g / m 2 , 300g / m 2 , 400g / m 2 , 500g / m 2 The area of ​​the grooves (eg, 226, 226', 227, 227') present in the absorbent material deposition area 8 is derived from the absorbent material deposition area to calculate the average basis weight.

[0173] Core wrap

[0174] The core wrap may be made of a single substrate, material, or nonwoven folded around the absorbent material, or may comprise two (or more) substrates, materials, or nonwovens attached to each other. Typical attachments are so-called C-wrappers and / or sandwich wraps. In a C-wrapper, for example, Fig.29 and Fig.34 As shown, the longitudinal edge and / or the transverse edge of one of the substrates are folded over another substrate to form a flap. Then, these side flaps are usually bonded to the outer surface of the other substrate by gluing.

[0175] The core wrap may be formed of any material suitable for receiving and containing the absorbent material.Typical substrate materials for making conventional cores may be used, in particular paper, tissue, film, woven or nonwoven fabric, or a laminate or composite of any of these materials.

[0176] The substrate may also be breathable (in addition to being liquid or fluid permeable). Thus, films useful herein may include micropores.

[0177] The core wrap can be at least partially sealed along all sides of the absorbent core so that substantially no absorbent material leaks out of the core. By "substantially no absorbent material", it is meant that less than 5%, less than 2%, less than 1% or about 0% of the absorbent material escapes from the core wrap by weight. The term "seal" should be understood in a broad sense. The seal need not be continuous along the entire periphery of the core wrap, but can be discontinuous along part or all of it, such as formed by a series of sealing points spaced apart in a line. The seal can be formed by gluing and / or thermal bonding.

[0178] If the core wrap is formed by two substrates 216, 216', four seals can be used to enclose the absorbent material 260 in the core wrap. For example, the first substrate 216 can be placed on one side of the core (e.g. Figure 33-35The top side shown in the figure) and the longitudinal edge of the core extends to at least partially wrap the relative bottom side of the core. The second substrate 216 'may be present between the wrapped fins of the first substrate 216 and the absorbent material 260. The fins of the first substrate 216 can be glued to the second substrate 216 'to provide a strong seal. Compared with the sandwich seal, the so-called C-shaped wrapper structure can provide a beneficial effect, such as improved crack resistance under a wet load state. Then, the front side and the back side of the core wrapper can also be sealed by gluing the first substrate and the second substrate to each other, so as to provide a complete encapsulation of the absorbent material across the entire periphery of the core. For the front side and the back side of the core, the first substrate and the second substrate can extend in a substantially planar direction and can be joined together, forming a so-called sandwich structure for these edges. In the so-called sandwich structure, the first substrate and the second substrate can also extend outward on all sides of the core, and are usually sealed flatly or substantially flatly along all or part of the periphery of the core by gluing and / or heat / pressure bonding. In one example, neither the first substrate nor the second substrate need to be shaped so that they can be cut rectangularly for ease of manufacture, but other shapes are also within the scope of the present disclosure.

[0179] The core wrap may also be formed from a single substrate which encloses the absorbent material in a wrap and is sealed along the front and back sides of the core and a longitudinal seal.

[0180] SAP deposition area

[0181] As seen from the top side of the absorbent core, the absorbent material deposition area can be defined by the perimeter of a layer formed by the absorbent material 260 within the core wrap. The absorbent material deposition area can have a variety of shapes, in particular, a so-called "dog bone" or "hourglass" shape that shows a taper along its width toward the middle or "crotch" region of the core. In this way, the absorbent material deposition area 8 can have a relatively narrow width in a core region that is intended to be placed in the crotch region of an absorbent article, such as Fig.28 This can provide better wearing comfort. The absorbent material deposition area 8 can also be roughly rectangular, for example Figure 31-Figure 33 As shown, however other deposition areas, such as rectangular, "T", "Y", "hourglass" or "dog bone" shapes are also within the scope of the present disclosure. The absorbent material may be deposited using any suitable technique that allows for relatively precise deposition of the SAP at relatively high speeds.

[0182] groove

[0183] The absorbent material deposition area may include at least one groove 226 that is at least partially oriented in the longitudinal direction of the article 280 (i.e., has a longitudinal vector component), such as Fig.28 and 29As shown. Other channels may be at least partially oriented in the lateral direction (i.e., having a lateral vector component) or oriented in any other direction. Hereinafter, the plural form of "groove" will be used to refer to "at least one groove". The groove may have a length L' projected onto the longitudinal axis 280 of the article, which is at least 10% of the length L of the article. The groove can be formed in various ways. For example, the groove may be formed by a zone in the absorbent material deposition area that may be substantially free of or free of absorbent material, specifically SAP. In another example, the groove may be formed by a zone in the absorbent material deposition area, where the absorbent material of the core includes cellulose, air felt, SAP, or a combination thereof, and the groove may be substantially free of or free of absorbent material, specifically SAP, cellulose, or air felt. In addition or alternatively, the groove may also be formed by continuously or discontinuously bonding the top side of the core wrap to the bottom side of the core wrap via the absorbent material deposition area. The groove may be continuous, but it is also envisioned that the groove may be intermittent. The acquisition-distribution system or layer 250 or other layers of the article may also comprise channels, which may or may not correspond to the channels of the absorbent core.

[0184] In some cases, the groove may exist at least at the same longitudinal level as the crotch point C or the lateral axis 260 in the absorbent article, such as Fig.28 The grooves may also extend from the crotch region 207 or may be present in the front waist region 205 and / or the back waist region 206 of the article.

[0185] The absorbent core 228 may also include more than two grooves, such as at least 3, at least 4, at least 5, or at least 6 or more grooves. Shorter grooves may also be present, for example, in the back waist region 206 or the front waist region 205 of the core, such as by Fig.28 The grooves may include one or more pairs of grooves arranged symmetrically with respect to the longitudinal axis 280, or arranged in other ways.

[0186] The grooves are particularly useful in absorbent cores when the absorbent material deposition area is rectangular, since the grooves improve the flexibility of the core to a lesser extent than would be advantageous with a non-rectangular (shaped) core. Of course, channels may also be present in a SAP layer having a shaped deposition area.

[0187] The channel may be completely longitudinally oriented and parallel to the longitudinal axis or completely transversely oriented and parallel to the lateral axis, but may also have at least portions that are curved.

[0188] To reduce the risk of fluid leakage, the longitudinal main grooves may not extend up to either edge of the absorbent material deposition area and may therefore be completely contained within the absorbent material deposition area of ​​the core. The minimum distance between the grooves and the nearest edge of the absorbent material deposition area may be at least 5 mm.

[0189] The groove may have a width Wc along at least a portion of its length, for example, at least 2 mm, at least 3 mm, at least 4 mm, up to, for example, 20 mm, 16 mm, or 12 mm. The width of the groove may be constant over substantially the entire length of the groove, or may vary along its length. When the groove is formed by an absorbent material-free zone within the absorbent material deposition region, the width of the groove is considered to be the width of the zone without material, without considering the possibility of a core wrap in the groove. If the groove is not formed by an absorbent material-free zone, for example, it is formed primarily by bonding of the core wrap within the entire absorbent material zone, the width of the groove is the width of the bonding.

[0190] At least some or all of the grooves can be permanent grooves, meaning that their integrity is maintained at least partially in a dry state and in a wet state. Permanent grooves can be obtained by providing one or more adhesive materials, such as adhesive material fiber layers or structural adhesives that help to adhere substrates and absorbent materials in the groove wall. Permanent grooves can also be formed by bonding the upper and lower sides (such as the first substrate 216 and the second substrate 216') of the core wrapping and / or bonding the top sheet 224 and the back sheet 225 together via the groove. Usually, adhesives can be used to bond the two sides or the top sheet and the back sheet of the core wrapping by the groove, but it can be bonded by other known methods, such as pressure bonding, ultrasonic bonding, thermal bonding or their combination. The core wrapping or the top sheet 224 and the back sheet 225 can be bonded continuously or intermittently along the groove. When the absorbent article is fully loaded with fluid, the groove can advantageously be kept or become visible through the top sheet and / or the back sheet at least. This can be obtained by making the groove substantially free of SAP, so that it will not swell, and is large enough to make it not closed when wet. Additionally, it may be advantageous to bond the core wrap to itself or to bond the topsheet to the backsheet through the slots.

[0191] Barrier leg cuffs

[0192] The absorbent article may include a pair of barrier leg cuffs 234. Each barrier leg cuff may be formed by a piece of material that is bonded to the absorbent article so that it can extend upward from the wearer-facing surface of the absorbent article and provide improved fluid and other body exudates near the junction of the wearer's torso and legs. The barrier leg cuff is defined by a proximal edge 264 and a free end edge 266 that are directly or indirectly bonded to the top sheet 224 and / or the back sheet 225, and is intended to contact the wearer's skin and form a seal. The barrier leg cuff 234 extends at least partially between the front waist edge 210 and the back waist edge 212 of the absorbent article on the opposite side of the longitudinal axis 280, and is present at least at the crotch point (C) or the position of the crotch area. The barrier leg cuff can be bonded to the base structure of the article at the proximal edge 264 by a bonding portion 265, which can be made by a combination of gluing, melt bonding or other suitable bonding methods. The bonding portion 265 at the proximal edge 264 can be continuous or intermittent. The bond 265 closest to the raised section of the barrier leg cuff defines the proximal edge 264 of the upstanding section of the leg cuff.

[0193] The barrier leg cuffs may be integral with the topsheet 224 or the backsheet 225, or may be separate materials joined to the chassis of the article. Each barrier leg cuff 234 may include one, two or more elastic bands 235 near the free end edge 266 to provide a better seal.

[0194] In addition to the barrier leg cuffs 234, the article may also include a gasketing cuff 232 that is joined to the chassis of the absorbent article (specifically the topsheet 224 and / or the backsheet 225) and may be positioned externally relative to the barrier leg cuffs. The gasketing cuffs 232 may provide a better seal around the wearer's thighs. Each gasketing leg cuff may include one or more elastic bands or elastic elements 233 in the chassis of the absorbent article between the topsheet 224 and the backsheet 225 in the leg opening area. All or a portion of the barrier leg cuffs and / or the gasketing cuffs may be treated with a lotion or another skin care composition.

[0195] Collection-distribution system

[0196] The absorbent articles of the present disclosure may include an acquisition-distribution layer or system 250 ("ADS"). One function of the ADS is to quickly acquire one or more fluids and distribute them to the absorbent core in an efficient manner. The ADS may include one, two or more layers, which may form an integral layer or may be maintained as discrete layers that may be attached to each other. In one example, the ADS may include two layers: a distribution layer 254 and an acquisition layer 252, which are disposed between the absorbent core and the top sheet, but the present disclosure is not limited thereto.

[0197] In one example, the high loft three-dimensional nonwoven material of the present disclosure may include a topsheet and an acquisition layer as a laminate. A distribution layer may also be disposed on the garment-facing side of the topsheet / acquisition layer laminate.

[0198] Carrier layer

[0199] In an example where the high loft three-dimensional nonwoven material of the present disclosure comprises a top sheet and an acquisition layer laminate, the distribution layer may need to be supported by a carrier layer (not shown), which may include one or more nonwoven materials or other materials. The distribution layer may be applied to or positioned on the carrier layer. Thus, the carrier layer may be positioned intermediate the acquisition layer and the distribution layer and in a facing relationship with the acquisition layer and the distribution layer.

[0200] Distribution Layer

[0201] The distribution layer of the ADS may contain at least 50% by weight of cross-linked cellulose fibers. The cross-linked cellulose fibers may be pleated, twisted, or curled, or combinations thereof (including pleated, twisted, and curled). This type of material is disclosed in U.S. Patent Publication 2008 / 0312622A1 (Hundorf). The cross-linked cellulose fibers provide higher elasticity and thus higher resistance to compression of the first absorbent layer in product packaging or under use conditions (e.g., under the weight of the wearer). This can provide higher void volume, permeability, and liquid absorption to the core, thereby reducing leakage and improving dryness.

[0202] A distribution layer comprising crosslinked cellulosic fibers of the present disclosure may contain other fibers, but the layer may advantageously contain at least 50%, or 60%, or 70%, or 80%, or 90%, or even up to 100% crosslinked cellulosic fibers (including the crosslinking agent) by weight of the layer.

[0203] Collection Layer

[0204] If the three-dimensional nonwoven material of the present disclosure is provided only as the top sheet of the absorbent article, the ADS 250 may include an acquisition layer 252. The acquisition layer may be disposed between the distribution layer 254 and the top sheet 224. In such an example, the acquisition layer 252 may be or may include a nonwoven material, such as a hydrophilic SMS or SMMS material, including a spunbond layer, a meltblown layer and another spunbond layer or alternatively a carded staple fiber chemically bonded nonwoven fabric. The nonwoven material may be latex bonded.

[0205] Fastening system

[0206] The absorbent article may include a fastening system. The fastening system may be used to provide lateral tension around the circumference of the absorbent article to keep the absorbent article on the wearer, which is typical for adhesive diapers. The fastening system may not be necessary for training pants products because the waist area of ​​these products has been bonded. The fastening system may include fasteners, such as band inserts, hook and loop fastening components, interlocking fasteners such as inserts and slits, buckles, buttons, snaps and / or hermaphroditic fastening components, but any other suitable fastening mechanisms are also within the scope of the present disclosure. The landing zone 244 is generally disposed on the surface of the first waist region 205 facing the garment for releasably attaching the fastener thereto.

[0207] Front and back ears

[0208] The absorbent article may include front ears 246 and back ears 240. The ears may be an integral part of the chassis, such as formed from the top sheet 224 and / or the back sheet 226 in the form of side panels. Alternatively, as Fig.28 As shown, the ears can be separate elements attached by gluing, heat embossing and / or pressure bonding. The back ears 240 can be stretchable to facilitate the attachment of the tabs 242 to the landing zone 244 and to keep the taped diaper in place around the waist of the wearer. The back ears 240 can also be elastic or extensible to provide a more comfortable and conformable fit to the wearer by initially conforming to the absorbent article and maintaining the fit throughout the wear period when the absorbent article is loaded with fluids or other body exudates because the elasticized ears allow the sides of the absorbent article to expand and contract.

[0209] Elastic waist construction

[0210] The absorbent article 220 may also include at least one elastic waist feature (not shown) that helps provide improved fit and restraint. Elastic waist features are generally intended to elastically expand and contract to dynamically fit the wearer's waist. The elastic waist feature may extend outwardly at least longitudinally from at least one waist edge of the absorbent core 228 and generally form at least a portion of the end edge of the absorbent article. A disposable diaper may be constructed so as to have two elastic waist features, one positioned in the front waist region and the other positioned in the back waist region.

[0211] Color signal

[0212] In one form, the absorbent articles of the present disclosure may have different colors in different layers or portions thereof (e.g., topsheet and acquisition layer, topsheet and nonwoven core cover, first and second portions of the topsheet, first and second portions of the acquisition layer). The different colors may be shades of the same color (e.g., dark blue and light blue), or may be actual different colors (e.g., purple and green). The different colors may have a ΔE, for example, in the range of about 1.5 to about 10, about 2 to about 8, or about 2 to about 6. Other ΔE ranges are also within the scope of the present disclosure.

[0213] In one example, a colored adhesive may be used to join the various layers of an absorbent article. The colored adhesive may be laid in a pattern on any suitable layer or layers. The adhesive pattern may or may not be complementary to the topsheet pattern. Such a pattern may enhance the appearance of depth in the absorbent article. In some cases, the colored adhesive may be blue.

[0214] In other cases, any of the layers may include indicia, such as printed ink, to contribute to the appearance, impression of depth, impression of absorbency, or impression of quality of the absorbent article.

[0215] In other cases, the color may be complementary or in register with the patterned three-dimensional features of the fabric 10 used as a component in an absorbent article. For example, a fabric having three-dimensional features in a first zone and a second zone that are visually distinct in a pattern may also have a color printed thereon to enhance, highlight, contrast, or otherwise change the visual appearance of the fabric 10. Color enhancement may be useful in communicating certain functional characteristics of the fabric 10 when in use to the user of the absorbent article. Thus, color may be used in conjunction with structural three-dimensional features in a component or combination of components to deliver a visually distinctive absorbent article. For example, a second topsheet or acquisition layer may have a patterned color or colors printed thereon that are complementary to the patterned three-dimensional features of the fabric 10 used as a topsheet in an absorbent article. Another example is an absorbent article comprising: 1) an absorbent core comprising a channel; 2) a top sheet having a registered three-dimensional pattern or a three-dimensional pattern that highlights one or more channels in the core; and 3) graphics, colored components, printed inks, or markings visible from the top sheet viewing surface (body contacting surface) or the back sheet viewing surface (garment facing surface) to further enhance the functional characteristics of the core channel or channels and the overall performance of the absorbent article.

[0216] Test Method :

[0217] Compression aging test

[0218] Initial thickness measurement :

[0219] • Cut five 3 inch by 3 inch specimens from each nonwoven fabric to be measured.

[0220] • Number each sample from 1 to 5.

[0221] • Measure thickness according to standard procedure using a Thwing-Albert thickness gauge at 0.5 kPa with a "standard" 65 mm foot.

[0222] Report the initial thickness of each of the five samples.

[0223] Report the average thickness of the five samples.

[0224] Aged Compression Method and Aged Thickness Measurement

[0225] • Stack five samples in an alternating pattern with each sample separated by a paper towel, the stack starting and ending with "Sample Number" 1 and 5 respectively.

[0226] • Place the alternating stack of samples in an aluminum sample holder and place appropriate weights on top of the samples (4 KPa, 14 KPa or 35 KPa).

[0227] • Place the stacked samples with weights in an oven at 40°C for 15 hours.

[0228] • After 15 hours the weight was removed, the samples separated and the thickness of each sample measured at 0.5 kPa with a "standard" 65 mm foot Thwing-Albert thickness gauge according to standard procedures.

[0229] Report the aged thickness value for each of the five specimens.

[0230] Report the average aged thickness of the five specimens.

[0231] Analytical Report :

[0232] Report the average initial thickness and aged thickness by position number.

[0233] Report thickness recovery index:

[0234] (Average aging thickness / average initial thickness)*100

[0235] Local basis weight

[0236] The "local basis weight" of a nonwoven fabric can be determined by several available techniques, but one simple representative technique involves a 3.0 cm 2A die of 100% area is used to cut a web sample piece from the selected area (out of the total area of ​​the nonwoven fabric). The sample piece is then weighed and divided by its area to obtain the local basis weight of the nonwoven fabric in hectometers per square meter. For each selected area, the results are reported as the average of 2 samples.

[0237] Villus content test

[0238] The "Fuzz Content Test" was conducted using a Sutherland Friction Tester (obtained from Thwing Albert Co, West Berlin, NJ) with aluminum oxide cloth (Ultra Smooth Finish, 320 Grit, 2 inch wide 50 yard roll available from McMaster-Carr, Elmhurst, IL as part number 8687A229 or equivalent) used as the abrasive / acceptor. After abrading the sample, the fuzz was stripped from the aluminum oxide cloth and sample surface using fiber removal tape (3M #3187 Adhesive Tape, available from the Netherland Rubber Company in 2 inch wide rolls) for gravimetric analysis. A 2 pound removable receptor block (also available from Thwing Albert Co) was used.

[0239] Prior to use, the rubber surfaces on the receptor block and sample stage were inspected for wear / damage and replaced if necessary per the manufacturer's instructions (replacement foam available from Thwing Albert Co).

[0240] Cut a piece of aluminum oxide emery cloth into strips 7.5 in. by 2.0 in. Use the clamps on the side of the receptor block to secure the aluminum oxide emery cloth so that the abrasive surface faces away from the block and the cloth lies flat against the bottom surface of the receptor block.

[0241] Cut out sample from nonwoven fabric to be tested, sample is at least 12cm along machine direction (MD) and is 6cm along cross direction (CD).The sample side to be tested is placed on laboratory workbench in face-down mode.Obtain a piece of 2-sided adhesive tape (3M#409, 2 inches wide, difference viscosity, purchased from Netherland Rubber Co, (Cincinnati OH) or equivalent), it is 12cm and takes advantage of 5.1cm, and removes release paper.Locate the adhesive tape, the adhesive side just exposed is attached to the nonwoven sample, makes the long edge parallel to the MD of sample.Release paper is placed on the adhesive surface facing up.Sample / tape laminate is cut into the final size of 11.0cm ± 0.1cm MD and takes advantage of 4.0cm ± 0.1cm CD.Remove release paper, and sample is attached to the center (being suitable for being attached to the sample platform of friction tester) of 65.5mm wide and takes advantage of 210mm long and takes advantage of 1.5mm thick stainless steel plate. With the sample facing up, a 2200 g weight (170 mm by 63 mm contact surface) was placed on top of the sample for 20 seconds and then the weight was removed.

[0242] The stainless steel plate was fixed to the sample stage of the friction tester using the integrated clamp of the stage, with the sample side facing upward. The removable receptor block was attached to the reciprocating arm of the friction tester, with the abrasive surface facing the sample. The friction tester was set to perform 20 cycles at a rate of 21 cycles / second.

[0243] Carefully remove the receptor block from the friction tester, be careful not to lose any loose microfibers coming from the aluminum oxide emery cloth surface or sample surface. The receptor block is placed on the laboratory bench, so that the aluminum oxide emery cloth faces up. Remove the steel plate with sample from the friction tester, and the sample side is placed face up on the laboratory bench. Cut out a 51mm wide fiber removal tape that takes advantage of 65.5mm long. At each end, the approximately 5mm of the tape end is folded onto itself, thereby facilitating the processing of the tape without contacting the adhesive. Put a light base weight release paper (approximately 75mm takes advantage of 60mm)) to protect the adhesive surface. Measure the quality of tape / release paper, and record it, accurate to 0.0001g. This is for the tape stripping fiber coming from the aluminum oxide emery cloth (tape A). In a similar manner, prepare the second tape / release paper for the tape stripping fiber coming from the surface (tape B) of the abraded sample, and record its quality, accurate to 0.0001g.

[0244] Get tape A and remove the release paper. Grab both ends of the tape and lightly dirty the aluminum oxide emery cloth to remove the nonwoven fibers from the surface. Repeat the process as necessary to remove all the fibers, being careful not to remove the aluminum oxide particles. Replace its release paper, measure the mass of the tape / release paper, and record the mass to the nearest 0.0001g.

[0245] Subtract the tared mass from the final mass. This is the "fiber mass" A. Get tape B and remove the release paper. Grab the tape at both ends and center the tape on the sample. Place a 2200g weight on the tape and hold for 20 seconds, then remove the weight. Grab the tape at both ends and lift the tape from the sample surface. Replace its release paper, measure the mass of the tape / release paper, and record the mass to the nearest 0.0001g.

[0246] Subtract the tared mass from the final mass. This is the "fiber mass" B. The "fuzz content" is the sum of the "fiber mass" A and the "fiber mass" B. Repeat the test in a similar manner for a total of ten replicates. Average the values ​​for the ten samples and record the "fuzz mass" to the nearest 0.10 mg. Calculate the "fuzz content" as "Average Fuzz Mass" (mg) / 44 cm 2 , and report it with an accuracy of 0.01mg / cm 2 .

[0247] Air permeability test

[0248] The "Air Permeability Test" is used to determine the level of air flow through the forming belt in cubic feet per minute (cfm). The "Air Permeability Test" is performed on a Textest Instruments, model FX3360 Portair Air Permeability Tester, available from Textest AG, Sonnenbergstrasse 72, CH 8603 Schwerzenbach, Switzerland. The unit utilizes a 20.7 mm orifice plate for a permeability range between 300-1000 cfm. If the permeability is below 300 cfm, the orifice plate needs to be reduced; if it is above 1000 cfm, the orifice plate needs to be increased. The air permeability can be measured in a localized area of ​​the forming belt to determine the difference in air permeability across the forming belt.

[0249] Testing process

[0250] 1. Turn on the power of the FX3360 instrument.

[0251] 2. Select a scheduled mode with the following settings:

[0252] a.Material: “Standard”

[0253] b. Measurement properties: air permeability (AP)

[0254] c. Test pressure: 125Pa (Pascal)

[0255] dT factor: 1.00

[0256] e. Test point pitch: 0.8 inches.

[0257] 3. Position a 20.7 mm orifice plate on the top side of the forming belt (the side with the 3D protrusions) at the location of interest.

[0258] 4. Select "Single Point Measurement" on the test unit's touch screen.

[0259] 5. If necessary, reset the sensor before measuring.

[0260] 6. Once reset, select the "Start" button to begin measuring.

[0261] 7. Wait until the measurement stabilizes and record the cfm reading on the screen.

[0262] 8. Select the Start button again to stop measuring.

[0263] 9. Report the results as the average of three measurements.

[0264] In-bag stacking height test

[0265] The in-bag stack height of a package of absorbent articles is determined as follows:

[0266] equipment

[0267] A thickness tester with a flat rigid horizontal slide is used. The thickness tester is configured so that the horizontal slide is free to move in the vertical direction, wherein the horizontal slide is always maintained in a horizontal orientation directly above a flat rigid horizontal substrate. The thickness tester includes a device suitable for measuring the gap between the horizontal slide and the horizontal substrate, accurate to within ±0.5 mm. The horizontal slide and the horizontal substrate 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 slide applies a downward force of 850±1 grams-force (8.34N) to the absorbent article package, which can be achieved by placing a suitable weight on the center of the top surface of the horizontal slide that does not contact the package, so that the total mass of the slide plus the added weight is 850±1 grams.

[0268] Testing process

[0269] Prior to measurement, the absorbent article packages were equilibrated at 23 ± 2°C and 50 ± 5% relative humidity.

[0270] The horizontal slide is raised and the absorbent article package is centered under the horizontal slide in such a way that the absorbent articles in the package are in a horizontal orientation (see Figure XX). Any handles or other packaging structures on the surface of the package that touches either of the plates are folded flat against the surface of the package to minimize their effect on the measurement. Slowly lower the horizontal slide table until it contacts the top surface of the package and then release. Ten seconds after releasing the horizontal slide table, measure the gap between the horizontal plates to within ±0.5 mm. Measure five identical packages (packages of the same size and the same number of absorbent articles) and report the arithmetic mean as the package width. Calculate and report "stack height in bag" = (package width / number of absorbent articles per stack) × 10 to within ±0.5 mm.

[0271] The dimensions and values ​​disclosed herein are not to be understood as being strictly limited to the exact numerical values ​​cited. Instead, unless otherwise indicated, each such dimension is intended to represent the stated value and a functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

[0272] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or patent application and any patent application or patent to which this application claims priority or the benefit of, is hereby incorporated by reference in its entirety. The citation of any document is not an admission that it is prior art with respect to any disclosure or claim herein, or that it, by itself or in combination with any other reference or references, proposes, suggests or discloses any aspect of the invention.

[0273] Further, if any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0274] Although specific embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that many other changes and modifications may be made without departing from the spirit and scope of the present invention. Therefore, it is intended that all such changes and modifications within the scope of the present invention be encompassed in the appended claims.

Claims

1. A forming belt for preparing a nonwoven substrate, It is characterized in that The shaping belt comprises a woven reinforcing member and a three-dimensional raised resin element, the woven reinforcing member being made of woven filaments, the shaping belt having: a first surface which, in use, defines a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction; and a plurality of discrete band patterns, the plurality of discrete band patterns being arranged in a sequential relationship with respect to the longitudinal direction, at least a majority of the plurality of discrete band patterns comprising: Total area of ​​discrete band patterns; a first shaped region having a first pattern of three-dimensional raised resin elements extending outwardly from the plane of the first surface; and a second shaped region having a second pattern of three-dimensional raised resin elements extending outwardly from the plane of the first surface; wherein the first pattern or the second pattern has an overload of about 0.030 inches to about 0.120 inches, the overload being the height of the three-dimensional raised resin elements above the woven reinforcement member; wherein the first pattern or the second pattern is continuous, substantially semi-continuous, or discontinuous; wherein the first forming region has a first air permeability value; wherein the second forming region has a second air permeability value; and Wherein the first air permeability value is different from the second air permeability value.

2. The forming belt according to claim 1, It is characterized in that In one of the shaped zones, the air permeability value varies along at least a lateral direction of the first surface.

3. The forming belt according to claim 1, It is characterized in that The first air permeability value differs from the second air permeability value by a factor of 1.

2.

4. The forming belt according to claim 1, It is characterized in that The first air permeability value differs from the second air permeability value by a factor of 2.

5. The forming belt according to claim 1, It is characterized in that The total area of ​​each discrete band pattern is 150 cm 2 Up to 500cm 2 .

6. A forming belt according to any one of claims 1 to 5, It is characterized in that At least a majority of the plurality of discrete band patterns also include a third formed area having a third pattern of three-dimensional raised resin elements extending outward from the plane of the first surface, the third formed area having a third permeability value, wherein the third pattern has an overload of approximately 0.030 inches to approximately 0.120 inches; and wherein the third pattern is continuous, substantially semi-continuous, or discontinuous.

7. A forming belt for preparing a nonwoven substrate, It is characterized in that The forming belt comprises a woven reinforcing member and a three-dimensional raised element, the woven reinforcing member being made of woven filaments, the forming belt having: a first surface which, in use, defines a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction; and a first discrete band pattern and a second discrete band pattern, wherein the first discrete band pattern and the second discrete band patterns are ordered in a sequential relationship with respect to the longitudinal direction, each of the discrete band patterns having a discrete band pattern total area; a first shaped region having a first pattern of three-dimensional raised elements extending outwardly from the plane of the first surface; and a second forming zone, wherein the second forming zone has a second pattern of three-dimensional raised elements extending outward from the plane of the first surface; wherein the first pattern or the second pattern has an overload of about 0.030 inches to about 0.120 inches, where the overload refers to the height of the three-dimensional raised elements above the woven reinforcement structure; and wherein the first pattern or the second pattern is continuous, substantially semi-continuous or discontinuous; wherein for both the first discrete band pattern and the second discrete band pattern, the first forming zone has a first permeability value and the second forming zone has a second permeability value, wherein the first permeability value is different from the second permeability value, and wherein the first discrete band pattern has a different visual appearance than the second discrete band pattern.

8. The forming belt according to claim 7, It is characterized in that The air permeability value of either the first discrete band pattern or the second discrete band pattern varies in a lateral direction of the first surface.

9. The forming belt according to claim 7, It is characterized in that The first discrete band pattern has a first air permeability value that differs from the second air permeability value by a factor of 1.

2.

10. The forming belt according to claim 7, It is characterized in that The first discrete band pattern has a first air permeability value that differs from the second air permeability value by a factor of 2.

11. The forming belt according to claim 7, It is characterized in that The total area of ​​each discrete band pattern is 150 cm 2 Up to 500cm 2 .

12. A forming belt according to any one of claims 7 to 11, It is characterized in that Each discrete band pattern also has a third formed area, wherein the third formed area has a third pattern of three-dimensional raised elements extending outward from the plane of the first surface, the third formed area has a third permeability value, wherein the third pattern has an overload of about 0.030 inches to about 0.120 inches; and wherein the third pattern is continuous, substantially semi-continuous or discontinuous.

13. An endless forming belt for preparing a nonwoven substrate, It is characterized in that The forming belt comprises a woven reinforcing member and a three-dimensional raised element, the woven reinforcing member being made of woven filaments, the forming belt comprising: a first surface which, in use, defines a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction; A plurality of discrete band patterns, the plurality of discrete band patterns being arranged in a sequential relationship relative to the longitudinal direction, each of the plurality of discrete band patterns having a discrete band pattern length, a first forming zone and a second forming zone, the first forming zone having a first pattern of three-dimensional raised elements extending outward from the plane of the first surface, and the second forming zone having a second pattern of three-dimensional raised elements extending outward from the plane of the first surface, wherein the first forming zone has a first permeability value, and the second forming zone has a second permeability value, and the first permeability value is different from the second permeability value; wherein the first forming zone or the second forming zone has an overload of about 0.030 inches to about 0.120 inches, the overload being the height of the three-dimensional raised elements above the woven reinforcement structure; wherein the first pattern or the second pattern is continuous, substantially semi-continuous or discontinuous; and wherein the sum of the discrete band pattern lengths equals the length of the annular forming band as measured parallel to the axis parallel to the longitudinal direction.

14. The forming belt according to claim 13, It is characterized in that The first pattern is visually distinct from the second pattern.

15. A forming belt according to claim 13 or 14, It is characterized in that The air permeability value varies along the lateral direction of the first surface.

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