Molded nonwoven fabric exhibiting high visual resolution

Abstract

A nonwoven fabric is disclosed. The nonwoven fabric may include a first surface and a second surface and a first visually distinguishable region of at least three-dimensional feature structures on one of the first surface or the second surface. Each of the three-dimensional feature structures may define a micro-region including a first region and a second region. The first region and the second region may have a difference in the value of strength characteristics, and the first visually distinguishable region may exhibit high visual resolution.

Description

Technical Field

[0001] The present disclosure relates to formed three-dimensional nonwoven fabrics that exhibit high visual resolution, and articles made from formed three-dimensional nonwoven fabrics that exhibit high visual resolution. Background Art

[0002] Nonwoven fabrics can be used in a variety of applications, including absorbent personal care products, clothing, medical applications, and cleaning applications. Nonwoven personal care products include baby care items such as diapers, child care items such as training pants, feminine care items such as sanitary napkins, and adult care items such as incontinence products, pads, and pants. Nonwoven clothing includes protective workwear and medical gowns such as surgical gowns. Other medical applications of nonwoven fabrics include nonwoven wound dressings and surgical dressings. Cleaning applications of nonwoven fabrics include towels and wipes.

[0003] Various properties of nonwoven fabrics can determine the suitability of the nonwoven fabric for a particular application. Thus, nonwoven fabrics can be processed to have different combinations of properties to meet different needs. Variable properties of nonwoven fabrics include liquid handling properties such as wettability, distribution, and absorbency; strength properties such as tensile strength and tear resistance; softness; and durability properties such as abrasion resistance. The physical shape / pattern of the nonwoven fabric also affects the functionality and aesthetic appearance of the nonwoven fabric. In addition, the aesthetics of the nonwoven fabric can be key to consumer preference for consumer goods that include such nonwoven fabrics, as the aesthetics of the nonwoven fabric can convey the value, quality, strength, softness, etc. of the product. An exemplary way to aesthetically convey many of the generally desired traits in a patterned nonwoven fabric is through a textured pattern that exhibits high visual resolution (i.e., a visually distinct pattern). Visually distinct patterns provide a higher quality perception to an observer because such nonwoven fabric patterns exhibit distinct, well-defined texture contrast lines and do not fade, blur, or have texture contrast lines that are difficult to visually identify.

[0004] Although progress has been made in the field of nonwoven fabrics, there is still a need for improved nonwoven fabrics having visually distinguishable regions with three-dimensional surface feature structures, where the visually distinguishable regions exhibit high visual resolution.

[0005] In addition, there is still a need for methods and apparatuses for manufacturing improved nonwoven fabrics having visually distinguishable regions with three-dimensional surface feature structures, where the visually distinguishable regions exhibit high visual resolution.

[0006] In addition, there is still a need for articles that utilize improved nonwoven fabrics having visually distinguishable regions with three-dimensional surface feature structures, including absorbent articles, where the visually distinguishable regions exhibit high visual resolution. Summary of the Invention

[0007] A nonwoven fabric is disclosed. The nonwoven fabric may include a first surface and a second surface and a first visually distinguishable region of at least three-dimensional feature structures on one of the first surface or the second surface. Each of the three-dimensional feature structures may define a micro-region including a first region and a second region. The first region and the second region may have a difference in the value of the strength characteristic, and the first visually distinguishable region may exhibit high visual resolution. Brief Description of the Drawings

[0008] Figure 1 A photograph of an example of the formed nonwoven fabric of the present disclosure.

[0009] Figure 2 A photograph of an example of the formed nonwoven fabric of the present disclosure.

[0010] Figure 3 A photograph of an example of the formed nonwoven fabric of the present disclosure.

[0011] Figure 4 As Figure 1 shown, a cross-section of a part of the fabric of the present disclosure.

[0012] Figure 5A A schematic diagram showing a cross-section of a filament made of primary component A and secondary component B in a side-by-side arrangement structure.

[0013] Figure 5B A schematic diagram showing a cross-section of a filament made of primary component A and secondary component B in an eccentric sheath / core arrangement structure.

[0014] Figure 5C A schematic diagram showing a cross-section of a filament made of primary component A and secondary component B in a concentric sheath / core arrangement structure.

[0015] Figure 6 A perspective photograph of a trilobal bicomponent fiber.

[0016] Figure 7 A schematic diagram of an apparatus for preparing the fabric of the present disclosure.

[0017] Figure 8 Details of a part of an apparatus for bonding a part of the fabric of the present disclosure.

[0018] Fig. 9 Additional details of a part of an apparatus for bonding a part of the fabric of the present disclosure.

[0019] Fig.10Details of a part of an apparatus for optionally attaching a part of the fabric of the present disclosure.

[0020] Fig.11 Photograph of an example of the present disclosure.

[0021] Fig.12 Photograph of a part of a forming belt that can be used in the present disclosure.

[0022] Fig.13 Is Fig.12 Cross-sectional view of a part of the shown forming belt.

[0023] Fig.14 Is used to prepare Fig.12 Image of a part of a mask for the shown forming belt.

[0024] Fig.15 Is used to prepare Fig.16 Image of a part of a mask for the shown forming belt.

[0025] Fig.16 Photograph of a part of a forming belt that can be used in the present disclosure.

[0026] Fig.17 Is used to prepare Fig.18 Image of a part of a mask for the shown forming belt.

[0027] Fig.18 Photograph of a part of a forming belt that can be used in the present disclosure.

[0028] Fig.19 Photograph of a part of a forming belt that can be used in the present disclosure.

[0029] Fig. 20 Is used to prepare Fig.19 Image of a mask for the shown forming belt.

[0030] Fig.21 Is Fig.19 Photograph of the fabric of the present disclosure prepared on the shown forming belt.

[0031] Fig. 22 Schematic perspective view of the forming belt of the present disclosure.

[0032] Fig.23 Plan view of a nonwoven substrate including the nonwoven fabric of the present disclosure.

[0033] Fig.24 Plan view of a nonwoven substrate including the nonwoven fabric of the present disclosure.

[0034] Fig.25A Plan view of the fabric of the present disclosure, with some parts removed for measuring the local basis weight.

[0035] Fig.25B A plan view of the fabric of the present disclosure, with some portions removed for measuring the local basis weight.

[0036] Fig.26 A graphical representation of the cross - machine direction variation of the basis weight of the fabric of the present disclosure.

[0037] Fig. 27 A schematic view of the package of the present disclosure.

[0038] Fig.28 A plan view of the absorbent article of the present disclosure.

[0039] Fig.29 A plan view of the absorbent article of the present disclosure

[0040] Fig.30 is Fig.28 a cross - sectional view of section 29 - 29 of

[0041] Fig.31 A plan view of the absorbent article of the present disclosure.

[0042] Fig.32 is Fig.31 a cross - sectional view of section 32 - 32 of

[0043] Fig.33 A plan view of the absorbent article of the present disclosure.

[0044] Fig.34 is Fig.33 a cross - sectional view of section 34 - 34 of

[0045] Fig.35 is Fig.33 a cross - sectional view of section 35 - 35 of

[0046] Fig.36 A photograph of an example of the formed nonwoven fabric of the present disclosure.

[0047] Fig.37 A photograph of an example of the formed nonwoven fabric of the present disclosure.

[0048] Fig.38 A photograph of an example of the formed nonwoven fabric of the present disclosure.

[0049] Fig.39 is Fig.38 a photograph of the cross - section of the example shown in

[0050] Fig.40 A micro - CT perspective view image of an example of the formed nonwoven fabric of the present disclosure.

[0051] Fig.41Micro-CT perspective view image of an example of the formed nonwoven fabric of the present disclosure.

[0052] Fig.42 is Fig.40 and Fig.41 Micro-CT image of the cross-section of the example shown.

[0053] Fig.43 is Fig.40 and Fig.41 Micro-CT plan view image of the example shown.

[0054] Fig.44 Graphical depiction of various beneficial effects of the formed nonwoven fabric of the present disclosure.

[0055] Fig.45 Photographic view image of a part of an example of the formed nonwoven fabric of the present disclosure.

[0056] Fig.46 Photographic view image of a part of an example of the formed nonwoven fabric of the present disclosure.

[0057] Fig.47 Photographic view image of a part of an example of the formed nonwoven fabric of the present disclosure.

[0058] Fig.48 Photographic view image of a part of an example of the formed nonwoven fabric of the present disclosure.

[0059] Fig.49 is Fig.47 and Fig.48 Photograph of the cross-section of the example shown.

[0060] Fig.50 Photographic view image of a part of an example of the formed nonwoven fabric of the present disclosure.

[0061] Fig.51 Photographic view image of a part of an example of the formed nonwoven fabric of the present disclosure.

[0062] Fig.52 Photographic view image of a part of an example of the formed nonwoven fabric of the present disclosure.

[0063] Fig.53 Photographic view image of a part of an example of the formed nonwoven fabric of the present disclosure.

[0064] Fig.54 is Fig.40 and Fig.41 Micro-CT plan view image of the example shown after undergoing additional processing.

[0065] Fig.55 is Fig.54Graphical depiction of the various beneficial effects of the invention of the present disclosure as shown.

[0066] Fig.56 Schematic diagram of an apparatus for preparing the fabric of the present disclosure.

[0067] Fig.57 Photograph of an example of the formed nonwoven fabric of the present disclosure.

[0068] Fig.58 Photograph of an example of the formed nonwoven fabric of the present disclosure having three identification locations in a method for testing gray level changes within an article.

[0069] Fig.59 Graph for plotting individual data points generated from samples of the formed nonwoven fabric of the present disclosure using the Haralick maximum contrast test method.

[0070] Fig.60 Image including six individual samples of the formed nonwoven fabric of the present disclosure for measuring gray level changes using the inter-article gray level change test method.

[0071] Fig.61 Graph for plotting individual data points generated from samples of the structured belt for producing a structured nonwoven fabric. Detailed Description

[0072] 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 assume a shape corresponding to the shape of the forming belt. The fabric of the present disclosure prepared by the method of the present disclosure on the forming belt of the present disclosure can be particularly advantageously used in personal care products, clothing, medical products, and cleaning products. The formed nonwoven fabric can be fluid-permeable such that it is used as the topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of a diaper, or the topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of a sanitary napkin, or the topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of an adult incontinence liner or pant, or the liner of a floor cleaning tool.

[0073] In some embodiments of the present disclosure, beneficial feature structures of nonwoven fabrics will be described in the context of the total area of the nonwoven fabric. The total area may be an area determined by dimensions suitable for certain uses, and various feature structures of the present invention provide beneficial properties for said certain uses. For example, the total area of the fabric may be the total area of a fabric having dimensions such that it is suitable for use as the topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layers of a diaper, or the topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layers of a sanitary napkin, or the topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layers of an adult incontinence pad or pant, or a liner for a floor cleaning tool. Thus, the total area may be based on a width dimension in the range of 3 cm to 50 cm and a length dimension in the range of 10 cm to 100 cm, resulting in a total area of 30 cm 2 to 500 cm 2 The foregoing ranges include every integer dimension as specifically recited between the boundaries of said ranges. By way of example, a total area of 176 cm 2 defined by a width of 11 cm and a length of 16 cm is disclosed within the above ranges. As will be understood from the present specification, the total area of the formed nonwoven fabric may be an area less than the area of the web of nonwoven material, which is a part of the web when the formed nonwoven fabric is commercially produced. That is, in a given web of commercially produced nonwoven material, there may be multiple formed nonwoven fabrics of the present invention, each of the formed nonwoven fabrics of the present invention having a total area less than the area of the web (on which the formed nonwoven fabric is produced).

[0074] A photograph of a representative example of the formed nonwoven fabric 10 is shown in Figures 1 to 3 The formed nonwoven fabric 10 may be a spunbond nonwoven substrate having a first surface 12 and a second surface 14. In Figures 1 to 3 , the second surface 14 faces the observer and is opposite the first surface 12, which is not visible in Figures 1 to 3 but is shown in Figure 4 . The term "surface" is used broadly for descriptive purposes to refer to the two 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 a flattened state, i.e., in the context of one or more X-Y planes parallel to the flattened state, and the plane corresponds to the cross-direction CD plane and the machine direction MD plane in the web manufacturing technology, as shown in Figures 1 to 3 . The total area A of the nonwoven fabric 10 is determined by the length L along the MD and the width W along the CD. As shown in Figure 4 (which is Figure 1As shown in the cross-section of a portion of the nonwoven fabric 10, for purposes of description, the three-dimensional feature structure of the shaped nonwoven fabric is described as extending outwardly from the X-Y plane of the first surface 16 in the Z direction (see Figure 4 ). In one embodiment, the maximum dimension of the three-dimensional feature structure in the Z direction may define the maximum distance between the plane of the first surface 16 and the X-Y plane of the second surface 18, and this distance may be measured as the average thickness AC of the nonwoven fabric 10. The average thickness may be determined via an optical non-contact device, or it may be determined by an instrument involving spaced-apart plates that measure the thickness of the nonwoven placed between them under a predetermined pressure. It is not necessary for all three-dimensional feature structures to have the same maximum dimension in the Z direction, but multiple three-dimensional feature structures may have substantially the same maximum dimension in the Z direction determined by the fiber deposition process and the characteristics of the forming belt described below.

[0075] Figures 1 to 4 The exemplary fabrics shown in

[0076] and other fabrics disclosed herein are fluid permeable. In one embodiment, the entire fabric may be considered fluid permeable. In one embodiment, a region or zone (described below) may be fluid permeable. As used herein, "fluid permeable" with respect to a fabric means that the fabric has at least one zone that allows liquid to pass through in the context of using a consumer product. For example, if the fabric is used as the topsheet on a disposable diaper, the fabric may have at least one zone with a certain fluid permeability to allow urine, thin BM, menstrual fluid, or any other body effluent to pass through the underlying absorbent core. As used herein, "fluid permeable" with respect to a region means that the region exhibits a porous structure that allows liquid to pass through.

[0076] As Figures 1 to 4 shown, the nonwoven fabric 10 may have a regular repeating pattern of multiple discrete and recognizably different three-dimensional feature structures (including the first three-dimensional feature structure 20, the second three-dimensional feature structure 22, and the third three-dimensional feature structure 24), as Figure 2 and Figure 3 shown. For example, in Figure 1 , the heart-shaped first three-dimensional feature structure 20 is recognizably different from the smaller, generally triangular second three-dimensional feature structure 22. The recognizable difference may be visual, such as recognizably different sizes and / or shapes.

[0077] The three-dimensional feature structure of the nonwoven fabric 10 can be formed by directly depositing fibers onto a forming belt having a pattern corresponding to the three-dimensional feature structure, such deposition being, for example, by carding, air-laying, solution spinning, or melt spinning. In a sense, the nonwoven fabric 10 is molded onto the forming belt, which determines the shape of the three-dimensional feature structure of the fabric 10. However, importantly, as described herein, the apparatus and method of the present invention produce a nonwoven 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 apparatus used to form the fabric, the fabric is also imparted with beneficial properties for personal care products, clothing, medical products, and cleaning products. Specifically, due to the nature of the forming belt and other apparatus elements, as described below, the three-dimensional feature structure of the nonwoven fabric 10 has strength properties that can vary between a first region and a second region within a microzone (more fully described below) or can vary from feature structure to feature structure in such a way as to provide beneficial properties for the nonwoven fabric 10 when used in personal care products, clothing, medical products, and cleaning products. For example, a first three-dimensional feature structure 20 can have a basis weight or density different from that of a second three-dimensional feature structure 22, and both can have a basis weight or density different from that of a third three-dimensional feature structure 24, thereby providing beneficial aesthetic and functional properties related to fluid collection, distribution, and / or absorption in a diaper or sanitary napkin.

[0078] It is believed that the differences in strength properties between the various three-dimensional feature structures of the nonwoven fabric 10 are due to fiber distribution and compaction resulting from the apparatus and method described below. Fiber distribution occurs during the fiber deposition process, rather than during a post-preparation process such as a hydroentangling process or an embossing process. Since the fibers are able to move freely during a process such as a melt spinning process, and in the presence of movement determined by the nature of the feature structure 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 the nonwoven fabric 10.

[0079] As can be seen in Figures 1 to 3 , and as can be understood from the specification herein, different three-dimensional feature structures can be defined by regions that are visually distinguishable (relative to the interior of the three-dimensional feature structure), and such regions can be in the form of a closed figure (such as Figure 1 and Figure 3 the heart shape in Figure 2 and Figure 3 the diamond shape in Figure 1 and Figure 3 ). The closed figure can be a curve-closed figure, such as Figure 4the region 21 shown, and when in the flattened state, they can be at least partially located in or on the first plane 16. For example, as Figure 1 shown, the first three-dimensional feature structure 20 is heart-shaped, and as shown by an exemplary first three-dimensional feature structure 20A, it is defined by a curved closed heart-shaped element. The curved element can be understood as a linear element that has a tangential vector V at any point along its length (in the case of a closed shape), such that the tangential vector V has both an MD component and a CD component, and the MD component and the CD component change values 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 can have a break that does not deviate from the overall impression of the closed figure. As discussed below in the context of the forming belt, the visually distinguishable curved closed heart-shaped element on the contour is formed by a corresponding closed heart-shaped raised element on the forming belt to prepare a heart-shaped closed figure on the fabric 10. In a repeating pattern, each shape (in the case of the first three-dimensional feature structure in Figure 1 is a heart shape) can result in an aesthetically pleasing, soft pillow-like feature structure on the total area OA of the second surface 14 of the fabric 10. In an embodiment where the nonwoven fabric 10 is used as the topsheet of a diaper or sanitary napkin, the second surface 14 of the nonwoven fabric 10 can face the body to deliver excellent aesthetic and performance benefits related to softness, compressibility resistance, and fluid absorption.

[0080] Specifically, in the regular repeating pattern of the closed three-dimensional feature structures shown in Figures 1 to 3 without being bound by theory, it is believed that the dimensions of the various feature structures, the average basis weight of the entire fabric 10 over its total area, and the following other processing parameters (which define different strength characteristics) contribute beneficially to improving compression recovery. It is believed that a plurality of relatively closely spaced, relatively small, and relatively pillow-like three-dimensional feature structures act as springs to resist compression and recover once the compressive force is removed. Compression recovery is important in, for example, personal care products such as diapers, sanitary napkins, or adult incontinence pads, the topsheets, backsheets nonwovens, acquisition layers, distribution layers, or other component layers of diapers or pants, because such products are typically packaged and folded in a compressed state. For aesthetic and performance purposes, manufacturers of personal care products want to maintain most (if not all) of the as-manufactured thickness. Due to the soft appearance and feel and the pleasingly crisp appearance, well-defined shapes, including very small shapes such as Figure 2The small heart shape shown, the three-dimensional nature of the formed feature structure provides important aesthetic benefits. The three-dimensional feature structure also provides softness, improved absorbency, less leakage, and an overall improved user experience during use. However, during the folding, encapsulation, shipping, and storage of personal care products, the necessary compression can cause a permanent loss of thickness in the topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layers of the absorbent article, thereby degrading the as-made functional benefits. The nonwoven fabrics of the present disclosure retain their as-made three-dimensional feature structure to a significant extent, even after undergoing compression encapsulation and distribution in the compressed encapsulated state.

[0081] Table 1 below shows the compression recovery data for two embodiments of the present disclosure. Example 1 corresponds to Figure 1 the nonwoven fabric 10 shown, and was prepared on a forming belt as referenced Fig.12 and Fig.14 described. Example 2 corresponds to Figure 2 the nonwoven fabric 10 shown, and was prepared on a forming belt as referenced Fig.15 and Fig.16 described. As can be seen from the data, when measured by the "compression aging test", the fabric 10 of the present invention shows significant benefits in terms of compression recovery. In one form, an absorbent article package having the compression recovery characteristics of the present disclosure can have a reduced in-bag stack height, but still deliver the aesthetic, absorbent, and softness benefits of an as-made diaper; or as if it had never been compression encapsulated. The present invention provides packages having a reduced in-bag stack height, which allow caregivers to easily grasp and store the packages, while also providing reduced distribution costs for manufacturers, while maintaining the as-made aesthetic clarity, absorbency, or softness performance of the absorbent article.

[0082] Example 1 :

[0083] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration, as Figure 6 shown, which is a scanning electron micrograph (SEM) showing the cross-section of the bicomponent trilobal fibers. The nonwoven fabric was spun on a forming belt having a repeating pattern as Fig.12 described, as hereinafter regarding Figure 7 and Figure 8 described, which is moved at a linear speed of about 25 meters per minute to an average basis weight of 30 grams per square meter, with a repeating pattern of heart shapes, as Figure 1As shown, the fibers of the fabric are further bonded at 130 °C on the first side 12 by heated compaction rollers 70, 72 (described below) and wound onto a reel at a winder 75.

[0084] Example 2 :

[0085] A bicomponent spunbond nonwoven fabric is produced by spinning a 50:50 ratio of polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration, as Figure 6 shown, which is a scanning electron micrograph showing the cross-section of the bicomponent trilobal fibers. The nonwoven fabric is spun onto a forming belt having a repeating pattern as Fig.16 described below with respect to Figure 7 and Figure 8 described, which moves at a linear speed of about 25 meters per minute to form a fabric 10 having an average basis weight of 30 grams per square meter, with a repeating pattern of diamond shapes, as Figure 2 shown. The fibers of the fabric are further bonded at 130 °C on the first surface 12 by heated compaction rollers 70, 72 (described below).

[0086] Table 1: Compression recovery

[0087]

[0088]

[0089] As can be seen from Table 1, the fabric 10 of the present invention retains a significant amount of thickness after being compressed at a 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 at 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: being encapsulated in a highly compressed diaper package and then remaining in this state during distribution to consumers, and then the package is finally opened by the consumer.

[0090] The present disclosure can utilize a melt spinning process. In melt spinning, there is no mass loss in the extrudate. Melt spinning is different from other spinning processes, such as wet spinning or dry spinning from a solution, where the solvent is removed by volatilization or diffusion from the extrudate, resulting in mass loss.

[0091] Melt spinning can be carried out at about 150 °C to about 280 °C, or in some embodiments, at about 190 °C to about 230 °C. The fiber spinning speed can be greater than 100 meters per minute, and can be about 1,000 meters per minute to about 10,000 meters per minute, and can be about 2,000 meters per minute to about 7,000 meters per minute, and can be about 2,500 meters per minute 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 smaller the fiber brittleness. Continuous fibers can be produced by a spunbond process or a meltblown process.

[0092] The nonwoven fabric 10 of the present disclosure can include continuous multi-component polymer filaments, including a primary polymer component and a secondary polymer component. The filaments can 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 can be arranged in substantially different regions across the cross-section of the bicomponent filament and can continuously extend along the length of the bicomponent filament. The secondary component B continuously forms at least a part of the circumferential surface of the bicomponent filament along the length of the bicomponent filament. The polymer component A and the polymer component B can be melt spun into multi-component fibers on a conventional melt spinning device. The device will be selected based on the desired multi-component configuration. A commercially available melt spinning device is purchased from Hills, Inc. located in Melbourne, Florida. The spinning temperature is in the range of 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 can have an average diameter of about 6 microns to about 40 microns, and preferably about 12 microns to about 40 microns.

[0093] Component A and component B can be arranged as Figure 5A shown in the side-by-side arrangement structure or as Figure 5B shown in the eccentric skin / core arrangement structure to obtain filaments exhibiting natural helical crimp. Alternatively, component A and component B can be arranged as Figure 5C shown in the concentric skin / core arrangement structure. Additionally, component A and component B can also be arranged as Figure 6 shown in the multi-lobed skin / core arrangement structure. Other multi-component fibers can be produced by using the compositions and methods of the present disclosure. The bicomponent fibers and multi-component fibers can be in the segmented pie, ribbon, sea-island configurations or any combination thereof. The skin can be continuous or discontinuous around the core. The weight ratio of the skin to the core is about 5:95 to about 95:5. The fibers of the present disclosure can have different geometries, including circular, elliptical, star-shaped, rectangular, and various other eccentricities.

[0094] Methods for extruding multi-component polymer filaments into such arrangement structures are well known to those of ordinary skill in the art.

[0095] A variety of polymers are suitable for practicing the present disclosure, including polyolefins (such as polyethylene, polypropylene, and polybutene), polyesters, polyamides, polyurethanes, elastomeric materials, and the like. Non-limiting examples of polymer materials that can be spun into continuous 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 gel material); and copolymers of polyolefins such as polyethylene-octene or polymers of monomer blends including 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: 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: polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, and mixtures thereof. Alternatively, the polymer may include polymers derived from bio-based monomers such as bio-polyethylene or bio-polypropylene.

[0096] The primary component A and the secondary component B can be selected such that the resulting bicomponent filaments provide improved nonwoven bonding and substrate softness. The primary polymer component A has a melting temperature lower than that of the secondary polymer component B.

[0097] The primary polymer component A may include polyethylene or a random copolymer of propylene and ethylene. The secondary polymer component B may include polypropylene or a random copolymer of propylene and ethylene. Polyethylene includes linear low density polyethylene and high density polyethylene. In addition, the secondary polymer component B may further include additives for enhancing the natural helical crimp of the filaments, reducing the bonding temperature of the filaments, and enhancing the abrasion resistance, strength, and softness of the resulting fabric.

[0098] Inorganic fillers such as oxides of magnesium, aluminum, silicon, and titanium can be added as inexpensive fillers or processing aids. Other inorganic materials include magnesium silicate hydrate, titanium dioxide, calcium carbonate, clay, chalk, boron nitride, limestone, diatomaceous earth, mica, glass, quartz, and ceramics.

[0099] 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 a resin, the slip agent gradually exudes or migrates to the surface during cooling or after manufacture, thus forming a uniform, invisibly thin coating, thereby producing a permanent lubricating effect. The slip agent is preferably a fast and intense slip agent and can be a hydrocarbon having one or more functional groups selected from hydroxides, aryls and substituted aryls, halogens, alkoxys, carboxylates, esters, carbon unsaturates, acrylates, oxygen, nitrogen, carboxyls, sulfates and phosphates.

[0100] During preparation or during post-treatment or even during both, the nonwoven fabric of the present invention can be treated with a surfactant or other reagent to hydrophilize the fiber web or make it hydrophobic. This is a standard practice for nonwovens used in absorbent articles. For example, the nonwoven fabric for the topsheet can be treated with a hydrophilizing material or surfactant so that it is permeable to body exudates such as urine. For other absorbent articles, the topsheet can remain in its natural hydrophobic state or be made more hydrophobic by adding a hydrophobizing material or surfactant.

[0101] Suitable materials for the multicomponent filaments for preparing the fabrics of the present disclosure include PH-835 polypropylene from LyondellBasell and Aspun-6850-A polyethylene from Dow Chemical Company.

[0102] When polyethylene is component A (skin) and polypropylene is component B (core), the bicomponent filaments can contain from about 5% to about 95% polyethylene and from about 95% to about 5% polypropylene by weight. The filaments can contain from about 40% to about 60% polyethylene and from about 60% to about 40% polypropylene by weight.

[0103] Turning to Figure 7 , a representative production line 30 for preparing the fabric 10 of the present disclosure is disclosed. The production line 30 is arranged to produce a fabric of bicomponent continuous filaments, but it should be understood that the present disclosure includes nonwoven fabrics made of single-component filaments or multicomponent filaments having more than two components. The bicomponent filaments can be trilobal.

[0104] Production line 30 includes a pair of extruders 32 and 34 driven by extruder drives 31 and 33 respectively, for separately extruding a primary polymer component A and a secondary polymer component B. Polymer component A is fed from a first hopper 36 into the corresponding extruder 32, and polymer component B is fed from a second hopper 38 into the corresponding extruder 34. Polymer component A and polymer component B can be fed from 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 polymer into a spinning assembly 48. The spinneret for extruding bicomponent filaments is well known to those of ordinary skill in the art and is not described in detail herein.

[0105] Generally described, the spinning assembly 48 includes a housing that includes a plurality of plates stacked on top of one another, having a pattern of openings that are arranged to create flow paths for separately guiding polymer component A and polymer component B through the spinneret. The spinning assembly 48 has openings arranged in one or more rows. When the polymer is extruded through the spinneret, the spinneret openings form a downwardly extending filament curtain. For the purposes of this disclosure, the spinneret can be arranged to form Figure 5A , Figure 5B and Figure 5C the sheath / core or side-by-side bicomponent filaments and non-circular fibers such as trilobal fibers shown, as Figure 6 shown. Additionally, the fiber can also be a single component comprising a polymer component such as polypropylene.

[0106] Production line 30 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 quench air can be directed from one side or both sides of the filament curtain.

[0107] An attenuator 52 is positioned below the spinneret and receives the quenched filaments. Fiber suction units or aspirators used as attenuators during the melt spinning of polymers are well known. Suitable fiber suction units for use in the processes of this disclosure include linear fiber attenuators of the type shown in U.S. Patent 3,802,817 and jet guns of the type shown in U.S. Patents 3,692,618 and 3,423,266, the disclosures of which are incorporated herein by reference.

[0108] Generally described, attenuator 52 includes an elongate vertical passage through which filaments are drawn by aspirating air that enters the passage from the side and flows downwardly through the passage. A shaped, annular and at least partially perforated forming belt 60 is positioned below the attenuator 52 and receives the continuous filaments from the exit orifice of the attenuator 52. The forming belt 60 is a belt and travels around a guide roller 62. A vacuum positioned below the forming belt 60 (where the filaments are deposited) aspirates the filaments against a forming surface. Although the forming belt 60 is shown as a belt in Figure 8 it should be understood that the forming belt may also be in other forms, such as a drum. Details of a specifically shaped forming belt are described below.

[0109] In operation of the production line 30, hoppers 36 and 38 are filled with respective polymer components A and polymer components B. Polymer components A and B are melted and extruded by respective extruders 32 and 34 through polymer conduits 40' and 42' and a spinning assembly 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.

[0110] As the extruded filaments extend below the spinneret, an air stream from the quench blower 50 at least partially quenches the filaments and, for some filaments, induces crystallization of the molten filaments. The quench air may flow in a direction substantially perpendicular to the filament length at a temperature of about 0 °C to about 35 °C and at a velocity of about 100 feet per minute to about 400 feet per minute. The filaments may be sufficiently quenched before being collected on the forming belt 60 such that the filaments can be arranged by forced air passing through the filaments and the forming surface. Quenching the filaments reduces the stickiness of the filaments such that the filaments do not adhere too closely to each other before being bonded and can thus be moved or arranged on the forming belt during collection of the filaments on the forming belt and formation of the fiber web.

[0111] After quenching, the filaments are drawn by the air stream 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.

[0112] The filaments may be deposited onto the shaped and traveling forming belt 60 through the exit orifice of the attenuator 52. As the filaments contact the forming surface of the forming belt 60, a vacuum aspirates air and filaments against the forming belt 60 to form a nonwoven fiber 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 the vacuum can move or arrange the filaments on the forming belt 60 as the filaments are collected on the forming belt 60 and formed into the fabric 10.

[0113] The production line 30 also includes one or more bonding devices, such as cylindrical compaction rollers 70 and 72, which form a nip through which the fabric can be compacted, i.e., calendered, and which can also be heated to bond the fibers. One or both of the compaction rollers 70, 72 can be heated to provide enhanced properties and benefits to the nonwoven fabric 10 by bonding some portions of the fabric. For example, heating believed to be sufficient to provide thermal bonding will improve the tensile properties of the fabric 10. The compaction rollers can be a pair of smooth-surface stainless steel rollers with independent heating controllers. The compaction rollers can be heated by electrical elements or hot oil circulation. The gap between the compaction rollers can be hydraulically controlled to apply a desired pressure to the fabric as it passes through the compaction rollers on the forming belt. In one embodiment, where the forming belt has a thickness of 1.4 mm and the spunbond nonwoven fabric has a basis weight of 30 gsm, the nip gap between the compaction rollers 70 and 72 can be approximately 1.4 mm.

[0114] In one embodiment, the compaction roller 70 can be heated sufficiently to melt-bond the fibers on the first surface 12 of the fabric 10, thereby imparting strength to the fabric such that it can be removed from the forming belt 60 without loss of integrity. As Figure 8 and Fig. 9 shown, for example, as the compaction rollers 70 and 72 rotate in the direction indicated by the arrows, the belt 60 (on which the spunbond fabric is laid) enters the nip formed by the compaction rollers 70 and 72. The heated compaction roller 70 can heat the following portion of the nonwoven fabric 10 that is pressed against it by the raised resin elements of the belt 60 (i.e., in region 21), thereby creating bonded fibers 80' on at least the first surface 12 of the fabric 10. As can be understood from the present specification, the bonded regions so formed can exhibit the pattern of the raised elements of the forming belt 60. For example, the bonded regions so formed can be a substantially continuous network or a substantially semi-continuous network on the first surface 12 of region 21, which forms the same pattern as Figure 1 and Fig.11 the heart shape. By adjusting the temperature and dwell time, the bonding can be mainly confined to the fibers closest to the first surface 12, or the thermal bonding can reach the second surface 14, as Fig.11 (this figure also shows the spot bond 90 described in more detail below) and Figures 45 to 49 shown. The bonding can also be a discontinuous network, such as the spot bond 90 described below.

[0115] The raised elements of the forming belt 60 can be selected to establish various network features of the bonding area between the forming belt and the nonwoven substrate 11 or the nonwoven fabric 10. The network corresponds to the resin of the raised elements that make up the forming belt 60 and can include options of being substantially continuous, substantially semi - continuous, discontinuous, or combinations thereof. These networks can describe the raised elements of the forming belt 60 as it relates to their appearance or constitution in the X - Y plane of the three - dimensional feature structure of the forming belt 60 or the nonwoven substrate 11 or nonwoven fabric 10 including the present invention.

[0116] A "substantially continuous" network refers to an area within which any two points can be connected by an uninterrupted line, and the entire length of the uninterrupted line extends entirely within that area. That is, a substantially continuous network has a basic "continuity" in all directions parallel to a first plane and terminates only at the edges of the area. In combination with "continuous", the term "substantially" is intended to indicate that while absolute continuity may be achievable, minor deviations from absolute continuity are tolerable as long as these deviations do not significantly affect the performance for which the fibrous structure (or molded member) is designed and intended.

[0117] A "substantially semi - continuous" network refers to an area that has "continuity" in all but at least one direction parallel to a first plane, and in this area, any two points cannot be connected by an uninterrupted line whose entire length extends entirely within the area. A semi - continuous framework may have continuity in only one direction parallel to the first plane. Similar to the continuous area described above, while absolute continuity in all but at least one direction is preferred, minor deviations from this continuity are also tolerable as long as these deviations do not significantly affect the performance of the fibrous structure.

[0118] A "discontinuous" network refers to discrete and separated areas that are discontinuous in all directions parallel to a first plane.

[0119] After compaction, the fabric can leave the forming belt 60 and can be calendered through the nip formed by the calender rolls 71, 73. Thereafter, the fabric can be wound onto a reel. As Fig.10As 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 a raised portion 88 that may provide additional compaction and bonding to the fabric 10. The raised portion 88 may be a regular pattern of relatively small, spaced "pins" that form a pattern of relatively small point bonds 90 in the nip between the calender rolls 71 and 73. The percentage of point bonds in the nonwoven fabric 10 may be 3% to 30% or 7% to 20%. The engraved pattern may be a plurality of closely spaced, regular, generally cylindrical, generally flat-topped pin shapes, wherein the pin height is in the range of 0.5 mm to 5 mm and preferably 1 mm to 3 mm. The pins of the bonding calender roll may form closely spaced, regular point bonds 90 in the nonwoven fabric 10, such as Fig.11 Further bonding can be achieved by, for example, heat-through-air bonding.

[0120] As follows about Fig.56 As described, through-air thermal bonding may be another method for producing a higher loft nonwoven structure that may be applicable to this application. Through-air thermal bonding involves applying hot air to the surface of the nonwoven fabric. The hot air flows through holes in a plenum located just above the nonwoven fabric. However, the air is not pushed through the nonwoven fabric as in a normal hot air oven. Negative pressure or suction pulls the air through the open conveyor baffles, which support the nonwoven fabric as it passes through the oven. Pulling air through the nonwoven fabric allows for a more rapid and uniform transfer of heat and minimizes deformation of the fabric. In addition to conventional through-air bonding units, it is conceivable that the bonding unit is placed on top of the 3D belt while setting a vacuum below the belt to simulate the through-air bonding process for this particular application.

[0121] The binder for through-air thermal bonding includes crystalline binder fiber, bicomponent binder fiber and powder. When using crystalline binder fiber or powder, the binder is completely melted and forms droplets in the cross section of the whole nonwoven fabric. When cooling, bonding occurs at these points. With regard to the skin / core binder fiber, the skin is a binder, and the core is a carrier fiber. In one embodiment, the nonwoven fabric comprises skin / core binder fiber, the skin comprises polyethylene, and the core comprises polypropylene. For such nonwoven fabrics, since the through-air bonding time will depend on the basis weight, the required strength level and the operating speed, the through-air thermal bonding air temperature can be in the range of 110°C to 150°C, and the residence time can be in the range of 0.5 seconds to 10 seconds, 5 seconds to 30 seconds or 30 seconds to 60 seconds. The products manufactured using the through-air oven tend to be large in volume, open, soft, firm, ductile, breathable and absorbent.

[0122] As used herein, dot bonding is a method of thermally bonding nonwoven fabrics, webs, or substrates. The method involves passing a web through a nip between two rolls, which consists of a heated convex patterned or engraved metal roll and a smooth or patterned metal roll. The convex patterned roll may have a plurality of raised, generally cylindrical pins, which produce circular dot bonds. The smooth roll may be heated or not heated depending on the application. In a nonwoven production line, a nonwoven fabric that may be a non-bonded web is fed into the calender nip, and the fiber temperature is raised to the point where the fibers are thermally fused to each other at the tips of the engraved points and against the smooth roll. The heating time is typically on the order of milliseconds. The fabric properties depend on process settings such as roll temperature, fiber web line speed, and nip pressure, all of which can be determined by a person skilled in the art based on the desired degree of dot bonding. Other types of dot bonding, commonly referred to as hot calender bonding, may consist of different geometries for bonding (other than circular shapes), such as oval, linear, circular, etc. In the exemplary embodiments disclosed herein, the dot bonding produces a pattern of dot bonds that are circles with a diameter of 0.5 mm and have a total bond area of 10%. Other embodiments include bonding shapes where the raised pins have a longest dimension of about 0.1 mm to 2.0 mm over the entire bond surface of the pin, and the total bond area is in the range of 5% to 30%.

[0123] As Fig.11 shown, in one embodiment, a heated compaction roll 70 may form a bond pattern that may be a substantially continuous network bond pattern (e.g., interconnected heart-shaped bond portions 80) on a first surface 12 of the nonwoven fabric 10 (not shown in Fig.11In [the figure], since it faces away from the observer), and the engraved calender roll 73 can form relatively small dot bond portions 90 on the second surface 14 of the fabric 10. The dot bond portions 90 secure the loose fibers which would otherwise tend to fuzz or pill during the use of the fabric 10. The advantages of the resulting structure of the nonwoven fabric 10 are most evident when used as the topsheet in personal care products such as diapers or sanitary napkins. When used in personal care products, the first surface 12 of the nonwoven fabric 10 can be relatively flat (relative to the second surface 14), and has a relatively large amount of bonding due to the heat-compacting roll, thereby forming bond portions 80 at the areas of the fabric pressed by the raised elements of the forming belt 60. This bonding imparts structural integrity to the nonwoven fabric 10 but may be relatively hard or rough for the user's skin. Thus, the first surface 12 of the nonwoven fabric 10 can be oriented to face the inside of the product in a diaper or sanitary napkin, i.e., away from the wearer's body. Similarly, the second surface 14 can face the body and contact the body during use. The relatively small dot bond portions 90 are less likely to be perceived visually or tactilely by the user, and the relatively soft three-dimensional feature structure remains visually non-fuzzy and non-pilling while feeling soft for the body during use. In addition to or in place of the above bonding, further bonding can also be used.

[0124] The forming belt 60 can be prepared according to the methods and processes described in the following patents: U.S. Patent 6,610,173, issued to Lindsay et al. on August 26, 2003, or U.S. Patent 5,514,523, issued to Trokhan et al. on May 7, 1996, or U.S. Patent 6,398,910, issued to Burazin et al. on June 4, 2002, or U.S. Publication 2013 / 0199741, published in the name of Stage et al. on August 8, 2013, each patent having the improved feature structures and patterns for preparing spunbond nonwoven webs as disclosed herein. The disclosures of Lindsay, Trokhan, Burazin, and Stage describe the following belts, which represent papermaking belts made of cured resin on woven reinforcing members, and the belts have improvements and can be used in the present disclosure as described herein.

[0125] An example of a forming belt 60 of the type that can be used in the present disclosure and can be prepared according to the disclosure of U.S. Patent 5,514,523 is shown in Fig.12 In [the figure]. As taught herein, the reinforcing member 94 (such as a woven belt of filaments 96) is fully coated with a liquid photosensitive polymer resin to a preselected thickness. Incorporating the desired raised element pattern repeating elements (e.g., Fig.14) The film or negative mask is juxtaposed on the liquid photosensitive resin. Then the resin is exposed to light of an appropriate wavelength passing through the mask, such as UV light (for UV curable resins). This exposure to light causes the curing of the resin in the exposed areas (i.e., the white or non-printed portions of the mask). The uncured resin (the resin beneath the opaque portions of the mask) is removed from the system, leaving the cured resin that forms a pattern, which is shown by the cured resin element 92 as shown, for example, Fig.12 as shown by the cured resin element 92. Other patterns can also be formed as described herein.

[0126] Fig.12 illustrates a portion of the forming belt 60 that can be used to prepare Figure 1 the nonwoven fabric 10 as shown. As shown, the forming belt 60 can include cured resin elements 92 on a woven reinforcement member 94. The reinforcement member 94 can be made of woven filaments 96, as is well known in the field of papermaking belts, including resin-coated papermaking belts. The cured resin elements can have Fig.12 the general formula structure as shown, and are prepared by using a mask 97 having Fig.14 the dimensions as shown. As shown in the schematic cross-section in Fig.13 , the cured resin element 92 flows around the reinforcement member 94 and is cured to "lock" to the reinforcement member, and can have a width of about 0.020 inches to about 0.060 inches, or about 0.025 inches to about 0.030 inches, at the distal end DW, and can have a total height above the reinforcement member 94 that is between about 0.015 inches and about 0.060 inches, or between about 0.020 inches and about 0.050 inches, or between about 0.025 inches and about 0.045 inches, or between about 0.030 inches and about 0.040 inches, or between about 0.030 inches and about 0.035 inches, which is called the overload OB. Fig.14 represents a portion of the mask 97, showing the design and representative dimensions of one repeat unit of the repeating heart-shaped design for Figure 1 the nonwoven fabric 10 as shown. The white portion 98 is transparent to UV light and, in the process of preparing the belt, as described in U.S. Patent 5,514,523, allows UV light to cure the underlying resin layer, which is cured to form raised elements on the reinforcement member 94. After the uncured resin is rinsed away, the forming belt 60 having the cured resin design as shown in Fig.12 is produced by sewing the ends of the belt length, and the length of the belt can depend on the design of the equipment, as shown in Figure 7 .

[0127] In a similar manner, Fig.15 represents a portion of the mask 97, showing for Figure 2The design of a repeating unit of the repeating design in the nonwoven fabric 10 shown. The white portion 98 is transparent to UV light and, in the process of preparing the belt, allows UV light to cure the underlying resin layer, which is cured to the reinforcement member 94. After the uncured resin is rinsed away, a formed belt 60 having a cured resin design as shown in Fig.16 is produced by sewing the ends of the belt length, and the length of the belt can depend on the design of the equipment, as shown in Figure 7 shown.

[0128] Additionally, in another non-limiting example, Fig.17 represents a portion of a mask and shows a design of a repeating unit of the repeating design in the nonwoven fabric 10 shown in Fig.18 . The white portion 98 is transparent to UV light and, in the process of preparing the belt, allows UV light to cure the underlying resin layer, which is cured to the reinforcement member 94. After the uncured resin is rinsed away, a formed belt 60 having a cured resin design as shown in Fig.18 is produced by sewing the ends of the length of the fabric 10.

[0129] Another example of a portion of a formed belt 60 of the type that can be used in the present disclosure is shown in Fig.19 . Fig.19 The portion of the formed belt 60 shown has a discrete belt pattern 61, which can have a length L and a width W corresponding to the length L and width W of the total area OA of the nonwoven fabric 10. That is, the formed belt 60 can have discrete belt patterns 61 (discussed more fully below with reference to Fig. 22 ), each having a discrete belt pattern total area DPOA corresponding to the total area OA of the nonwoven fabric 10. Fig. 20 represents a portion of a mask and shows Fig.21 the design of a repeating unit of the repeating design in the nonwoven fabric 10 shown. The white portion 98 is transparent to UV light and, in the process of preparing the belt, allows UV light to cure the underlying resin layer, which is cured to the reinforcement member 94. After the uncured resin is rinsed away, a formed belt 60 having Fig.19 the cured resin design shown is produced by sewing the ends of the belt length.

[0130] Fig.19 The portion of the formed belt shown shows another beneficial effect of the present disclosure. Fig.19 The portion of the formed belt 60 shown can be used to prepare Fig.21 the fabric 10 shown. Fig.21 The nonwoven fabric 10 shown can have a width W dimension, a length L dimension, and a total area OA, making it suitable for use, for example, as the topsheet in a disposable diaper. In the manner shown in Fig.19The nonwoven fabric 10 made on the forming belt 60 illustrated is different from Figures 1 to 3 the nonwoven fabric shown because the pattern of the three-dimensional feature structure formed by the discrete cured resin elements 92 on the forming belt 60 is not a regularly repeating pattern over the entire total area. Instead, the pattern of the three-dimensional raised elements in the total discrete belt pattern area DPOA can be described as an irregular pattern including different parts called zones. The difference between zones can be visual, i.e., a visually distinguishable difference, or in the nonwoven fabric 10, the difference can result in a difference in average strength characteristics such as basis weight or density or a combination of visual and strength characteristics. If an observer can visually distinguish a pattern difference between zones such as a first zone 112 and a second zone 122 under ordinary indoor lighting conditions (e.g., 20 / 20 vision, sufficient light for reading), there is a visually distinguishable difference.

[0131] The nonwoven fabric 10 can also have visually distinguishable zones corresponding to the zones of the forming belt. As Fig.21 shown, for example, the fabric 10 can have at least two, three, or four visually distinguishable zones. A first zone 110 having a first pattern of three-dimensional feature structure and a first average strength characteristic can have a first area located generally centrally within the total area OA. A second zone 120 having a second pattern of three-dimensional feature structure and a second average strength characteristic can have a second area distributed generally around and, in one embodiment, completely surrounding the first zone 110 within the total area OA. A third zone 130 having a third pattern of three-dimensional feature structure and a third average strength characteristic can have a third area distributed generally around and, in one embodiment, completely surrounding the second zone 120 within the total area OA. A fourth zone 140 having a fourth three-dimensional feature structure and a fourth average strength characteristic can have a fourth area located within the total area OA in any position, such as at the front zone of the topsheet, such as Fig.21 the heart-shaped design shown. Generally, there can be n zones, where n is a positive integer. Each of the n zones can have an nth pattern of three-dimensional feature structure and an nth area and an nth average strength characteristic.

[0132] As Fig.21 shown, the visually distinguishable zones can include visually distinguishable three-dimensional feature structures. These different three-dimensional feature structures can be defined by regions of relatively higher density (relative to the interior of the three-dimensional feature structure), which can be in the form of a closed figure, such as Figure 1 and Figure 3 the heart shape in Figure 2 and Figure 3a diamond shape. Generally, as discussed more fully below, including in the context of a micro-region, a three-dimensional feature structure can be defined by a first region and a second region, where the first region and the second region are visually distinct, and there are common intensity characteristics associated with each of the first region and the second region, and there is a difference in the values of the common intensity characteristics of the first region and the second region. In one embodiment, the three-dimensional feature structure can be defined by a first region and a second region, where the first region is at a higher height (a dimension measured in the Z direction) than the second region relative to the plane of the first surface. In another embodiment, the three-dimensional feature structure can be defined by a first region and a second region, where the first region is at a higher base than the second region.

[0133] As can be appreciated, instead of having a constant repeating pattern that is uniform across the forming belt, the forming belt 60 of the present disclosure allows for the production of a nonwoven material that can have a repeating irregular discrete belt pattern 61, each discrete belt pattern 61 being similar to Fig.19 the discrete belt pattern shown. Each discrete belt pattern 61 can be used to form a nonwoven fabric 10 having a total area OA, for example, suitable for use in a disposable absorbent article such as a diaper or a sanitary napkin. The nonwoven fabric 10 can be produced sequentially, i.e., on-line, and optionally produced in parallel lanes in a sequential manner, each lane being a sequential line of the nonwoven fabric 10. The sequential lines of the nonwoven fabric 10 can be produced along an axis parallel to the processing direction in the processing direction. The nonwoven material can then be cut or otherwise sized to produce the nonwoven fabric 10 that is used as the topsheet in a disposable absorbent article such as a diaper or a sanitary napkin.

[0134] In one embodiment, the patterns within each discrete belt pattern total area DPOA can be the same or different. That is, the sequentially spaced discrete belt patterns can be substantially the same, or they can be different in visual appearance and / or in intensity characteristics (resulting from the nonwoven substrate produced thereon). For example, as Fig. 22Illustratively, the pattern of three-dimensional raised elements in the first zone 112 of the discrete belt pattern 61A can be different from the pattern of three-dimensional raised elements in the first zone 112 of the discrete belt pattern 61B. The forming belt 60 thus provides flexibility in the process of producing a nonwoven web 10 suitable for consumer products, which consumer products include disposable absorbent articles. For example, in a package of diapers, the topsheets of at least two diapers can be different because they are produced sequentially in a spunbond process as described herein, with sequential discrete belt patterns having different patterns of zones. In one embodiment, the topsheet or backsheet nonwoven pattern for one size of diaper can be different from the topsheet or backsheet nonwoven pattern for another size of diaper, thereby giving the caregiver a visual cue as to the diaper size. Similarly, the fabric 10 can be used for the topsheet in a sanitary napkin, where the visual pattern of the three-dimensional feature structure indicates the absorbency of the sanitary napkin. In any case, various patterns of the fabric 10 can be produced on a single belt by preparing different discrete belt patterns as needed.

[0135] Reference Fig. 22 , the forming belt has an axis A parallel to the longitudinal direction, which longitudinal direction is the processing direction. The forming belt 60 can have a plurality of discrete belt patterns 61 that are sorted into at least one sequential relationship relative to the longitudinal direction. Each discrete belt pattern 61 can have a total discrete belt pattern area DPOA, which total area is defined by a length L and a width W as shown for the discrete belt pattern 61A in a rectangular-shaped pattern. Each discrete belt pattern within its total area DPOA can have a first zone 112 and a second zone 122, 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 three-dimensional raised element extending outward from the plane of the first surface. The first forming zone can have a first air permeability value, and the second forming zone can have a second air permeability value, and the first air permeability value can be different from the second air permeability value. The patterns within each sequentially sorted total discrete belt pattern area DPOA can be the same or different.

[0136] By way of example, and with reference Fig.19 to the discrete belt pattern 61 of the forming belt 60 shown and Fig.21 the nonwoven fabric 10 shown, the following characteristics were determined. The first zone 110 of the nonwoven fabric 10 can have an average basis weight of from about 5 gsm to about 30 gsm; the second zone 120 can have an average basis weight of from about 50 gsm to about 70 gsm; and the third zone 130 can have an average basis weight of from about 25 gsm to about 60 gsm. The difference in basis weight from one zone to another can be attributed to the difference in air permeability of the forming belt 60. In the production of Fig. 20In an embodiment of the nonwoven fabric 10 shown, wherein the basis weights of the first zone 110, the second zone 120, and the third zone 130 are 15 gsm, 53 gsm, and 25 gsm, respectively, the air permeabilities of the corresponding first zone 112, second zone 122, and third zone 132 of the forming belt 60 are 379 cfm, 805 cfm, and 625 cfm, respectively. Thus, by varying the air permeabilities of the zones in the forming belt 10, the strength characteristics of the average basis weight and average density in each zone can be facilitated over the total area of the fabric 10.

[0137] As can be understood from the description of Fig. 22 the forming belt 60 and with reference to Fig.23 , in one embodiment, the nonwoven substrate 11 prepared on the belt 60 can be described as a nonwoven substrate 11 having a plurality of portions which are described herein as the fabric 10 being sorted into at least one sequential relationship with respect to the longitudinal direction, i.e., the processing direction, when prepared on the forming belt 60. Fig.23 FIG. is a schematic view of a spunbond nonwoven substrate 11 showing the fabrics 10 sorted sequentially, each fabric 10 having a different pattern in various zones. Each fabric 10 can 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 can have at least a first zone 110 within its total area OA, the first zone having a first pattern of three-dimensional characteristic structure and a first average strength characteristic and a first area located within the total area OA; a second zone 120, the second zone having a second pattern of three-dimensional characteristic structure and a second average strength characteristic, having a second area located within the total area OA. Optionally, there can be more zones, such as a third zone 130, the third zone having a third pattern of three-dimensional characteristic structure and a third average strength characteristic, and having a third area within the total area OA. As Fig.23 shown in the exemplary schematic view of, the first pattern 110A of the fabric 10A can be different from the first pattern 110B of the fabric 10B and can be different from the first pattern 110C of the fabric 10C. The same can be true for the second zones 120A, 120B, and 120C.

[0138] Generally speaking, the sequentially sorted nonwoven fabrics 10 of the nonwoven material 11 made on the forming belt 60 can vary in their respective total areas, strength characteristics, and visual appearances. One common strength characteristic is more than one zone (with respect to a zoning pattern, such as Fig.21 the zoning pattern shown) or region (for a three-dimensional characteristic structure, such as a regularly repeating pattern, such as Figure 1The strength characteristics of the regular repeating pattern shown). Such strength characteristics of the nonwoven fabric 10 may be average values and may include, but are not limited to, density, bulk density, basis weight, thickness, and opacity. For example, if density is a common strength characteristic of two different zones or regions, the density value in one zone or region may be different from the density value in the other zone or region. Zones (such as, for example, a first zone and a second zone) may be recognizable regions that are distinguishable from each other visually and by different strength characteristics averaged within the zone.

[0139] Once produced, each nonwoven fabric 10 can be cut to size and used for its intended purpose, such as for the topsheet in a disposable absorbent article. For example, a disposable diaper 1006 in a flattened orientation is shown in Fig.24 FIG. 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 web and cut to size after assembly.

[0140] As can be appreciated with reference to Fig.24 FIG., in one embodiment, the nonwoven substrate 11 made on the belt 60 can be described as a nonwoven fabric 11 having a plurality of parts, which are described herein as fabrics 10 that are sorted into at least one sequential relationship with respect to the longitudinal direction, i.e., the processing direction, when prepared on the forming belt 60, and into at least one juxtaposed relationship, i.e., along the transverse direction, when prepared on the forming belt 60. Fig.24 FIG. is a schematic view of the spunbond nonwoven substrate 11, showing the sequentially sorted fabrics 10 in adjacent processing direction lanes 13, with each fabric 10 adjacent in the adjacent lanes, which fabric is in Fig.24are labeled 10D, 10E, and 10F in the figure. 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 first pattern of a three-dimensional characteristic structure and a first average strength characteristic and a first area located within the total area OA; a second zone 120, the second zone having a second pattern of a three-dimensional characteristic structure and a second average strength characteristic, having a second area located within the total area OA. Optionally, there may be more zones, such as a third zone 130, the third zone having a third pattern of a three-dimensional characteristic structure and a third average strength characteristic, and having a third area within the total area OA. Each fabric 10 in the juxtaposed lanes may be substantially the same, or they may be different with respect to size, visual appearance, and / or strength characteristics. Once produced, the nonwoven substrate 11 may be wound onto a reel for cutting into lanes for processing into consumer products, or may be cut and then wound onto a reel.

[0141] By comparing the basis weight differences of the fabric 10 made of a regularly repeated uniform pattern and the fabric 10 made of a non-uniform partition pattern with representative samples, the nonwoven fabric 10 of Example 1 was compared with a fabric having a pattern similar to Fig.21 the pattern shown (and referred to as Example 3). Example 3 is a bicomponent spunbond nonwoven web, which was produced on the apparatus disclosed herein by spinning a 50:50 ratio of polyethylene skin (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 moving at a linear speed of about 25 meters per minute to an average basis weight of 30 grams per square meter on a forming belt with a partition pattern as Fig.19 shown. A second substrate was formed under the same conditions, but having at least one cross-section with a regularly repeated uniform pattern on a forming belt as Fig.16 shown (from which the basis weight was determined). The fiber spinning conditions, throughput, forming belt linear speed, and calender roll bonding temperature were the same for both substrates.

[0142] Example 3

[0143] A bicomponent spunbond nonwoven fabric is produced by spinning a 50:50 ratio of polyethylene skin (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 grams per square meter. A nonwoven fabric is produced as described with respect to Figure 7 and Figure 8 and is moved at a forming belt line speed of about 25 meters per minute to form a fabric having a zoned pattern as shown in Fig. 20 . The fibers of the fabric are further bonded at 130 °C on the first surface 12 by heated calendering rolls 70, 72, and the fabric is wound onto a reel at a winder 75.

[0144] Example 4

[0145] A bicomponent spunbond nonwoven fabric is produced by spinning a 50:50 ratio of polyethylene skin (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 grams per square meter. A nonwoven fabric is produced as described with respect to Figure 7 and Figure 8 and is moved at a forming belt line speed of about 25 meters per minute to form a fabric having a repeating (non-zoned) pattern as shown in Figure 2 . The fibers of the fabric are further bonded at 130 °C on the first surface 12 by heated calendering rolls 70, 72, and are wound onto a reel at a winder 75.

[0146] Table 2 below shows the average local basis weights measured according to the "local basis weight" test method of the present disclosure and averaged over 10 samples. The samples used for the measurement were taken from the fabrics shown in Fig.25A and Fig.25B , where the dark rectangles are the areas of the samples from which 3 cm 2 was removed for the measurement sites. As can be seen, these fabrics are labeled A to E in the cross direction (CD). The measured values show not only significant basis weight differences between the zones of the zoned fabric, but also the CD distribution shown in Fig.26 .

[0147] Table 2: Average basis weight distribution in nonwoven fabric 10 measured in grams per square meter (gsm)

[0148]

[0149] As can be seen in Table 2, the fabric 10 made on the forming belt 60 having different air permeability zones exhibits a basic change in the fiber laying layer, and thus the basic change in basis weight within the CD of the nonwoven fabric 10 indicates the ability of the fibers to travel with air into the high permeability zones. The non-partitioned regular repeating pattern fabric 10 exhibits approximately the same basis weight within the CD of the fabric.

[0150] In addition to the differences in air permeability of the various zones of the forming belt 60, the structure of the forming belt 60 can also affect other strength characteristics of the various zones in the fabric 10, such as average thickness, average softness, average compressibility resistance, and fluid absorption characteristics.

[0151] Another aspect of the present invention relates to a spunbond commercial production line where multiple boxes are used for improved laying layer opacity and uniformity of the fabric. In some cases, the equipment can include a triple spunbond box (referred to in the art as "SSS"), and can be combined with meltblown (M), for example, in equipment such as a "SSMMS" spunbond production line.

[0152] By calendering the nonwoven fabric 10 to have dot bonds 90, this can reduce fuzzing. Fuzzing refers to the tendency of the fibers to become loose and be removed from the fabric 10. The loosening and removal can be attributed to frictional engagement with manufacturing equipment during the production of disposable absorbent articles, or the interaction of another surface such as a person's skin with the fabric 10. In some applications, such as for the topsheet in disposable absorbent articles, fuzzing is a negative consumer phenomenon. However, bonding the fibers in place can also be consumer negative because it can create roughness on the surface of an otherwise soft nonwoven substrate. As desired, we have found that the nonwoven fabric substrate and nonwoven fabric of the present disclosure can ensure an increase in bonding (and thus a reduction in fuzzing that occurs) with a minimal loss of softness. The bonding can be achieved by relatively closely spaced dot bonds 90, where the spacing depends on the desired degree of fuzzing reduction. Bonding can also be achieved by known methods for chemically or thermally bonding nonwoven fibers, such as thermal bonding, ultrasonic bonding, pressure bonding, latex adhesive bonding, and combinations of such methods. Examples 5 and 6 below illustrate the reduction in fuzz achieved through bonding.

[0153] Example 5

[0154] A bicomponent spunbond nonwoven fabric is produced by the following method: as described with respect to Figure 7 and Figure 8The polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a 50:50 ratio are spun in a trilobal fiber configuration onto the forming belt to an average basis weight of about 30 g / m², which moves at a linear speed of about 25 m / min to form a fabric having a repeating pattern as shown in Fig.36 The fibers of the fabric are further bonded on the first surface 12 by compaction rollers 70, 72, where compaction roller 70 is heated to 130°C to form a substantially continuous bond 80.

[0155] Example 6

[0156] A bicomponent spunbond nonwoven fabric is produced by spinning, onto a forming belt as described with respect to Figure 7 and Figure 8 the polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a 50:50 ratio in a trilobal fiber configuration to an average basis weight of about 30 g / m², which moves at a linear speed of about 25 m / min to form a fabric having a repeating pattern as shown in Fig.37 The fibers of the fabric are further bonded on the first surface 12 by compaction rollers 70, 72, where compaction roller 70 is heated to 130°C to form a substantially continuous bond 80. The fibers of the fabric are further calender bonded at calender rollers 71, 73, where calender roller 73 is an engraved roller having raised portions 88 in the form of pins, with a pin height of 1.25 mm and an open gap of 0.62 mm in a 10% dot bond pattern. Calender roller 73 is heated to 135°C to form dot bonds 90 on the second side 14 of the fabric 10, as shown in Fig.11 The fabrics 10 of Examples 5 and 6 differ only in the absence or presence of dot 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 dot bonds in fixing the fibers to the fabric surface. The fuzz test results for Examples 5 and 6 are shown in Table 3.

[0157]

[0158] Table 3: MD villus results

[0159] Sample No. <![CDATA[MD fluff value (mg / cm 2 )]]> Example 5 0.36 Example 6 0.19

[0160] As shown above, the dot bonds 90 result in a significant reduction in the MD fuzz value. Despite the bonding treatment, it retains its softness, absorbency, and aesthetic benefits, and now also has the desired fuzz resistance for consumer use.​

[0161] Absorbent articles of the present disclosure are typically placed in packages for transportation, storage, and sale. The package may comprise a polymeric film and / or other materials. Graphics and / or markings related to the characteristics of the absorbent article may be formed on, printed on, positioned on, and / or placed on an outer portion of the package. Each package may include 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 quantity of absorbent articles for each package. By encapsulating the absorbent articles under compression, a caregiver can easily handle and store the package, while also providing savings in distribution for the manufacturer due to the size of the package. Fig. 27 An exemplary package 1000 including a plurality of absorbent articles 1004 is shown. 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 in one or more stacks 1006.

[0162] According to the in-bag stack height test described herein, the absorbent article package of the present disclosure may have an in-bag stack height of less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 85 mm, but greater than about 75 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm, or less than about 74 mm, specifically listing all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby. Alternatively, according to the in-bag stack height test described herein, the absorbent article package of the present disclosure may have an in-bag stack height of about 70 mm to about 100 mm, about 70 mm to about 95 mm, about 72 mm to about 85 mm, about 72 mm to about 80 mm, or about 74 mm to about 78 mm, specifically listing all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby.

[0163] General description of absorbent articles

[0164] The three-dimensional nonwoven fabric 10 of the present disclosure can be used as a component of the following 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 220 in the form of a diaper is shown in Figures 28 to 30 in. Fig.28 is a plan view of an exemplary diaper in a flat state, where some parts of the structure are cut away to more clearly show the construction of the absorbent article 220 (diaper). Fig.28The wearer-facing surface of the absorbent article 220 (diaper) faces the observer. The absorbent article 220 (diaper) is shown for illustrative purposes only, as the three-dimensional nonwoven materials of the present disclosure can be used as one or more components of an absorbent article, such as a topsheet, acquisition layer, topsheet and acquisition layer, or topsheet and acquisition and / or distribution system (“ADS”). In any case, the three-dimensional nonwoven materials of the present disclosure can be liquid-permeable.

[0165] The absorbent article 220 can include a liquid-permeable material or topsheet 224, a liquid-impermeable material or backsheet 225, and an absorbent core 228 and barrier leg cuffs 234 that are at least partially positioned between the topsheet 224 and the backsheet 225. The absorbent article can also include an ADS 250, which in the example shown includes a distribution layer 254 and an acquisition layer 252 that will be discussed further below. The absorbent article 220 can also include an elastomeric gusset cuff 232, which includes an elastomeric member 233 that is generally joined to the infrastructure of the absorbent article via the topsheet and / or backsheet and is substantially planar with the infrastructure of the diaper.

[0166] Fig.28 and Fig.31 Also shown are typical diaper components, such as a fastening system, which includes tabs 242 that are attached toward the rear edge of the article and mate with a landing zone 244 on the front portion of the absorbent article. The absorbent article can also include other typical elements not shown, such as, for example, a rear elastic waist feature, a front elastic waist feature, one or more lateral barrier cuffs, and / or lotion application.

[0167] The absorbent article 220 includes a front waist edge 210, a rear waist edge 212 that is longitudinally opposite the front waist edge 210, a first side edge 203, and a second side edge 204 that is 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 rear waist edge 212 is the opposite edge. The absorbent article 220 can 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 rear waist edge 212 and divides the article into two halves that are substantially symmetric with respect to the longitudinal axis 280, where the article is laid flat, unfolded, and viewed from above, as Fig.28As shown. The absorbent article 220 may also have a lateral axis 290 that extends 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 the point located on the longitudinal axis at a distance of two-fifths (2 / 5) L from the front edge 210 of the absorbent 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 one-third of the longitudinal length L of the absorbent article.

[0168] The topsheet 224, the backsheet 225, the absorbent core 228, and other article components may be assembled in a variety of configurations, specifically by, for example, gluing or thermally embossing.

[0169] The absorbent core 228 may include absorbent material and a core wrapper that encapsulates superabsorbent polymer, and the absorbent material contains 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 of superabsorbent polymer. The core wrapper generally may include two materials, substrates, or nonwoven materials for the top and bottom sides of the core. These types of cores are referred to as cores without breathable felts. The core may include one or more channels, represented in Fig.28 as four channels 226, 226' and 227, 227'. The channels 226, 226', 227, and 227' are optional features. In contrast, the core may not have any channels or may have any number of channels.

[0170] These and other components of the exemplary absorbent article will now be discussed in more detail.

[0171] Top sheet

[0172] In the present disclosure, the topsheet (the part of the absorbent article that contacts the wearer's skin and receives fluids) may be formed of a part or all of one or more of the three-dimensional nonwoven materials described herein, and / or have one or more nonwoven materials positioned thereon and / or joined thereto such that one or more nonwoven materials contact the wearer's skin. Other parts of the topsheet (parts other than the three-dimensional nonwoven materials) may also contact the wearer's skin. The three-dimensional nonwoven material may be positioned as a strip or patch on top of a typical topsheet 224. Alternatively, the three-dimensional nonwoven material may only form the central CD region of the topsheet. The central CD region may extend the full MD length of the topsheet or be less than the full MD length of the topsheet.

[0173] As is well known to those skilled in the art, the topsheet 224 can be joined to the backsheet 225, the absorbent core 228, and / or any other layer. Typically, the topsheet 224 and the backsheet 225 are directly joined to each other at some locations (e.g., at or near the perimeter of the absorbent article), and indirectly joined together at other locations by joining them directly to one or more other elements of the absorbent article 220.

[0174] The topsheet 224 can be compliant, feel soft, and non-irritating to the wearer's skin. Additionally, part or all of the topsheet 224 can be liquid-permeable, allowing liquids to easily penetrate through its thickness. Further, part or all of the topsheet 224 can be treated with surfactants or other agents to hydrophilize the fibrous web or make it hydrophobic. As is commonly disclosed in the art, any portion of the topsheet 224 can be coated with a lotion and / or skin care composition. The topsheet 224 can also include or be treated with an antibacterial agent.

[0175] Negatives

[0176] The backsheet 225 is typically that portion of the absorbent article 220 that is positioned adjacent to the absorbent core 228 and facing the clothing, and it prevents or at least inhibits the fluids and body exudates absorbed and contained therein from soiling articles such as sheets and undergarments. The backsheet 225 is typically impermeable to fluids (e.g., urine), or at least substantially impermeable. The backsheet can be, for example, or include, a thin plastic film such as a thermoplastic film having a thickness of from about 0.012 mm to about 0.051 mm. Other suitable backsheet materials can include breathable materials that allow vapors to escape from the absorbent article 220 while still preventing or at least inhibiting the passage of fluids through the backsheet 225.

[0177] The backsheet 225 can 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.

[0178] An absorbent article may include a backsheet that includes an outer cover or an outer cover nonwoven. The outer cover or the outer cover nonwoven of absorbent article 220 may cover at least a portion or all of backsheet 225 to form a soft garment-facing surface of the absorbent article. The outer cover or the outer cover nonwoven may be formed of the high-loft three-dimensional nonwoven materials described herein. Alternatively, the outer cover or the outer cover nonwoven may include one or more known outer cover materials. If the outer cover includes one of the three-dimensional nonwoven materials of the present disclosure, the three-dimensional nonwoven material of the outer cover may or may not match (e.g., the same material, the same pattern) the three-dimensional nonwoven material used as the topsheet or the topsheet and acquisition layer of the absorbent article. In other instances, 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 topsheet or the topsheet and acquisition layer laminate of the absorbent article. The outer cover may be joined to at least a portion of backsheet 225 by mechanical bonding, ultrasonic bonding, thermal bonding, adhesive bonding, or other suitable attachment methods.

[0179] Absorbent core

[0180] The absorbent core is the following component of the absorbent article, which has the maximum absorbency capacity and includes absorbent material and a core wrapper or core bag that encapsulates the absorbent material. The absorbent core does not include an acquisition and / or distribution system or any other component of the absorbent article that is not an integral part of or not placed within the core wrapper or core bag. The absorbent core may include substantially or consist of a core wrapper, the absorbent material in question (e.g., superabsorbent polymer and little or no cellulosic fibers), and glue.

[0181] Absorbent core 228 may contain absorbent material having a high amount of superabsorbent polymer (abbreviated herein as "SAP") encapsulated within the core wrapper. The SAP content may be expressed as 70% to 100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99%, or 100% by weight of the absorbent material contained within the core wrapper. For the purpose of evaluating the percentage of SAP in the absorbent core, the core wrapper is not considered absorbent material. The absorbent core may contain a breathable felt with or without superabsorbent polymer.

[0182] The so-called "absorbent material" refers to materials having some absorbent properties or liquid retention properties, such as SAP, cellulose fibers, and synthetic fibers. Generally, the adhesives used to prepare the absorbent core do not have or have very little absorbent properties and are not considered absorbent materials. The SAP content can be higher than 80%, such as at least 85%, at least 90%, at least 95%, at least 99%, and even up to and including 100% of the weight of the absorbent material contained within the core wrapper. The core without the breathable mat is relatively thin compared to a conventional core that typically contains between 40% and 60% by weight of SAP and a high content of cellulose fibers. The absorbent material can specifically contain less than 15% by weight or less than 10% by weight of natural fibers, cellulose fibers, or synthetic fibers, less than 5% by weight, less than 3% by weight, less than 2% by weight, less than 1% by weight, or can even be substantially free of natural fibers, cellulose fibers, and / or synthetic fibers.

[0183] As described above, compared to a conventional core, the core without the breathable mat with very little or no natural fibers, cellulose fibers, and / or synthetic fibers is quite thin, making the overall absorbent article thinner than an absorbent article with a core containing a mixture of SAP and cellulose fibers (e.g., 40% to 60% cellulose fibers). This core thinness may lead consumers to perceive reduced absorbency and performance, but technically this is not the case. Currently, these thin cores are typically used with a substantially planar or open-celled topsheet. Additionally, absorbent articles having these thin cores without the breathable mat also have reduced capillary void space because there are very few or no natural fibers, cellulose fibers, or synthetic fibers present in the core. Therefore, sometimes there may not be sufficient capillary void space in the absorbent article to adequately receive multiple or a single large assault of body exudates.

[0184] To address such issues, the present disclosure provides absorbent articles with these thin airfelt-free cores, which are combined with one of the highly fluffed three-dimensional nonwoven materials described herein as the topsheet or topsheet and acquisition layer laminate. In such an instance, 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 highly fluffed three-dimensional nonwoven material. Additionally, when used with these thin airfelt-free cores and acting as the topsheet or topsheet and acquisition layer laminate, the three-dimensional nonwoven material adds capillary void space back into the absorbent article while still allowing for a minimal stack height, thereby passing cost savings on to the consumer and manufacturer. Thus, due to this increased capillary void space, the absorbent articles of the present disclosure can readily absorb multiple body exudates or a single large exudate. Further, the absorbent articles including the nonwoven material as the topsheet or topsheet and acquisition layer laminate also provide an aesthetically pleasing topsheet to the consumer as compared to a planar topsheet or an apertured topsheet with an increased thickness and thus enhanced consumer perception of absorbency and performance.

[0185] In Figure 33 to Figure 35 is shown in isolation Figure 31 to Figure 32 the exemplary absorbent core 228 of the absorbent article 220. The absorbent core 228 can 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 can 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 intended to be placed toward the front waist edge 210 of the absorbent article. As viewed from the top in the plan view as shown in Fig.28 , the absorbent core 228 can have a longitudinal axis 280' that substantially corresponds to the longitudinal axis 280 of the absorbent article 220. Absorbent material can be distributed toward the front side 480 in a greater amount than toward the back side 282 because greater absorbency may be required at the front portion of the particular absorbent article. The front side 480 and the back side 282 of the core can be shorter than the longitudinal sides 284 and 286 of the core. The core wrap can be formed of two nonwoven materials, substrates, laminates, or other materials, which can be sealed at least partially along the longitudinal sides 284, 286 of the absorbent core 228. The core wrap can be sealed at least partially along its front side 480, back side 282, and two longitudinal sides 284, 286 such that substantially no absorbent material leaks out of the absorbent core wrap. A first material, substrate, or nonwoven fabric 216 can at least partially surround a second material, substrate, or nonwoven fabric 216' to form the core wrap, as shown in Fig.34 . The first material 216 can surround portions of the second material 216' adjacent the longitudinal sides 284 and 286.

[0186] The absorbent core may include, for example, an adhesive to help secure the SAP within the core wrapper and / or ensure the integrity of the core wrapper, particularly when the core wrapper is made of two or more substrates. The adhesive may be a hot melt adhesive supplied, for example, by H.B.Fuller. The core wrapper may extend into an area larger than that strictly required to contain the absorbent material therein.

[0187] The absorbent material may be a continuous layer present within the core wrapper. Alternatively, the absorbent material may consist of individual bags or strips of absorbent material encapsulated within the core wrapper. In the first case, the absorbent material may be obtained, for example, by applying a single continuous layer of absorbent material. A continuous layer of absorbent material (specifically, SAP) may also be obtained by combining two absorbent layers having a discontinuous absorbent material application pattern, where the resulting layer is substantially continuously distributed in areas of absorbent particulate polymer material, as disclosed, for example, in U.S. Patent Application Publication 2008 / 0312622A1 (Hundorf). The absorbent core 228 may include a first absorbent layer and a second absorbent layer. The first absorbent layer may include a first material 216 and a first layer 261 of absorbent material, which may be 100% or less SAP. The second absorbent layer may include a second material 216’ and a second layer 262 of absorbent material, which may be 100% or less SAP. The absorbent core 228 may also include a fibrous thermoplastic adhesive material 251 that at least partially bonds the first layer 261 and the second layer 262 of absorbent material to their respective materials. This is shown in Figure 34 to Figure 35 for example, where a first SAP layer and a second SAP layer have been applied in the form of transverse strips or “landing zones” on their respective substrates and then combined, the transverse strips or “landing zones” having the same width as the desired absorbent material deposition area. The strips may contain different amounts of absorbent material (SAP) to provide a basis weight distribution along the longitudinal axis of the core. The first material 216 and the second material 216’ may form the core wrapper.

[0188] The fibrous thermoplastic adhesive material 251 may at least partially contact the absorbent material in the landing zone and at least partially contact the material in the bonding zone. This imparts a substantially three-dimensional structure to the fibrous layer of the fibrous thermoplastic adhesive material, which is itself a substantially two-dimensional structure having a relatively small thickness compared to the dimensions in the length and width directions. Thus, the fibrous thermoplastic adhesive material may provide cavities to cover the absorbent material in the landing zone, thereby securing the absorbent material, which may be 100% or less SAP.

[0189] The thermoplastic adhesive for the fibrous layer may have elastomeric properties such that the fibrous web formed by the fibers on the SAP layer can be stretched when the SAP swells.

[0190] Superabsorbent polymer (SAP)

[0191] The SAPs useful in the present disclosure may include a variety of water-insoluble but water-swellable polymers capable of absorbing large amounts of fluid.

[0192] The superabsorbent polymer may be in particulate form so as to be flowable in the dry state. The particulate absorbent polymer material may be made of poly(meth)acrylic acid polymers. However, starch-based particulate absorbent polymer materials may also be used, as well as starch-grafted copolymers of polyacrylamide copolymers, ethylene maleic anhydride copolymers, crosslinked carboxymethyl cellulose, polyvinyl alcohol copolymers, crosslinked polyethylene oxide, and polyacrylonitrile.

[0193] The SAPs may have a variety of shapes. The term "particle" refers to granule, fiber, flake, sphere, powder, sheet, and other shapes and forms known to those skilled in the art of superabsorbent polymer particles. The SAP particles may be in the shape of fibers, i.e., elongated needle-like superabsorbent polymer particles. The fibers may also be in the form of woven filaments. The SAP may be spherical particles. The absorbent core may comprise one or more types of SAP.

[0194] For most absorbent articles, the liquid discharge of the wearer mainly occurs in the front half of the absorbent article (specifically, the diaper). Therefore, the front half of the article (as defined by the region between the front edge and the transverse line set at a distance of half L from the front waist edge 210 or the rear waist edge 212) may include most of the absorption capacity of the core. Therefore, 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 rear half of the absorbent article. Alternatively, the SAP may be uniformly distributed throughout the core or may have other suitable distributions.

[0195] The total amount of SAP present in the absorbent core may also vary according to the intended 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 within the SAP deposition region 8 (or "at least one" if there are several) may be at least 50, 100, 200, 300, 400, 500 g / m 2 or more. The area of the channels (e.g., 226, 226', 227, 227') present in the absorbent material deposition region 8 is derived from the absorbent material deposition area to calculate this average basis weight.

[0196] Core wrap

[0197] The core wrapper can be made of a single substrate, material, or nonwoven fabric folded around the absorbent material, or can include two (or more) substrates, materials, or nonwoven fabrics attached to each other. Typical attachments are the so-called C-wrappers and / or sandwich wrappers. In a C-wrapper, as shown in the figure, for example, in Fig.29 and Fig.34 , the longitudinal and / or transverse edges of one of the substrates are folded over the other substrate to form flaps. These flaps are then typically bonded to the outer surface of the other substrate by gluing.

[0198] The core wrapper can be formed from any material suitable for receiving and containing the absorbent material. Typical substrate materials used for preparing conventional cores can be used, specifically, paper, tissue, film, woven or nonwoven fabric, or a laminate or composite material of any of these materials.

[0199] The substrate can also be breathable (in addition to being liquid or fluid permeable). Thus, the membranes that can be used herein can include micropores.

[0200] The core wrapper can be sealed at least partially along all sides of the absorbent core such that substantially no absorbent material leaks out of the core. By "substantially no absorbent material" is meant less than 5%, less than 2%, less than 1%, or about 0% by weight of the absorbent material escaping from the core wrapper. The term "sealed" should be understood broadly. The seal does not need to be continuous along the entire perimeter of the core wrapper, but can be discontinuous along part or all of it, such as formed by a series of seal points spaced in a line. The seal can be formed by gluing and / or heat bonding.

[0201] If the core wrapper is formed from two substrates, four seals can be used to encapsulate the absorbent material 260 within the core wrapper. For example, the first substrate 216 can be placed on one side of the core (as Figure 33 to Figure 35The top side as shown) and extends around the longitudinal edge of the core to at least partially wrap the opposite bottom side of the core. A second substrate 216' may be present between the wrapped flap of the first substrate 216 and the absorbent material 260. The flap of the first substrate 216 may be adhesively bonded to the second substrate 216' to provide a strong seal. Compared to a sandwich seal, this so-called C-wrap configuration may provide benefits such as improved burst resistance in a wet load condition. Then, the front and back sides of the core wrap may also be sealed by adhesively bonding the first substrate and the second substrate to each other to provide a complete encapsulation of the absorbent material across the entire perimeter of the core. For the front and back sides of the core, the first substrate and the second substrate may extend in a substantially planar direction and may be joined together to form a so-called sandwich configuration for these edges. In the so-called sandwich configuration, the first substrate and the second substrate may also extend outwardly on all sides of the core and are generally sealed flatly or substantially flatly along all or a portion of the perimeter of the core by adhesive bonding and / or heat / pressure bonding. In one example, neither the first substrate nor the second substrate need be formed, such that they may be cut rectilinearly for ease of preparation, but other shapes are also within the scope of the present disclosure.

[0202] The core wrap may also be formed from a single substrate that encapsulates the absorbent material in a wrap and seals along the front and back sides of the core and a longitudinal seal.

[0203] SAP deposition area

[0204] As seen from the top side of the absorbent core, the absorbent material deposition region 208 may be defined by the perimeter of a layer defined by the absorbent material 260 within the core wrap. The absorbent material deposition region 208 may have various shapes, specifically the so-called "dog bone" or "hourglass" shapes, which show a taper along its width towards the middle or "crotch" region of the core. In this way, the absorbent material deposition region 8 may have a relatively narrow width in the core region intended to be placed in the crotch region of the absorbent article, as Fig.28 shown. This may provide better wearing comfort. The absorbent material deposition region 8 may also be generally rectangular, for example as Figure 31 to Figure 33 shown, but other deposition regions, such as rectangular, "T", "Y", "hourglass" or "dog bone" shapes are also within the scope of the present disclosure. Any suitable technique may be used to deposit the absorbent material, which may allow for relatively precise deposition of SAP at a relatively high speed.

[0205] aisle

[0206] The absorbent material deposition region 208 may include at least one channel 226 that is at least partially oriented longitudinally (i.e., has a longitudinal vector component) along the article, as Fig.28 and Fig.29As shown. Other channels may be at least partially laterally oriented (i.e., having a lateral vector component) or oriented in any other direction. Hereinafter, the plural form "channels" will be used to refer to "at least one channel". The channel may have a length L' projected on the longitudinal axis 280 of the article, and this length is at least 10% of the length L of the article. The channels can be formed in various ways. For example, the channel can be formed by a region within the absorbent material deposition region 208 that is substantially free or free of absorbent material, specifically SAP. In another example, the channel can be formed by a region within the absorbent material deposition region 208 where the absorbent material of the core includes cellulose, breathable felt, SAP, or a combination thereof, and the channel can be substantially free or free of absorbent material, specifically SAP, cellulose, or breathable felt. Additionally or alternatively, one or more channels can also be formed by adhesively bonding the top and bottom sides of the core wrapper continuously or discontinuously via the absorbent material deposition region 208. The channels can be continuous, but it is also contemplated that the channels can be discontinuous. The collection - distribution system or layer 250 or other layers of the article can also include channels, which may or may not correspond to the channels of the absorbent core.

[0207] In some instances, the channels can be present at least at the same longitudinal position as the crotch point C or the lateral axis in the absorbent article, as Fig.28 represented by two longitudinally extending channels 226, 226' in. The channels can also extend from the crotch region 207 or can be present in the front waist region 205 and / or the back waist region 206 of the article.

[0208] The absorbent core 228 can also include more than two channels, such as at least 3, at least 4, at least 5, or at least 6 or more channels. Shorter channels can also be present, for example, in the back waist region 206 or the front waist region 205 of the core, as represented by Fig.28 a pair of channels 227, 227' towards the front of the article in. The channels can include one or more pairs of channels arranged symmetrically with respect to the longitudinal axis 280 or arranged in other ways.

[0209] When the absorbent material deposition region is rectangular, the channels can be particularly useful for the absorbent core because the channels can improve the flexibility of the core to a lesser extent when using a non - rectangular (formed) core. Of course, channels can also be present in the SAP layer with a formed deposition region.

[0210] The channels can be completely longitudinally oriented and parallel to the longitudinal axis or completely transversely oriented and parallel to the lateral axis, but can also have at least some curved portions.

[0211] To reduce the risk of fluid leakage, the longitudinal main channel may not extend to any edge of the absorbent material deposition area 208 and may thus be entirely included within the absorbent material deposition area 208 of the core. The minimum distance between the channel and the nearest edge of the absorbent material deposition area 208 may be at least 5 mm.

[0212] At least a portion of the channel along its length may have a width Wc, which is for example at least 2 mm, at least 3 mm, at least 4 mm, and at most for example 20 mm, 16 mm or 12 mm. The width of one or more channels may be constant along substantially the entire length of the channel or may vary along its length. When the channel is formed by a non-absorbent material zone within the absorbent material deposition area 208, the width of the channel is considered to be the width of the non-material zone, without considering the possibility of the presence of core wraps within the channel. If the channel is not formed by a non-absorbent material zone, for example mainly by bonding of core wraps throughout the absorbent material, the width of the channel is the width of the bond.

[0213] At least some or all of the channels may be permanent channels, meaning that their integrity is maintained at least in part in both the dry and wet states. Permanent channels can be obtained by providing one or more adhesive materials, such as a fibrous layer of adhesive material or a structural adhesive that helps to adhere the substrate to the absorbent material within the channel walls. Permanent channels can also be formed by bonding the upper and lower sides of the core wrap (e.g., the first substrate 216 and the second substrate 216') and / or bonding the topsheet 224 to the backsheet 225 via the channel. Generally, an adhesive can be used to bond the two sides of the core wrap or the topsheet and the backsheet through the channel, but it can be bonded via other known methods, such as pressure bonding, ultrasonic bonding, thermal bonding, or a combination thereof. The core wrap or the topsheet 224 and the backsheet 225 can be bonded continuously or intermittently along the channel. When the absorbent article is fully loaded with fluid, the channel can advantageously remain or become at least visible through the topsheet and / or the backsheet. This can be achieved by making the channel substantially free of SAP so that it will not swell and is large enough so that it will not close upon wetting. Additionally, it can be advantageous to bond the core wrap itself or the topsheet to the backsheet through the channel.

[0214] Barrier leg cuffs

[0215] An absorbent article may include a pair of barrier leg cuffs 34. Each barrier leg cuff may be formed from a material piece that is bonded to the absorbent article such that it may extend upwardly from the wearer-facing surface of the absorbent article and provide improved containment of fluids and other bodily exudates near the juncture of the wearer's torso and legs. The barrier leg cuff is defined by a proximal edge 264 that is directly or indirectly joined to the topsheet 224 and / or the backsheet 225 and a free end edge 266 that 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 opposite sides of the longitudinal axis 280 and is present at least at the crotch point (C) or in the location of the crotch region. The barrier leg cuff may be joined to the infrastructure of the article at the proximal edge 264 by an adhesive portion 265 that may be made by a combination of gluing, melt bonding, or other suitable bonding methods. The adhesive portion 265 at the proximal edge 264 may be continuous or discontinuous. The adhesive portion 265 closest to the raised segment of the leg cuff defines the proximal edge 264 of the upright segment of the leg cuff.

[0216] The barrier leg cuff may be integral with the topsheet 224 or the backsheet 225, or may be a separate material joined to the infrastructure 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.

[0217] In addition to the barrier leg cuff 234, the article may also include a gusset cuff 232 that is joined to the infrastructure of the absorbent article (specifically the topsheet 224 and / or the backsheet 225) and may be positioned externally relative to the barrier leg cuff. The gusset cuff 232 may provide a better seal around the wearer's thigh. Each gusset leg cuff may include one or more elastic bands or elastic elements between the topsheet 224 and the backsheet 225 in the leg opening region of the absorbent article. All or a portion of the barrier leg cuff and / or the gusset cuff may be treated with a lotion or another skin care composition.

[0218] Collection-distribution system

[0219] The absorbent article of the present disclosure may include a collection-distribution layer or system 250 ("ADS"). One function of the ADS is to rapidly collect one or more of the fluids and distribute them in an efficient manner to the absorbent core. The ADS may include one, two, or more layers that may form an integral layer or may remain as discrete layers that are attachable to each other. In one example, the ADS may include two layers: a distribution layer 254 and a collection layer 252, which are disposed between the absorbent core and the topsheet, but the present disclosure is not limited thereto.

[0220] In one example, the highly fluffed three-dimensional nonwoven material of the present disclosure may include the topsheet and the collection layer as a laminate. The distribution layer may also be disposed on the clothing-facing side of the topsheet / collection layer laminate.

[0221] Carrier layer

[0222] In an example where the highly bulking three-dimensional nonwoven material of the present disclosure includes a topsheet and an acquisition layer laminate, the distribution layer may need to be supported by a carrier layer (not shown), which may comprise 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 facing relation to the acquisition layer and the distribution layer.

[0223] Distribution Layer

[0224] The distribution layer of the ADS may comprise at least 50% by weight of crosslinked cellulose fibers. The crosslinked cellulose fibers may be crinkled, twisted, or curled or a combination thereof (including crinkled, twisted, and curled). Materials of this type are disclosed in U.S. Patent Publication 2008 / 0312622A1 (Hundorf). The crosslinked cellulose fibers provide higher elasticity and thus higher resistance to compression of the first absorbent layer in product packaging or under conditions of use (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.

[0225] The distribution layer comprising the crosslinked cellulose fibers of the present disclosure may comprise other fibers, but the layer may advantageously comprise at least 50%, or 60%, or 70%, or 80%, or 90%, or even up to 100% by weight of the layer of crosslinked cellulose fibers (including crosslinking agents).

[0226] Collection Layer

[0227] If the three-dimensional nonwoven material of the present disclosure is provided only as the topsheet of an absorbent article, the ADS 250 may include an acquisition layer 252. The acquisition layer may be disposed between the distribution layer 254 and the topsheet 224. In such an example, the acquisition layer 252 may be or may comprise 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 web of staple fiber chemically bonded nonwoven fabric. The nonwoven material may be latex bonded.

[0228] Fastening system

[0229] An 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 hold the absorbent article in place on the wearer, which is typical for adhesive diapers. The fastening system may not be necessary for training pant articles, since the waist regions of these articles are already bonded. The fastening system may include fasteners such as tape tabs, hook-and-loop fastening components, interlocking fasteners such as tabs and slots, buckles, buttons, snaps, and / or hermaphroditic fastening components, but any other suitable fastening mechanism is also within the scope of the present disclosure. A landing zone 244 is typically provided on the garment-facing surface of the front waist region 205 for releasably attaching the fastener thereto.

[0230] Front and back ears

[0231] The absorbent article may include a front ear tab 246 and a rear ear tab 240. The ear tabs may be an integral part of the substrate structure, such as formed by the topsheet 224 and / or the backsheet 226 in the form of side flaps. Alternatively, as Fig.28 shown, the ear tabs may be separate elements attached by adhesive, heat embossing, and / or pressure bonding. The rear ear tab 240 may be stretchable to assist in attaching the tab 242 to the landing zone 244 and holding the adhesive diaper in place around the wearer's waist. The rear ear tab 240 may also be elastic or extensible to provide a more comfortable and conforming fit for the wearer by initially conforming to the absorbent article, and maintaining that fit throughout the wear period when the absorbent article is loaded with fluid or other body exudates, since the elastified ear tabs allow the sides of the absorbent article to stretch and contract.

[0232] Elastic waist feature

[0233] The absorbent article 220 may also include at least one elastic waist feature (not shown) that helps to provide an improved fit and containment. The elastic waist feature is generally designed to elastically stretch and contract to dynamically conform to the wearer's waist. The elastic waist feature may extend at least longitudinally outward from at least one waist edge of the absorbent core 228 and generally form at least a portion of the end edge of the absorbent article. A disposable diaper may be constructed to have two elastic waist features, one positioned in the front waist region and the other positioned in the rear waist region.

[0234] Color signal

[0235] In one form, the absorbent article of the present disclosure may have different colors in different layers or portions thereof (e.g., the topsheet and the acquisition layer, the topsheet and the nonwoven core cover, the first and second portions of the topsheet, the 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 actually different colors (e.g., purple and green). The different colors may have a ΔE in the range of, for example, from about 1.5 to about 10, from about 2 to about 8, or from about 2 to about 6. Other ΔE ranges are also within the scope of the present disclosure.

[0236] In one example, a colored adhesive may be used to join the various layers of the absorbent article. The colored adhesive may be laid down in a pattern on any suitable one or more 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 certain examples, the colored adhesive may be blue.

[0237] In other examples, any one of the layers may include markings, such as printed ink, to contribute to the appearance, depth impression, absorbency impression, or quality impression of the absorbent article.

[0238] In other examples, the colors may be complementary or registered with the pattern of the three-dimensional feature structure of the nonwoven fabric 10 used as a component in the absorbent article. For example, a fabric having first and second regions with visually different patterns of three-dimensional feature structures may also have colors printed thereon to enhance, highlight, contrast with, or otherwise alter the visual appearance of the fabric 10. Color enhancement may be beneficial for communicating certain functional characteristics of the nonwoven fabric 10 in use to the user of the absorbent article. Thus, colors may be used in combination with the structural three-dimensional feature structures 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 pattern of one or more colors printed thereon that is complementary to the pattern of the three-dimensional feature structure of the fabric 10 used as the topsheet in the absorbent article. Another example is an absorbent article that includes: 1) an absorbent core that includes channels; 2) a topsheet with 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 ink, or markings visible from the topsheet viewing surface (body contact surface) or the backsheet viewing surface (clothes-facing surface) to further enhance the functional feature structure of one or more core channels and the overall performance of the absorbent article.

[0239] Further characterization of the novelty aspects of the present disclosure can be achieved by focusing on three-dimensional feature structures within visually distinguishable zones. Each of the zones discussed above, such as the first zone 110, the second zone 120, and the third zone 130, can be further described in terms of microzones. A microzone is a portion of the nonwoven fabric 10 within a zone that has at least two visually distinguishable regions and a difference in average strength characteristics between these two regions. A microzone can include a portion of the nonwoven fabric 10 that passes through two or more zone boundaries having at least two visually distinguishable regions and a difference in average strength characteristics between these two regions.

[0240] The beneficial effect of considering microzones in the present disclosure is to illustrate that, in addition to the differences in average strength characteristics from zones such as the first zone 110, the second zone 120, and the third zone 130 (as described above), the present disclosure also provides a fabric having differences in actual and / or average strength characteristics between regions defined by three-dimensional feature structures within the zones, where the three-dimensional feature structures are precisely placed according to the design of the forming belt used to produce the fabric. The differences in strength characteristics between regions of the three-dimensional feature structures provide additional visual and functional beneficial effects. The distinct visual contrast between regions can provide an extremely fine visually differentiating design within and between zones. Similarly, the precise positioning of regions provided by the precisely manufactured forming belt can provide excellent and customized softness, strength, and fluid handling characteristics of the zones. Thus, in one embodiment, the present invention provides a combination of differences in average strength characteristics between zones and differences in strength characteristics of regions constituting the microzones.

[0241] Reference Fig.38 and Fig.39 It is possible to understand the regions defined by the three-dimensional feature structures. Fig.38 An optical microscope image of a portion of the fabric 10 according to the present disclosure is shown, and Fig.39 is Fig.38 a scanning electron micrograph (SEM) of a cross-section of a portion of the fabric shown in Fig.38 and Fig.39 show an enlarged portion of the nonwoven fabric 10 to more precisely describe the otherwise visually distinguishable feature structures of the fabric. Fig.38 The portion of the nonwoven fabric 10 shown is approximately 36 mm in the CD direction and exhibits portions of at least three visually distinct zones, as described below.

[0242] In Fig.38 and Fig.39 is shown a portion of a pattern of the nonwoven fabric 10, the first zone 110 (in Fig.38to the left) is characterized in that a first region 300 of variable-width rows with a substantially MD orientation is separated from a second region 310 of variable-width rows with an MD orientation. The first region is also a three-dimensional feature structure 20 that defines the first region 300 and the second region 310. In one embodiment, the three-dimensional feature structure is a part of the nonwoven fabric 10 formed between or around the raised elements of the forming belt, and this part is the first region 300 in this specification, so that the resulting structure has a relatively larger dimension in the Z direction. The adjacent second region 310 generally has the same strength characteristics as the first region 300 and, in one embodiment, has a relatively low thickness value, i.e., a smaller dimension in the Z direction. In Fig.39 the relative dimensions in the Z direction with respect to the plane of the first surface 16 as described above can be seen. The absolute dimensions are not critical; however, without magnification, the dimensional differences can be visually discerned on the nonwoven fabric 10.

[0243] The present invention of the present disclosure allows for the optimal expression of beneficial features with respect to the regions defined by the three-dimensional feature structure in the microregions. For example, as Fig.38 shown, in the first zone 110, for each three-dimensional feature structure 20, there is a visual difference between the first region 300 and the second region 310. As described above, without magnification, there can be a visual difference in the nonwoven fabric 10; the magnified views used herein are for the purpose of clearly disclosing. Any region that extends along the boundary between the sufficient first region 300 and the second region 310 such that the difference in their respective strength characteristics can be determined within the region can be a microregion. Additionally, optical microscopy or micro-CT images of the structure can also be used to establish the location of the regions and the regions of the microregions.

[0244] Fig.38 A part of the nonwoven fabric 10 shown further illustrates another beneficial feature of the fabric 10, which is that the difference in strength characteristics between adjacent regions can be a cross-zone difference. Thus, microregions can be identified that span the first region 300 including the second region 310 of the second zone 120 and the third zone 130. In certain embodiments, including in Fig.38 and Fig.39 the nonwoven fabric 10 shown, the difference in strength characteristics exhibited by the regions in the microregions is such that the amplitude of the zone boundary can be significantly different from the difference in strength characteristics exhibited by the regions within the zone.

[0245] Regardless of which zone or partition boundary a particular microzone includes, the three-dimensional feature structure can be characterized by differences between the intensity characteristics of the regions defined by them. Generally speaking, the nonwoven fabric of the present disclosure can be a spunbond nonwoven fabric having a first surface that is a plane defining a first surface. The fabric can have a plurality of three-dimensional feature structures, each three-dimensional feature structure defining a first region and a second region, these regions having common intensity characteristics with different values therebetween. In one embodiment, the first region can be distinguished as being at a higher height relative to the plane of the first surface, and thus exhibits a difference in the common intensity characteristics of the thickness of each region. The two regions can also be distinguished as having different densities, basis weights, and bulk densities. That is, the two regions can be distinguished within the microzone of the spunbond nonwoven fabric because they are different in common intensity characteristics, including characteristics such as thickness, density, basis weight, and bulk density. In one embodiment, one or both regions of the microzone can be fluid permeable. In one embodiment, the higher density region of the microzone can be fluid permeable.

[0246] For example, within the first zone 110 of a portion of the fabric shown in Fig.38 there can be a three-dimensional feature structure 20 that defines at least two regions, namely a first region 300 and a second region 310. Fig.38 The differences in thickness, basis weight, and bulk density between the first region and the second region of the first zone 110 shown can be 274 microns, 1 gsm, and 0.437 g / cc, respectively.

[0247] Similarly, within the third zone 130 of a portion of the fabric shown in Fig.38 there can be a three-dimensional feature structure 20 that defines at least two regions, namely a first region 300 and a second region 310. Fig.38 The differences in thickness, basis weight, and bulk density between the first region and the second region of the third zone 130 shown can be 2083 microns, 116 gsm, and 0.462 g / cc, respectively.

[0248] In addition, within the second zone 120 of a portion of the fabric shown in Fig.38 there can be a three-dimensional feature structure 20 that defines at least two regions, namely a first region 300 and a second region 310. Fig.38 The differences in thickness, basis weight, and bulk density between the first region and the second region of a portion of the fabric shown can be 204 microns, 20 gsm, and 0.53 g / cc, respectively. In the embodiment shown, the second zone 120 forms the zone that appears in the non-magnified view of the nonwoven fabric 10, which is the stitching boundary between the first zone 110 and the third zone 130.

[0249] In addition, Fig.38A region showing the boundary between a second region 120 and a third region 130 including a part of the fabric. For example, there are at least two regions, a first region 300 in the third region 130 and a second region 310 in the second region 120. Fig.38 The differences in thickness, basis weight, and volume density between the first region and the second region of the shown part of the fabric can be 2027 microns, 58 gsm, and 0.525 g / cc, respectively.

[0250] Reference Figure 40 to Figure 42 and Fig.44 The data depicted in discuss the micro-regions in more detail. Figure 40 to Figure 42 A micro-CT scan of a part of the nonwoven fabric 10, the pattern of which is similar to Fig.38 the pattern of the shown nonwoven fabric 10. The micro-CT scan allows the same characteristic structure as shown to be described in a slightly different way and in a way that allows very precise measurement of the intensity characteristics. Fig.38 the same characteristic structure as shown.

[0251] As Fig.40 shown, the first region 110, the second region 120, and the third region 130 are clearly visible, having their respective three-dimensional characteristic structures 20. As Fig.40 and Fig.41 shown, the three-dimensional characteristic structure is the dark part, where the dark color also represents the first region 300 of the three-dimensional characteristic structure 20, and the adjacent light part is the second region 310 of the three-dimensional characteristic structure 20.

[0252] The micro-CT scan allows the image to be "cut" and a cross-section to be shown, as shown by the cutting plane 450 in Fig.41 . The cutting plane can be placed at any position in the image; for the purposes of the present disclosure, the cutting plane 450 cuts a cross-section substantially parallel to the Z-axis in order to produce Fig.42 the cross-sectional image in.

[0253] The micro-CT technique allows the intensity characteristics to be measured precisely and directly. Thickness measurements can be made directly from the imaged cross-section based on the magnification factor, such as the cross-section shown in Fig.42 . Additionally, the color difference between the first region and the second region is representative and proportional to the differences in basis weight, volume density, and other intensity characteristics that can also be measured directly. The micro-CT method is explained in the Test Methods section below.

[0254] Figure 43 For Figure 40 and Figure 41 shown, a micro-CT scan image of a part of the nonwoven fabric 10. For specific first and second regions shown as numbered parts of the nonwoven fabric 10, their utilization can be analyzed. In Figure 43Specific regions are manually selected and analyzed to measure thickness, basis weight, and bulk density, and data is generated in Figure 44 therein.

[0255] Figure 44 Shows grouped data for first region and second region measurements taken in the three zones depicted in Figure 44 The x-axis is the region, where the numbers correspond to the numbered regions on Figure 43 . First region measurements are labeled Fn (e.g., F1), and second region measurements are labeled Sn (e.g., S1). Thus, regions 1 to 5 are the first region F1, with each region in the first zone 110. Regions 6 to 10 are the second region S1, also in the first zone 110. Similarly, the first region F2 is regions 16 to 20 in the second zone 120, and regions 11 to 15 and 21 to 25 are the second region S2 in the second zone 120. Finally, regions 31 to 35 are the first region F3 in the third zone 130, and regions 26 to 30 are the second region S2 in the third zone 130. The numbered regions are depicted consistently on all three graphs in Figure 44 , but for simplicity, only the first zone 110, second zone 120, and third zone 130 are depicted on the thickness map.

[0256] Figure 44 The graphs shown graphically represent the magnitude of the difference in intensity characteristics between the first and second regions within any of the zones, and can be used to graphically observe the difference in intensity characteristics of the region pairs that make up the microzones. For example, it can be seen that in the first zone 110, the basis weight between the two regions can be substantially the same, but the thickness (caliper) can vary from approximately 400 microns in the first region to approximately 40 microns in the second region, or a difference of approximately 10X. The bulk density in zone 110 can vary from approximately 0.1 g / cc to approximately 0.6 g / cc. Similar quantifiable differences can be understood for each of the zones shown.

[0257] Thus, with reference to both Figure 43 and Figure 44 , a further characterization of the beneficial structure of the fabric 10 of the present disclosure can be understood. The nonwoven fabric 10 can be described as having at least two visually distinct zones, such as the first zone 110 and the second zone 120, where each of the zones has a pattern of three-dimensional characteristic structures, each of the three-dimensional characteristic structures defining a microzone including a first region and a second region such as the first region 300, the second region 310, and where the difference in the value of at least one of the microzones in the first zone is quantifiably different from the difference in the value of at least one of the microzones in the second zone. For example, in Figure 43Among them, two representative micro-regions 400 in the third region 130 are designated as region pairs marked as regions 31 and 27 and regions 33 and 26. That is, the first region 31 and the second region 27 form a micro-region, and the first region 33 and the second region 26 form a micro-region. Similarly, two representative micro-regions 400 in the second region 120 are designated as region pairs marked as regions 19 and 24 and regions 17 and 22. From Figure 44 Among them, Table 4 to 7 can be filled as follows:

[0258] Table 4: Illustrative Examples of Thickness Differences in Microregions

[0259]

[0260] Table 5: Illustrative Examples of Basis Weight Differences in Microregions

[0261]

[0262]

[0263] Table 6: Illustrative Examples of Volume Density Differences in Microregions

[0264]

[0265] Table 7: Illustrative Examples of Strength Property Differences in Different Regions :

[0266]

[0267] For illustrative purposes, Tables 4 to 6 show four representative micro-regions from two regions. However, as can be understood, Figure 43 each pair of the first region and the second region in can also be quantified to further fill additional rows in Table 4, but this is not done for the sake of simplicity. Generally speaking, for any fabric having two or more regions, each region has a pattern of a three-dimensional characteristic structure that defines a micro-region, as shown in reference to Figure 43 and Figure 44 as shown, the intensity characteristics can be measured and listed to understand both the differences in the values of the intensity characteristics within the region and the differences in the values of the intensity characteristics between one region in the first region and another region in the second region.

[0268] Micro-regions spanning two zones such as the first zone 110 and the third zone 130 can have even greater differences in intensity characteristics compared to micro-regions within a single zone. For example, observing the data of micro-regions in the first region across the third zone 130 such as at the first region 32 and the second region in the first zone 110 such as at the second region 8, the micro-regions exhibit significant differences in all thickness, basis weight, and volume density aspects. The thickness of the first region 32 in the third zone 130 is approximately 2100 microns, while the thickness of the second region 8 in the first zone 110 is approximately 29 microns, or a difference of about 72X. Similarly, the basis weight of the first region 32 in the third zone 130 can be as high as 150 gsm, while the basis weight of the second region 8 in the first zone 110 can be about 14 gsm, or a difference of about 10X. Additionally, the volume density of the first region 32 in the third zone 130 can be about 0.069 g / cc, while the volume density of the second region 8 in the first zone 110 can be 0.492 g / cc, or a difference of about 7X.

[0269] For each of the intensity characteristic parameters measured for the respective regions of the micro-regions, such measurements are made using the micro-CT method described herein. The solution of this method supports establishing the intensity characteristics of the micro-region areas, and thus the dimensions can be set for the comparison of differences and ratios of the areas as described herein.

[0270] Further characterization of the fabric 10 can be made with reference to Figures 45 to 49 for Figures 45 to 49 an SEM that more detailedly shows certain aspects of the nonwoven fabric 10 and the regions therein. Figures 45 to 49 is Figure 38 a photograph of an enlarged portion of the first zone 110 of the fabric shown. Figure 38 The nonwoven fabric 10 shown is prepared according to the method described above with reference to Figure 7 wherein the fabric is processed through the nip formed by the compaction rollers 70 and 72, and the compaction roller 72 in contact with the first side 12 is heated to cause local bonding of the fibers in the second region 301. Figure 45 (facing the belt) and Figure 46 (facing the heated compaction roller) are SEMs of portions of the second surface 14 and the first surface 12 enlarged to 20X respectively. Figure 47 (facing the belt) and Figure 48 (facing the heated compaction roller) are photographs of portions of the second surface 14 and the first surface 12 enlarged to 90X respectively, and show in detail the beneficial structural features of the partial bonding of the fibers formed by the compaction rollers 70 and 72.

[0271] From Figure 47 and Figure 48 as well as Figure 49As best seen in the cross-sectional view, the heated compaction roller can cause the fibers to thermally bond to different degrees, thereby having a beneficial effect on the overall fabric 10. As shown, the fibers in contact with the heated roller (e.g., the compaction roller 70 in contact with the first surface 12 of the fabric 10) can be melt-bonded, such that the first surface 12 undergoes relatively greater fiber-to-fiber bonding than the second surface 14. In one embodiment, the bonded fibers 80' on the first surface can actually be substantially completely melt-bonded to form a film skin of bonded fibers, while the fibers in the second region 310 on the second side 14 can undergo little or no bonding. This characteristic structure allows the nonwoven fabric 10 used in a disposable absorbent article, such as a topsheet, to maintain physical integrity during manufacturing and use, as well as relative softness on one side, which can be the skin-contact side facing the user.

[0272] Even in the micro-regions with the largest thickness differences, this "skin bonding" effect is used to maintain the integrity of the fiber web while not significantly affecting softness or other beneficial properties such as fluid handling properties. As can be referred to Figures 50 to 53 As understood, the difference in the degree of thermal bonding of the fibers can cause the fibers on the first surface 12 at the second region 310 to be intact or substantially intact, while the degree of thermal bonding of the fibers on the second surface 14 at the first region 300 can be minimal or even non-existent.

[0273] Figure 50 Also shown is Figure 38 a portion of the nonwoven fabric 10 shown. Figures 51 to 53 Shown is Figure 50 an enlarged image of a micro-region represented as the first region 300 and the second region 310 in, which visually appears as cavities or holes. Figure 51 and Figure 52 show the micro-regions magnified to 40X and 200X respectively, manifested on the second surface 14. Figure 53 Shown is the second region 310 manifested on the first side 12 at a magnification of 200X. The fibers in the second region 310 are completely or substantially completely bonded, while the fibers in the first region 300 are not completely or substantially not completely bonded. The beneficial effect of the shown structure is that the micro-regions can be used as fluid-permeable holes, while the bonded regions of the second region 310 act simultaneously to maintain the physical integrity of the fabric 10.

[0274] Accordingly, the micro-regions play an important role in the overall physical structure and function of the fabric 10 of the present invention. By means of the forming belts disclosed herein to achieve relatively closely spaced, precisely designed three-dimensional feature structures, the fabric 10 can exhibit visually distinct regions, micro-regions, and three-dimensional feature structures, which provide functional advantages in at least the areas of softness and fluid handling, and provide an aesthetically appealing design. The potential differences in the physical properties of the first and second surfaces allow the nonwoven fabric 10 to be designed with respect to both strength and softness, and both forming and function.

[0275] Figure 54 To be similar to Figure 40 and Figure 41 A micro-CT scan image of a portion of the nonwoven fabric 10 as shown, but with an additional processing step of forming the dot bond portion 90 in the nip of the calender rolls 71 and 73. As described above, with respect to Figure 43 and Figure 44 discussion, for a specific dot bond micro-region 400’, the first and second regions shown as numbered portions of the nonwoven fabric 10 can be analyzed, and include the dot bond regions (especially in numbered regions 31 to 35). For example, adjacent regions 32 and 26 form a dot bond micro-region 400’ in the third region 130. In Figure 54 visually distinguish specific regions to identify the regions including the added dot bond regions and analyze them to measure thickness, basis weight, and volume density, and generate Figure 55 data in

[0276] Figure 55 wherein the thickness, basis weight, and volume density of all regions (including the dot bond regions) are quantified and compared. Figure 54 depicts grouped data of the first and second region measurements taken in the three regions depicted in Figure 43 The x-axis is the region, where the numbers correspond to the numbered regions on Figure 55 The first region measurements are labeled Fn (e.g., F1), and the second region measurements are labeled Sn (e.g., S1). Thus, regions 1 to 5 are the first region F1, each region being in the first region 110. Regions 6 to 10 are the second region S1, also in the first region 110. Similarly, the first region F2 is the region 16 to 20 in the second region 120, and regions 11 to 15 and 21 to 25 are the second region S2 in the second region 120. Finally, regions 31 to 35 are the second region, but since they have been formed by the dot bond process, they are represented as the dot bond portion 90 labeled B1 on Figure 55The numbered regions are depicted consistently on all three of the diagrams, but for simplicity, only the first region 110, the second region 120, and the third region 130 are depicted on the thickness map.

[0277] Figure 54 The diagrams shown graphically represent the magnitude of the difference in strength characteristics between a first region and a second region within any of the regions of the fabric undergoing the calender point bonding step, and can be used to graphically observe the difference in strength characteristics of the pairs of regions that make up the micro-regions. For example, it can be seen that in the first region 110, the basis weight between two regions can vary within a narrower range than the thickness or volume density. For example, the thickness (caliper) can vary from approximately 325 microns in the first region to approximately 29 microns in the second region of the first region 110, or a difference of about 10X. The volume density in the first region 110 can vary from approximately 0.08 g / cc to approximately 0.39 g / cc. Similar quantifiable differences can be understood for each of the regions shown.

[0278] Generally speaking, the regions of the micro-regions can have a wide range of values for basis weight, thickness, and volume density.

[0279] Therefore, with reference to Figure 54 and Figure 55 , the further characterization of the beneficial structure of the fabric 10 of the present disclosure with respect to the calender point bond 90 can be specifically understood. For the purpose of describing the third region 130, a three-dimensional characteristic structure defining a micro-region including a first region and a second region as the point bond region can be identified, and the values of the strength characteristics can be quantified. For example, in Figure 54 , the representative point bond micro-region 400' in the third region 130 can be a pair of regions labeled region 26 and 32 or region 30 and 35. That is, the first region 26 and the second region 32 form the point bond micro-region 400', and the first region 30 and the second region 35 form the point bond micro-region 400'.

[0280] The differences in certain strength characteristics of the point bond micro-regions can be seen in Figure 55 . For example, using the above two point bond micro-regions 400', such as the two point bond micro-regions 400' of region 26 and 32 and region 30 and 35 respectively, it can be seen that there is a slight difference in the basis weight between the first region and the second region, which is in the range of approximately 55 gsm to approximately 60 gsm, but the thickness of the same regions shows a significant difference of approximately 430 microns to approximately 460 microns to approximately 125 microns, and the volume density shows a significant difference of approximately 0.13 g / cc - 0.14 g / cc to approximately 0.41 g / cc - 0.48 g / cc. Other differences in strength characteristics can be observed by referring to Figure 55 .

[0281] The dot bonding portion 90 can play an important role in the overall physical structure and function of the fabric 10 of the present invention. By adding the dot bonding portion 90 to the fabric 10 (including the relatively closely spaced and precisely designed three-dimensional feature structures achieved through the forming belts disclosed herein), the fabric 10 can be further improved to exhibit a combination of visually distinct regions, micro-regions, and three-dimensional feature structures, which provide functional advantages in terms of a high-performance combination of softness, strength, low linting, and fluid handling, and provide an aesthetically appealing design. The bonded dot feature structures provide the highest combined performance in terms of strength, softness, fluid handling, and visual aesthetics, especially for the nonwoven fabric 10 designed considering both forming and function.

[0282] One beneficial effect of the formed nonwoven fiber webs of the present disclosure is improved softness. Softness can be measured using the Emtec Tissue Softness Analyzer provided by Emtec Paper Testing Technology, Emtec Electronic, GmbH. Table 5 below shows the softness values as the TS7 measurement values from the Emtec Tissue Softness Analyzer according to the following Emtec test method. For all of the following Examples 7 to 9, as Figure 16 described, the nonwoven fabric is prepared on a belt, where the nonwoven fiber web has an appearance similar to Figure 2 that shown.

[0283] Table 5: TS7 Values of the Molded Nonwovens of the Present Disclosure

[0284]

[0285] Example 7 :

[0286] A bicomponent spunbond nonwoven fabric fiber web is produced by spinning a 50:50 ratio of polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration, as discussed with reference to Example 2 above. The nonwoven fabric is spun onto a forming belt that has a repeating pattern as Figure 16 described, which is moved at a linear speed of about 25 meters per minute to form a fabric 10 with an average basis weight of 25 grams per square meter, with a repeating pattern of diamond shapes, as Figure 2 shown. The fibers of the fabric are compacted by compaction rollers 70, 72 but not calendered, and are further bonded at a temperature of 145 °C through the through-air bonding unit as Figure 56 described.

[0287] Example 8 :

[0288] A bicomponent spunbond nonwoven fabric is produced by using a bi-pack spunbond process to spin a 30:70 ratio of polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (HG475 FP from Borealis) in a circular fiber configuration, as Figure 56 described. The nonwoven fabric is spun onto a forming belt that has a Figure 16 repeating pattern as Figure 7 described above, which moves at a linear speed of about 152 meters per minute to an average basis weight of 35 grams per square meter to form a repeating pattern in the shape of a diamond as Figure 2 shown. The difference between the formed nonwoven fiber web prepared according to Figure 7 the method and Example 8 is that Example 8 is prepared on a hybrid method of the Figure 7 method described and the method described below Figure 56 described. Specifically, the method involves two spinning packs as Figure 56 shown, however, the final heating step is by calender rolls 71, 73 instead of through through-air bonding. The fibers of the fabric are bonded on the first surface 12 by heated compaction rolls 70A and 72A after the first pack at 110 °C and heated compaction rolls 70B and 72B after the second pack at 110 °C, and are calender bonded at calender rolls 71 and 73 at about 140 °C before being wound onto a reel at winder 75.

[0289] Example 9 :

[0290] A bicomponent spunbond nonwoven fabric is produced by using a bi-pack spunbond process to spin a 30:70 ratio of polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (HG475 FP from Borealis) in a circular fiber configuration, as Figure 56 described. The nonwoven fabric is spun onto a forming belt that has a Figure 16 repeating pattern, which moves at a linear speed of about 228 meters per minute to an average basis weight of 25 grams per square meter to form a repeating pattern in the shape of a diamond as Figure 2 shown. The fibers of the fabric are further bonded on the first surface 12 by heated compaction rolls 70A and 72A after the first pack at 110 °C and heated compaction rolls 70B and 72B after the second pack at 110 °C, and are thermally through-air bonded at three heating zones of through-air bonders 76 at 100 °C, 135 °C and 135 °C (as Figure 56 shown) before being wound onto a reel at winder 75.

[0291] Examples 7 through 9 represent the formed nonwoven fabrics of the present disclosure, which exhibit improved softness as indicated by the Emtec measurements. The Emtec measurements can range from about 1 dB V 2 rms to about 15 dB V 2 rms, or from about 3 dB V 2 rms to about 10 dB V 2 rms, or from about 5 dB V 2 rms to about 8 dB V 2 rms. Generally speaking, the Emtec measurement of the first surface or the second surface can be any integer value up to about 15 dB V 2 rms, and any integer range between 1 and 15. Additionally, generally speaking, the ratio of the measured Emtec values from the first side to the second side can be between 1 and 3, and can be any real number between 1 and 3.

[0292] Without being bound by theory, it is believed that the improvement in softness exhibited by the formed nonwoven fabrics of the present invention is achieved through the methods and apparatuses of the present invention, which allow for different strength characteristics in relatively small zones, including the disclosed zones and microzones. For example, the ability to design and prepare formed nonwoven fabrics having the disclosed basis weight, density, or thickness differences while delivering the combined fabrics for the topsheet in an absorbent article breaks the prior art trade-off between surface texture and softness. That is, the formed nonwoven fabrics of the present disclosure can deliver a visibly apparent surface texture including an irregular pattern, as well as excellent softness, as indicated by the measured Emtec values. Additionally, the formed nonwoven fabrics of the present disclosure can deliver a visibly apparent surface texture having a combined physical integrity and reduced fuzzing characteristics, as well as excellent softness, as indicated by the measured Emtec values.

[0293] As described above, in one example, the method of preparing the formed nonwoven fabric can be a modified form of the Figure 7 method described. One modification is described with respect to Figure 56 As shown in Figure 56 the method can include the belt 60 as described above, which employs more than one spinning box in a melt spinning process. As shown, only the spinning assemblies 48A and 48B are schematically shown, and two boxes can be used to melt spin the fibers onto the belt 60, where a compaction operation occurs after each box. Vacuum boxes 64A and 64B can also be operatively associated with each spinning box 48A and 48B, respectively.

[0294] After the fibers are spun onto the belt 60 and after compaction, which includes optionally thermally bonding during compaction as described above, the formed nonwoven web can be additionally heated by a through-air heater 76, which can have a plurality of chambers with individually controlled temperatures, such as three chambers 76A, 76B, and 76C.

[0295] Examples 7 and 9 above were manufactured on a twin-box production line and through-air bonding was carried out in the Figure 56 process schematically shown. Without being bound by theory, it is shown that through-air bonding retains most of the three-dimensionality of the three-dimensional characteristic structure of the formed nonwoven fabric, as indicated by the difference in the TS7 values in Table 5. Alternatively, if a nonwoven fabric with less side shape is desired, it is shown that calender bonding tends to make the TS7 values uniform, as shown in Example 8 in Table 5. Thus, as described herein, the process parameters can be controlled to obtain a predetermined softness on each side (i.e., surface) of the formed nonwoven fabric.

[0296] In addition to the beneficial effects detailed above, another beneficial effect of the formed nonwoven web of the present disclosure is the ability to provide a nonwoven web with microzones that have hydrophobic regions and separate hydrophilic regions. The hydrophilicity and / or hydrophobicity in specific regions of the microzones can be determined by the wicking time measurements using the wicking time test method as described herein and / or the contact angle measurements using the contact angle test method as described herein. As used herein, the term "hydrophilic" with respect to a specific region of the microzone means that the wicking time of the specific region is less than 10 seconds when tested using the wicking time test method. As used herein, the term "hydrophobic" with respect to a specific region of the microzone means that the contact angle of the specific region is 90° or greater when tested using the contact angle test method.

[0297] Table 6 below details the contact angle and wicking time measurements of the formed nonwoven fabric as detailed herein. For both Examples 10 and 11 below, as Figure 16 described, the nonwoven fabric was prepared on a belt, where the nonwoven web has an appearance similar to Figure 2 that shown.

[0298] Table 6: Contact Angle and Capillary Rise Time of the Molded Nonwovens of the Present Disclosure

[0299]

[0300] Example 10:

[0301] A bicomponent spunbond nonwoven fabric web is produced by spinning a 50:50 ratio of polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration, as discussed with reference to Example 2 above. The nonwoven fabric is spun onto a forming belt that has a repeating pattern as Figure 16 described, which moves at a linear speed of about 25 meters per minute to form a fabric 10 with an average basis weight of 25 grams per square meter, with a repeating diamond-shaped pattern, as Figure 2 shown. The fibers of the fabric are compacted by compaction rollers 70, 72, but not calendered, and further bonding is achieved at a temperature of 145 °C through the air-through bonding unit as described with respect to Figure 56 above.

[0302] Then, the surfactant Stantex S6327 (a combination of castor oil ethoxylate and PEG diester) supplied by Pulcra Chemicals is set on the backside surface of the nonwoven fabric (i.e., the flat side surface opposite the side on which the relatively pillow-like three-dimensional feature structure is provided) through a kiss coating process. The coating process is carried out using a Reicofil kiss roll and an Omega drying process, both of which are well known in the art. The surfactant concentration of the surfactant in water for the kiss roll process is 6% at a temperature of 40 °C. The kiss roll contact angle is set at 250°, and the drying temperature is 80 °C. Then, the nonwoven fabric is brought into contact with a kiss roll operating at a speed of 13 rpm, thereby delivering 0.45 wt% of the surfactant to the nonwoven fabric (surfactant % is the weight of the surfactant added per 1 m 2 divided by the weight of 1 m 2 of the nonwoven fabric).

[0303] Example 11 :

[0304] A bicomponent spunbond nonwoven fabric web is produced by spinning a 50:50 ratio of polyethylene skin (Aspun-6850-A from Dow chemical company) and polypropylene core (PH-835 from LyondellBasell) in a trilobal fiber configuration, as discussed with reference to Example 2 above. The nonwoven fabric is spun onto a forming belt that has a repeating pattern as Figure 16 described, which moves at a linear speed of about 25 meters per minute to form a fabric 10 with an average basis weight of 25 grams per square meter, with a repeating diamond-shaped pattern, as Figure 2 shown. The fibers of the fabric are compacted by compaction rollers 70, 72, but not calendered, and as follows with respect toFigure 56 The ventilation bonding unit achieves further bonding at a temperature of 145 °C.

[0305] Then, the surfactant Stantex S6327 (a combination of castor oil ethoxylate and PEG diester) supplied by Pulcra Chemicals is set on the front surface of the nonwoven fabric (i.e., the side on which the pillow-like three-dimensional feature structure is disposed) by an inkjet printing process. The inkjet printing process is performed using a Dimatix DMP 2831 inkjet printer equipped with an ink cartridge, model DMC-11610 / PM 700-10702-01 (10 pL). The printhead temperature is 40 °C. The surfactant used in the inkjet printing process consists of 75% weight / weight Stantex S 6327 and 25% weight / weight ethanol. The surfactant is printed in the second region of the microzone of the nonwoven fabric by orienting the nonwoven fabric sample such that the second region of the first row of microzones is aligned with the printhead direction and printing a first series of straight lines (where the droplet spacing is adjusted to 170 µm). Then, the nonwoven fabric sample is rotated by an angle such that the second region of the second row of microzones is aligned with the printhead and a second series of straight lines is printed at 170 µm. The basis weight of the fibers in the second region is approximately 16.0 gsm. The basis weight of the surfactant inkjet printed onto the second region is approximately 0.25 gsm. Accordingly, the amount of surfactant locally printed onto the second region is determined to be approximately 1.6 wt% surfactant (0.25 gsm / 16.0 gsm). Overall, the amount of surfactant printed onto the nonwoven fabric sample is determined to be approximately 0.2 wt% surfactant by the ratio between the printed line width and the line spacing.

[0306] In addition to Stantex S 6327, the use of other surfactants to render the first and / or second regions of the specific microregions hydrophilic and / or hydrophobic (by any application method) is considered to be within the scope of the present disclosure. Other potential surfactants for use in the process and nonwoven fabrics detailed herein include nonionic surfactants, including esters, amides, carboxylic acids, alcohols, ethoxylated polyoxyethylene, polyoxypropylene, sorbitan, ethoxylated fatty alcohols, allylphenol polyethoxylates, lecithin, glycerol esters and their ethoxylates, and sugar-based surfactants (polysorbates, polyglycosides), and anionic surfactants, including sulfonates, sulfates, phosphates, alkali metal salts of fatty acids, sulfuric acid monoesters of fatty alcohols, linear alkylbenzene sulfonates, alkyl diphenyl ether sulfonates, lignosulfonates, olefin sulfonates, sulfosuccinates and sulfated ethoxylates of fatty alcohols, and cationic surfactants, including amines (primary, secondary, tertiary), quaternary ammonium, pyridine, quaternary ammonium salts - QUATS, alkylated pyridinium salts, alkyl primary, secondary, tertiary amines and alkanolamides, and zwitterionic surfactants, including amino acids and derivatives, amine oxides, betaines and alkylamine oxides, and polymeric surfactants, including polyamines, carboxylic acid polymers and copolymers, EO / PO block copolymers, ethylene oxide polymers and copolymers and polyvinylpyrrolidone, and silicone surfactants, including dimethyl silicone polymers with hydrophiles, and perfluorocarboxylates and fluorinated surfactants.

[0307] The formed nonwoven fabric detailed above has microregions with regions having different strength characteristics such as, for example, basis weight, density, or thickness. Those same formed nonwoven fabrics can also simultaneously have such regions of microregions that are particularly and individually hydrophobic and / or hydrophilic. Any of the examples of formed nonwoven fabrics detailed herein (e.g., including zones and / or microregions with regions having different thickness, basis weight, and / or bulk density and / or samples having surfaces with various TS7 values disclosed herein) can also have regions of microregions with different hydrophilicity, as detailed herein. Hydrophilicity can be provided by targeting the application of one or more surfactants to specific regions of the microregions of the formed nonwoven fabric. For example, a second region of a microregion can have a surfactant disposed thereon, while a first region of the same microregion can have no surfactant disposed thereon. Additionally, a first region of a microregion can have a surfactant disposed thereon, while a second region of the same microregion can have no surfactant disposed thereon. For example, in a microregion, the first region or the second region can have a surfactant in any concentric range from about 0.01% to about 5.0%, from about 0.05% to about 4.0%, from about 1.0% to about 3.0%, and within the range of about 0.01% to about 5.0%, and the other region has no surfactant (i.e., is surfactant-free). For example, in a microregion, the second region can have a surfactant in any concentric range from about 0.01% to about 5.0%, from about 0.05% to about 4.0%, from about 1.0% to about 3.0%, and within the range of about 0.01% to about 5.0%, and the first region has no surfactant (i.e., is surfactant-free). Thus, some of the formed nonwoven fabrics disclosed herein have microregions where at least one of the first region and the second region has a surfactant, and the ratio of the % surfactant in the first region to the % surfactant in the second region is less than 1. Additionally, some of the formed nonwoven fabrics disclosed herein have microregions where at least a second region of the microregion has a surfactant, and the ratio of the % surfactant in the first region to the % surfactant in the second region is less than 1.

[0308] As another example, the second region of the micro-region may have a specific amount of surfactant or surfactant % disposed thereon, while the first region of the same micro-region may have a different amount of surfactant or surfactant % disposed thereon. For example, in one micro-region, the first region may have from about 0.01% to about 2.0%, from about 0.05% to about 1.5%, from about 0.1% to about 1.0%, and any concentric range within from about 0.01% to about 2.0% of surfactant, and the second region may have a different amount. Additionally, in one micro-region, the second region may have from about 0.01% to about 5.0%, from about 0.05% to about 4.0%, from about 1.0% to about 3.0%, and any concentric range within from about 0.01% to about 5.0% of surfactant, and the first region may have a different amount. The surfactant % for a specific region of the micro-region can be determined by taking the grams of surfactant per square meter disposed in the specific region and dividing it by the basis weight of the fibers of the formed nonwoven fabric included within the same region. The grams of surfactant per square meter disposed in the specific region can be determined using any currently known method in the art (e.g., gravimetric analysis, etc.). The basis weight of the fibers of the formed nonwoven fabric included within a specific region of the micro-region can also be determined using any currently known method in the art (e.g., gravimetric analysis, micro-CT, etc.). For specific micro-region examples, the basis weight ranges / examples of the fibers included in the first and second regions are detailed above.

[0309] The surfactant can be disposed on the formed nonwoven fabric by any method known in the art. Specific examples include touch coating, inkjet printing, gravure printing, offset gravure printing, flexographic printing of surfactant, and registered printing of surfactant. Any such method can dispose the surfactant on the first surface and / or the second surface of the formed nonwoven fabric. For the overall formed nonwoven fabric (considering all the individual zones and micro-regions on the fabric), the surfactant can be added to the formed nonwoven fabric in an amount from about 0.01% to about 2.0%, from about 0.05% to about 1.5%, from about 0.1% to about 1.0%, and any concentric range within from about 0.01% to about 2.0%. To calculate the surfactant % added to the overall formed nonwoven fabric, the grams of surfactant per square meter in the overall formed nonwoven fabric are divided by the basis weight of the overall formed nonwoven fabric. The grams of surfactant per square meter disposed in the overall formed nonwoven fabric can be determined using any currently known method in the art (e.g., gravimetric analysis, etc.). The basis weight of the overall formed nonwoven fabric can also be determined using any currently known method in the art (e.g., gravimetric analysis, micro-CT, etc.).

[0310] Referring again to Figure 38 and Figure 39 which shows a portion of a pattern of nonwoven fabric 10, first zone 110 (inFigure 38 On the left side of) is characterized in that a first region 300 of variable-width rows with a substantially MD orientation is separated from a second region 310 of variable-width rows with an MD orientation (the first and second regions are within a micro-region). The first region is also a three-dimensional feature structure 20 that defines the first region 300 and the second region 310. In one embodiment, the three-dimensional feature structure is a part of the nonwoven fabric 10 formed between or around the raised elements of the forming belt, and this part is the first region 300 in this specification, such that when compared with the second region 310, the resulting structure has a relatively large dimension in the Z direction, a relatively high basis weight, and a low bulk density. In addition, the first region 300 can be hydrophobic, and the second region 310 can be hydrophilic. Targeted addition of a surfactant to the second region 310 of the micro-region can cause the second region to be hydrophilic. Therefore, when tested by the contact angle test method detailed herein, the first region 300 of the micro-region can have a contact angle greater than about 90°, or between about 90° and about 140°, or between about 110° and about 135°, or between about 125° and about 135°, or within any concentric range included between about 90° and about 140°. When tested by the contact angle test method detailed herein, the second region 310 of the micro-region can have a contact angle less than 90°. The first region 300 of the micro-region can have a wicking time value greater than about 10 seconds or between about 10 seconds and 60 seconds, as measured by the wicking time test method detailed herein. The second region 310 of the micro-region can have a wicking time value less than about 10 seconds, less than about 5 seconds, or less than about 2.5 seconds, or less than about 1 second, or less than about 0.5 seconds, as measured by the wicking time test method detailed herein. The formed nonwoven fabrics contemplated herein include any of the parameter ranges detailed above for the contact angle and / or wicking time measurements for the first region and / or the second region, combined with any other strength characteristics / property differences disclosed herein for the same or different regions in the same or different micro-regions on the formed nonwoven fabric.

[0311] The formed nonwoven fabrics having the micro-regions detailed above with regions having differences in, for example, basis weight, density, or thickness, and also having such regions that are individually hydrophobic and / or hydrophilic in specific micro-regions can provide many useful applications, such as topsheet materials for baby care, feminine care, and adult incontinence products, as well as for medical pads, wipes, and cleaning pads, etc.

[0312] Texture is a key component of human visual perception. If the textured pattern exhibits visual clarity and uniformity, the textured patterned nonwoven fabric can be aesthetically more pleasing to consumers. Such a uniform and visually clear texture pattern can be regarded as an indication of the quality of the nonwoven fabric. The uniform and visually clear textured pattern on the nonwoven fabric imparts distinct and well-defined texture contrast lines or boundaries to the visual perception of the nonwoven fabric. Overall, the uniform and visually clear textured pattern on the nonwoven fabric can be described as exhibiting high visual resolution.

[0313] Thus, in addition to the beneficial effects detailed above, another beneficial effect of the formed nonwoven web of the present disclosure is the ability to provide a textured nonwoven web having at least a first distinguishable region that exhibits visual clarity and uniformity. As used herein, the term "visual clarity" is defined as the characteristic of being able to visually separate something into its component parts. In other words, visual clarity is the ability to visually distinguish two objects as separate structures rather than a single blurred object. In another embodiment, visual clarity requires distinct and well-defined texture contrast lines or boundaries between the observed regions or areas, rather than faded, blurred, or difficult-to-visualize texture contrast lines.

[0314] The visually clear patterns of the textured nonwoven fabrics detailed herein can be quantified in various ways. One way to measure the visual clarity of the textured nonwoven fabric patterns detailed herein is through Haralick feature extraction and analysis ("Haralick texture analysis"). Haralick texture analysis is a general process for analyzing an image to obtain higher-level information (e.g., color, shape, texture). The specific Haralick texture analysis employed herein utilizes one or more images to measure the spatial distribution of gray values. Those distributions are then used to calculate contrast values within the textured nonwoven fabric. Such contrast values indicate the visual clarity of the patterned nonwoven fabric.

[0315] As further detailed in the Test Methods section below, the first step in Haralick texture analysis is to calculate the Gray Level Co-occurrence Matrix (GLCM). The GLCM is a list of the frequencies of the different combinations of pixel gray levels that can occur in an image. In other words, the GLCM shows the frequency at which each gray level, as a function of the gray levels, occurs at pixels located at a fixed geometric position relative to each other pixel. In the second step, texture features are calculated from the GLCM. The texture features can be scalar numbers, discrete histograms, or empirical distributions, and reflect the regular variation of the gray values in the image. The goal is to assign an unknown sample image to one of a set of known texture classes. Specific parameters obtained by Haralick texture analysis of the formed nonwoven fiber webs of the present disclosure include the Haralick maximum average contrast value, the Haralick maximum 90° contrast value, the Haralick maximum 0° contrast value, and the presence or absence of a periodic Haralick wave response. An additional measure of visual clarity is the gray level contrast slope. More details of such parameters and their measurement methods will be described in further detail herein.

[0316] In addition to being visually clear, the patterns of the textured nonwovens detailed herein can also be uniform in appearance. One way to measure the uniformity of the patterns of the textured nonwovens detailed herein is by gray level variation. The gray level variation can be calculated within a single article, or between multiple articles, as further detailed herein.

[0317] Table 7A - D below details the Haralick analysis data for the formed nonwovens as detailed herein, as well as comparative data for flat, standard, non-patterned nonwovens.

[0318] Example 12 :

[0319] Side-by-side bicomponent spunbond nonwoven fabric webs are prepared by spinning a 30:70 ratio of polypropylene (PP3155, obtained from ExxonMobil company) and a 75 / 25 mixture of polypropylene (PP3854 and PP3155, obtained from ExxonMobil company) in a circular fiber configuration. The nonwoven fabric is spun onto a forming belt having a repeating pattern (such as Figure 12 , Figure 16 , Figure 18 and Figure 19 shown and the same type of cured resin forming belt as described herein - but with visually distinguishable regions having different belt three-dimensional feature structures of the pattern) and moved at a linear speed of about 20 meters per minute to form a fabric having an average basis weight of 35 grams per square meter. As Figure 7As shown, the fibers of the fabric are compacted by the compaction rollers 70, 72 heated to 140°C. The fibers of the fabric are further calendered and bonded at the calender rollers 71, 73, where the calender roller 73 is a engraved roller with raised portions 88 in the form of nails. The calender roller 73 is heated to 140°C to form dot bonding portions 90 on the second side of the fabric (similar to the description of Example 6 detailed herein). An image of the nonwoven fabric of Example 12 is shown in Figure 57 in.

[0320] Example 13 :

[0321] A side-by-side bicomponent spunbond nonwoven fabric web is prepared by spinning a 30:70 ratio of polypropylene (PP3155, obtained from ExxonMobil company) and a 75 / 25 mixture of polypropylene (PP3854 and PP3155, obtained from ExxonMobil company) in a circular fiber configuration. The nonwoven fabric is spun onto a flat standard permeable laying belt (i.e., the belt does not contain cured resin to give a belt structure) and moved at a linear speed of about 20 meters per minute to form a fabric with an average basis weight of 34 grams per square meter. As Figure 7 shown, the fibers of the fabric are compacted by the compaction rollers 70, 72 heated to 90°C. The fibers of the fabric are further calendered and bonded at the calender rollers 71, 73, where the calender roller 73 is a engraved roller with raised portions 88 in the form of nails. The calender roller 73 is heated to 140°C to form dot bonding portions 90 on the second side of the fabric (similar to the description of Example 6 detailed herein). The nonwoven fabric of Example 13 is flat and does not have any visually distinguishable areas with a pattern of three-dimensional characteristic structures.

[0322] Example 12 is representative of the formed nonwoven fabrics of the present disclosure that exhibit improved visual clarity. For this example and any other formed nonwoven fabrics described herein, the formed nonwoven fabric does not contain pores. In other words, the nonwoven fabrics described herein do not include any segments with a zero basis weight. Further, in the formed nonwoven fabrics described herein, when an area is defined as having a strength characteristic, it must have a value greater than zero for that characteristic (basis weight, thickness, volume, etc.). Example 13 is a standard flat nonwoven fabric that does not have any visually distinguishable areas with a pattern of three-dimensional characteristic structures. Example 13 does not exhibit a pattern with high visual clarity and is used for comparison with the visual clarity pattern exhibited by the new formed nonwoven fabrics detailed herein - demonstrated by Example 12 detailed herein.

[0323] Table 7A - D: Data of the Molded Nonwovens of the Present Disclosure and Comparative Examples Exhibiting Improved Visual Clarity and / or Uniformity

[0324] Using the in - article gray - level change test method detailed below, the gray - level change values of Example 12 were measured in three different 4 - inch by 4 - inch scans of the visually distinguishable regions on the formed non - woven fabric. The positions of these three scans are shown and identified as Positions 1, 2, and 3 in Figure 58 The gray - level change values of Example 13 were also measured in a single 4 - inch by 4 - inch scan using the in - article gray - level change test method. These measurements for Example 13 were made at different positions on a flat, non - patterned non - woven fabric twice.

[0325] Table 7A: Gray - Level Changes Measured by the Gray - Level Change Test Method within the Article

[0326] Sample Number / Position Gray - Level Change Example 12, Position 1 3.8 Example 12, Position 2 2.8 Example 12, Position 3 3.5 Example 13, First Position 4.2 Example 13, Second Position 4.7

[0327] Using the Haralick maximum contrast test method detailed below, the Haralick maximum 90° contrast value, Haralick maximum 0° contrast value, Haralick maximum 45° contrast value, Haralick maximum 135° contrast value, and Haralick maximum average contrast value of Example 12 were measured in three different 4 - inch by 4 - inch scans of the visually distinguishable regions on the formed non - woven fabric. The positions of these three scans are shown and identified as Positions 1, 2, and 3 in Figure 58 The Haralick maximum 90° contrast value, Haralick maximum 90° contrast value, Haralick maximum 45° contrast value, Haralick maximum 135° contrast value, and Haralick maximum average contrast value of Example 13 were also measured in two 4 - inch by 4 - inch scans using the Haralick maximum contrast test method. These measurements for Example 13 were made at different positions on a flat, non - patterned non - woven fabric twice.

[0328] For clarity, Figure 59 the chart of Figure 58 provides a visual depiction of 150 individual data points of the Haralick 0° contrast value of Example 12 obtained at Position 1, 150 individual data points of the Haralick 45° contrast value, 150 individual data points of the Haralick 90° contrast value, 150 individual data points of the Haralick 135° contrast value, and the Haralick average contrast value generated from those 600 data points. (

[0329] Table 7B: Haralick Maximum 90° Contrast, Maximum 0° Contrast, and Maximum Average Contrast

[0330]

[0331] Using the gray level contrast slope test method detailed below, the gray level contrast slope of Example 12 was measured at ten random positions on the nonwoven fabric. The gray level contrast slope measured for Example 12 had a high value of 23.9 and a low value of 11.0. The average gray level contrast slope measured for Example 12 was 16.7.

[0332] Table 7C: Gray - Level Contrast Slope

[0333]

[0334]

[0335] Using the inter-product gray level change test method detailed below, the gray level change values of six nonwoven fabrics as detailed in Example 12 were measured in the same visually distinguishable region on the formed nonwoven fabric. Images of the scanned regions of the six nonwoven fabrics are shown in Figure 60 and are identified as A, B, C, D, E, and F. The average gray level values of the six nonwoven fabrics are identified below, and the standard deviation of those values is the gray level change value.

[0336] Table 7D: Gray - Level Changes Measured by the Gray - Level Change Test Method between Articles

[0337] Sample Average Gray - Level Value A 136.7 B 137.6 C 133.3 D 134.5 E 134.7 F 133.4

[0338] The standard deviation or gray level change value between the six samples was 1.8.

[0339] In one way of demonstrating the uniformity within a single article (i.e., defining the contrast of pixels separated by a distance X), the gray level change value in a visually distinguishable region (e.g., the first visually distinguishable region) can be between about 0.1 and about 10.0, or between about 0.1 and about 7.0, or between about 0.1 and about 5.0, or between about 0.1 and about 4.7, or between about 0.1 and about 4.2, or between about 0.1 and 4.1, or between about 0.1 and about 4.0, or between about 0.1 and about 3.8, or between about 1.2 and 3.8, or less than 4.5, or less than 4.2, or less than 4.0, or less than 3.8, or less than 3.0, or less than 2.0, or less than 1.0. Generally speaking, the measured gray level change value in a visually distinguishable region (in a single article) can be any value up to about 10, and any value range between 0.1 and 10. The gray level change within a single article is measured according to the intra-article gray level change test method detailed herein.

[0340] In a first way of demonstrating visual clarity within a single article, the Haralick maximum average contrast value of a visually distinguishable region (e.g., a first visually distinguishable region) can be between about 80 and about 750, or between about 90 and about 600, or between about 100 and about 500, or between about 200 and about 500, or between about 300 and about 450, or greater than about 80, or greater than about 90, or greater than about 100, or greater than about 150, or greater than about 200, or greater than about 250, or greater than 300. Generally speaking, the Haralick maximum average contrast value within a visually distinguishable region can be any integer range between 80 and 750.

[0341] In a second way of demonstrating such visual clarity within a single article, the Haralick maximum 90° contrast value of a visually distinguishable region (e.g., a first visually distinguishable region) can be between about 80 and about 750, or between about 90 and about 600, or between about 100 and about 500, or between about 200 and about 500, or between about 300 and about 450, or greater than about 80, or greater than about 90, or greater than about 100, or greater than about 150, or greater than about 200, or greater than about 250, or greater than about 300, or greater than 315. Generally speaking, the Haralick maximum 90° contrast value within a visually distinguishable region can be any integer range between 80 and 750.

[0342] In a third way of demonstrating such visual clarity within a single article, the Haralick maximum 0° contrast value of a visually distinguishable region (e.g., a first visually distinguishable region) can be between about 80 and about 750, or between about 90 and about 600, or between about 100 and about 500, or between about 200 and about 500, or between about 300 and about 450, or greater than about 80, or greater than about 90, or greater than about 100, or greater than about 150, or greater than about 200, or greater than about 250, or greater than about 300, or greater than about 350, or greater than 381. Generally speaking, the Haralick maximum 0° contrast value within a visually distinguishable region can be any integer range between 80 and 750.

[0343] In a fourth way of demonstrating such visual clarity within a single article, the gray-level contrast slope of a first visually distinguishable region (e.g., a first visually distinguishable region) can be between about 5.0 and about 35.0, or between about 10.0 and about 30.0, or between about 11.0 and about 25.0, or between about 11.0 and about 23.9, or greater than about 11.0, or less than 23.9. Generally speaking, the gray-level contrast slope within a single article can be any numerical range between 10.0 and 30.0.

[0344] In a fifth way of demonstrating such visual clarity within a single article, a visually distinguishable region (e.g., a first visually distinguishable region) may have a periodic Haralick wave response as determined according to the Haralick maximum contrast method as defined herein. For clarity, the wave response may be defined as periodic if at least one peak and at least one valley are observed in the Haralick response. As further defined in the method, the periodic response only applies to the Haralick maximum 90° or 0° contrast values.

[0345] In one way of demonstrating consistent high uniformity between multiple articles, such uniformity may be demonstrated by a gray level change value between about 0.1 and about 10.0, or between about 0.1 and about 7.0, or between about 0.1 and about 5.0, or between about 0.1 and about 4.7, or between about 0.1 and about 4.2, or between about 0.1 and 4.1, or between about 0.1 and about 4.0, or between about 0.1 and about 3.8, or between about 0.1 and about 1.2, or less than 4.5, or less than 4.2, or less than 4.0, or less than 3.8, or less than 3.0, or less than 2.0, or less than 1.2, or less than 1.0. Generally speaking, the gray level change measurement of a visually distinguishable region (e.g., a first visually distinguishable region between multiple articles) can be any value up to about 10, as well as any value range between 0.1 and 10. The gray level change between multiple articles is measured according to the inter-article gray level change test method detailed herein.

[0346] Any one of the various Haralick parameters detailed above for demonstrating visual clarity in the formed nonwoven fabric can be combined with one or more additional ways (additional Haralick parameters or other parameters) for demonstrating visual clarity in the formed nonwoven fabric. In addition, the formed nonwoven fabric detailed above has microregions with regions of different strength characteristics (such as basis weight, density, or thickness). Those nonwoven fabrics of the same shape can also simultaneously have visually clear patterns with any and / or all of the Haralick analysis values detailed herein. Any of the examples of the formed nonwoven fabrics detailed herein (e.g., samples including regions and / or microregions with regions of different thickness, basis weight, and / or volume density, hydrophilic and / or hydrophobic areas, and / or surfaces having various TS7 values disclosed herein) can also have visual clarity that can be demonstrated by gray level change, Haralick maximum average contrast value, Haralick maximum 90° contrast value, Haralick maximum 0 0Visually distinct patterns quantified by the presence or absence of contrast values, gray level contrast slopes, and periodic Haralick wave responses. Additionally, a package of any of the exemplary formed nonwoven fabrics detailed herein (e.g., including zones and / or microzones with regions of varying thickness, basis weight, and / or bulk density and / or samples having surfaces with various TS7 values disclosed herein) may include a nonwoven fabric that also has a visually distinct pattern quantifiable by variations between gray levels.

[0347] Formed nonwoven fabrics having the microzones detailed above with regions of varying basis weight, density, or thickness, respectively, and also having a visually distinct pattern with any and / or all of the Haralick analysis values detailed herein can provide many useful applications such as topsheet materials for baby care, feminine care, and adult incontinence products, and for medical pads, wipes, cleaning pads, and the like.

[0348] Furthermore, in order to manufacture such formed nonwoven fabrics with high visual resolution patterns using the methods detailed herein, the inventors have unexpectedly found that the forming belt must have a selected combination of knuckle area percentage (hereinafter referred to as “%KA”) and / or air permeability and / or superload. Without being bound by theory, the inventors have found that the formed nonwoven fabrics of the present invention with high visual resolution patterns can be achieved only with forming belts having a selected %KA and / or air permeability and / or superload because these belt designs can facilitate deeper migration of fibers into the opening regions of the forming belt, a greater count of filaments in the opening regions relative to the knuckle or resin regions of the belt, more cooling-induced fiber shaping upon deposition in the opening regions of the belt, less fiber consolidation loss at the resin wall regions of the belt, maintenance of fiber wall steepness and structure during post-preparation consolidation / bonding, maintenance of fiber wall steepness and structure in the intermediate rollers used for feeding into the production line, and even in the article under compression packaging, and / or other factors, all of which individually or simultaneously contribute to establishing a steep transition slope of filaments at the region boundaries of the nonwoven fabric and unexpectedly achieving a high visual resolution texture.

[0349] In the context of the entire forming belt, %KA can be calculated by dividing the area of the forming belt that includes the knuckles (i.e., the total area of the resin that forms the raised portions) by the total area of the entire forming belt. In a defined segment of the forming belt, %KA can be calculated by dividing the area of the defined segment that includes the knuckles (i.e., the total area of the resin that forms the raised portions) by the total area of the defined segment. Methods for measuring the air permeability of the forming belt as defined herein are detailed in the following method section.

[0350] % KA, air permeability, and superload can be measured in any defined segment of the forming belt as defined herein, including: 1) a defined segment including a part or the entire repeating pattern of the forming belt (e.g., Figure 12 , Figure 16 or Figure 18 the entire segment of the forming belt shown, or Figure 12 , Figure 16 or any part of the forming belt shown in Figure 18); 2) a defined segment including a discrete belt pattern on the forming belt (e.g., a discrete belt pattern 61 as shown in the forming belt segment such as Figure 19 ); 3) a defined segment including any distinguishable area on the forming belt (e.g., any defined segment of the discrete belt pattern 61 in Figure 19 that includes a visually distinguishable area); and 4) a defined segment including any combination of distinguishable areas on the forming belt (e.g., any defined segment of the discrete belt pattern 61 in Figure 19 that includes a combination of one or more visually distinguishable areas).

[0351] For the forming belt as defined herein for delivering a high visual resolution patterned nonwoven, % KA can be between about 2% and about 35%, or between about 5% and about 30%, or between about 8% and about 25%, or between about 10% and about 25%. The air permeability can be between about 400 cfm and about 1000 cfm, or between about 400 cfm and about 800 cfm, or between about 500 cfm and about 750 cfm, or between about 650 cfm and about 700 cfm. As defined herein, the superload OB can be between about 0.015 inches and about 0.060 inches, or between about 0.020 and about 0.050 inches, or between about 0.025 inches and about 0.045 inches, or between about 0.030 inches and about 0.040 inches, or between about 0.030 inches and about 0.035 inches.

[0352] Table 8A and Figure 61 (which plots the data from Table 8A) show the desired combination ranges of % KA and air permeability for a forming belt for manufacturing a formed nonwoven fabric with a high visual resolution pattern. When the forming belt has a % KA between about 2% and about 35% and an air permeability between about 400 cfm and about 1000 cfm, the belt can produce a formed nonwoven fabric with a high visual resolution pattern as described herein (i.e., a nonwoven fabric exhibiting high visual clarity as quantified by the presence or absence of gray level variations, Haralick maximum average contrast value, Haralick maximum 90° contrast value, Haralick maximum 0° contrast value, gray level contrast slope, and periodic Haralick wave response). Such forming belts are identified as high visual resolution. In Figure 61In it, a box is drawn around the data points of the high visual resolution forming belt to indicate the range of the %KA and air permeability parameters displayed by such a belt. When the forming belt has a %KA higher than 35%, or an air permeability lower than about 350 cfm, or a combination of a %KA higher than 35% and an air permeability lower than 400 cfm, such a belt does not produce a formed nonwoven fabric with a high visual resolution pattern as described herein. Such forming belts are identified as having low visual resolution. Data for some examples of low visual resolution belts are shown in detail in Table 8B below and are also plotted on Figure 61 above.

[0353] Table 8A: %KA and Air Permeability of the High - Visual - Resolution Forming Belt

[0354]

[0355]

[0356] Table 8B: %KA and Air Permeability of the Low - Visual - Resolution Forming Belt

[0357] %KA Air Permeability 36.0 336 41.0 305 60.0 117

[0358] In some high visual resolution forming belts of interest, the belt may have a %KA between about 8% and about 25% and an air permeability between about 500 cfm and about 850 cfm. In other high visual resolution forming belts of interest, the belt may have a %KA between about 10% and about 25% and an air permeability between about 650 cfm and about 700 cfm. In other high visual resolution forming belts of interest, the belt may have a %KA between about 8% and about 25% and an air permeability between about 500 cfm and about 850 cfm and an overload between about 0.015 inches and about 0.060 inches. In other high visual resolution forming belts of interest, the belt may have a %KA between about 10% and about 25% and an air permeability between about 650 cfm and about 700 cfm and an overload between about 0.025 inches and about 0.045 inches.

[0359] Any one of the Haralick parameters described above for demonstrating the visual clarity of the formed nonwoven fabric can be combined with one or more parameters (% KA and / or air permeability and / or overload) related to the structured forming belt used to manufacture the formed nonwoven fabric. In addition, the formed nonwoven fabric prepared on the forming belt described above has microregions with regions having different strength characteristics (such as basis weight, density, or thickness), and can also simultaneously have a visually clear pattern with any and / or all of the Haralick analysis values described herein. Any one of the examples of the formed nonwoven fabric described herein (for example, including regions and / or microregions with regions having different thickness, basis weight, and / or volume density, hydrophilic and / or hydrophobic areas, and / or samples having surfaces with various TS7 values disclosed herein) can also simultaneously have a visually clear pattern that can be quantified by the presence or absence of gray-level changes, Haralick maximum average contrast value, Haralick maximum 90° contrast value, Haralick maximum 0° contrast value, gray-level contrast slope, and periodic Haralick wave response, and / or is prepared on a structured forming belt as described herein (% KA and / or air permeability and / or overload). In addition, the package of any one of the examples of the formed nonwoven fabric described herein (for example, including regions and / or microregions with regions having different thickness, basis weight, and / or volume density, and / or samples having surfaces with various TS7 values disclosed herein) can include a nonwoven fabric that also has a visually clear pattern that can be quantified by gray-level changes between levels.

[0360] Test Method:

[0361] Compression Aging Test Method

[0362] Initial Thickness Measurement :

[0363] · Cut five 3-inch by 3-inch samples from each nonwoven fabric to be measured.

[0364] · Number each sample from 1 to 5.

[0365] · Using a Thwing-Albert thickness gauge, measure the thickness at 0.5 kPa with a "standard"

[0366] 65 mm foot according to standard procedures.

[0367] · Report the initial thickness of each of the five samples.

[0368] · Report the average thickness of the five samples.

[0369] Aging Compression Method and Aging Thickness Measurement

[0370] · Stack five samples in an alternating pattern, with each sample separated by a paper towel, and the stack starts and ends with "Sample No." 1 and 5 respectively.

[0371] · Place the alternately stacked samples in an aluminum sample holder, and place an appropriate weight on top of the samples (4 KPa, 14 KPa, or 35 KPa).

[0372] · Place the stacked samples with weights in an oven at 40 °C for 15 hours.

[0373] · After 15 hours, remove the weights, separate the samples, and measure the thickness of each sample using a Thwing - Albert thickness gauge with a "standard" 65 mm foot at 0.5 kPa according to standard procedures.

[0374] · Report the aged thickness values for each of the five samples.

[0375] · Report the average aged thickness of the five samples.

[0376] Analysis Report:

[0377] · Report the average initial thickness and aged thickness by position number

[0378] · Report the thickness recovery index:

[0379] (Average aged thickness / Average initial thickness) * 100

[0380] Local Basis Weight Test Method

[0381] The "local basis weight" of a non - woven fabric can be determined by several available techniques, but a simple representative technique involves a die with an area of 3.0 cm 2 which is used to cut out a fibrous web sample piece from a selected area (from the total area of the non - woven fabric). Then the sample piece is weighed and divided by its area to obtain the local basis weight of the non - woven fabric, in grams per square meter. For each selected area, the result is reported as the average of 2 samples.

[0382] Fluff Content Test Method

[0383] The fuzz content test is used to determine the amount of fibers removed from a non - woven material under abrasive forces (i.e., fuzz content).

[0384] The fuzz content test uses the following materials:

[0385] · A Sutherland Ink friction tester with a 2 - pound weight, purchased from Danilee Co, San Antonio, TX.

[0386] · Aluminum oxide abrasive cloth, 320 grit, roll, prepared by Plymouth Coatings, (617)447-7731. This material is also available through McMaster Carr, part number 468.7A51,

[0387] (330)995-5500 for ordering.

[0388] · Double-sided tape, 3M #409, purchased from Netherland Rubber Company, (513)733-1085.

[0389] · Fiber removal tape, 3M #3187, purchased from Netherland Rubber Company, (513)733-1085.

[0390] · Analytical balance (+ / -0.0001g)

[0391] · Paper cutter

[0392] · 2200g weight (metal), 170mm x 63mm.

[0393] · Heavy-duty release liner board - 0.0445 inches (1.13mm) thickness.

[0394] Material Preparation

[0395] Measure and cut the aluminum oxide abrasive cloth into lengths of 7.5 inches (19.0mm). Measure and cut strips of 3M #3187 into lengths of 6.5 inches (16.5cm), two strips per sample. Fold less than approximately 0.25 inches (0.6cm) at each end of the 3M #3187 strip for ease of handling. Place the 3M #3187 strips on heavy-duty release paper for later use.

[0396] Sample Preparation

[0397] Before handling or testing either material, wash hands with soap and water to remove excess oil from the hands. Optionally, latex gloves may be worn. Cut samples of the nonwoven fabric to be tested to dimensions of at least 11cm in the MD and 4cm in the CD. Lay the samples of the nonwoven fabric to be tested flat, with the side to be tested facing down. Cut a piece of 3M #409 double-sided tape at least 11cm in length from the roll. Remove the backing, and apply the side of the double-sided tape facing the backing longitudinally (MD) to the longitudinal sample of nonwoven fabric. Replace the backing on the exposed strip. Using a paper cutter, cut the test sample within the tape adhesion area of 11cm MD and 4cm CD.

[0398] Test Procedure

[0399] 1. Mount an alumina abrasive cloth slice on the Sutherland Ink friction tester using a 2-pound weight. Place a second alumina abrasive cloth slice on top of the heavy-duty release liner cardboard (use a new slice for each test). Place both of these on top of the 2-pound weight. The sides will fold down into the fixture - ensure that the alumina abrasive cloth and the heavy-duty release liner cardboard are flat.

[0400] 2. Mount the sample on the Sutherland Ink friction tester platform and center it on the metal plate. Place a 2200g weight on top of the sample for 20 seconds.

[0401] 3. Attach the metal plate and the 2-pound weight to the Sutherland Ink friction tester.

[0402] 4. Turn on the friction tester. If the table lamp is not on, press the reset button. Press the table button to set the friction cycle to 20 cycles. Use the speed button to select speed 1, slow (the lamp is not on). Press "Start".

[0403] 5. When turning off the friction tester, carefully remove the alumina abrasive cloth / weight, ensuring that no loose microfibers (lint) are lost. In some cases, the microfibers will adhere to both the surface of the alumina abrasive cloth and the sample nonwoven fabric. Invert the weight and place it on the workbench.

[0404] 6. Weigh the fiber removal tape with the release paper attached. The fiber removal tape is fixed by its folded end. Remove the release paper and set it aside. Gently place the tape on the alumina abrasive cloth to remove all lint. Remove the fiber removal tape and place it back on the release paper. Weigh the fiber removal tape and record the weight.

[0405] 7. Another pre-weighed fiber removal tape is fixed by its folded end. Gently place the fiber removal tape on the surface of the friction-tested nonwoven fabric sample. Place the flat metal plate on top of the fiber removal tape.

[0406] 8. Place a 2200g weight on top of the metal plate for 20 seconds. Remove the fiber removal tape. The pre-weighed fiber removal tape is fixed by its folded end to avoid fingerprints. Place the pre-weighed fiber removal tape back on the release paper. Weigh the fiber removal tape and record the weight.

[0407] 9. The lint weight is the sum of the weight increases of the two fiber removal tapes.

[0408] 10. The lint weight is reported as the average of 10 measurements.

[0409] Calculation

[0410] For a given sample, add the weight of the lint collected from the alumina abrasive cloth in grams to the weight of the lint collected from the abraded sample nonwoven fabric in grams. Multiply the combined weight in grams by 1000 to convert to milligrams (mg). To convert this measurement from absolute weight loss to weight loss per unit area, divide the total weight of the lint by the area of the abraded zone.

[0411] Air Permeability Test Method

[0412] 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, purchased from Textest AG, Sonnenbergstrasse 72, CH 8603 Schwerzenbach, Switzerland. The unit utilizes a 20.7 mm orifice plate for air permeability ranges between 300 cfm and 1000 cfm. If the air permeability is below 300 cfm, a smaller orifice plate is required; if above 1000 cfm, a larger orifice plate is required. The air permeability can be measured in local zones of the forming belt to determine the air permeability difference across the forming belt.

[0413] Test Procedure

[0414] 1. Power on the FX3360 instrument.

[0415] 2. Select a predefined mode with the following settings:

[0416] a. Material: "Standard"

[0417] b. Measurement property: Air permeability (AP)

[0418] c. Test pressure: 125 Pa (Pascals)

[0419] d. T factor: 1.00

[0420] e. Test point pitch: 0.8 inches.

[0421] 3. Position the 20.7 mm orifice plate on the top side of the forming belt (the side with the three-dimensional protrusions) at the location of interest.

[0422] 4. Select "Single Point Measurement" on the touch screen of the test unit.

[0423] 5. Reset the sensor before measurement if necessary.

[0424] 6. Once reset, select the "Start" button to begin the measurement.

[0425] 7. Wait until the measured value stabilizes and record the cfm reading on the screen.

[0426] 8. Select the "Start" button again to stop the measurement.

[0427] Stack Height in Bag Test Method

[0428] Determine the in-bag stack height of the absorbent article package as follows:

[0429] Equipment

[0430] Use a thickness tester with a flat rigid horizontal slide plate. The thickness tester is configured such that the horizontal slide plate moves freely in the vertical direction, where the horizontal slide plate is always maintained in a horizontal orientation directly above a flat rigid horizontal substrate. The thickness tester includes means for measuring the gap between the horizontal slide plate and the horizontal substrate, accurate to within ±0.5 mm. The horizontal slide plate 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 plate applies a downward force of 850 grams ± 1 gram-force (8.34 N) to the absorbent article package, which can be achieved by placing a suitable weight at the center of the top surface of the horizontal slide plate that does not contact the package, such that the total mass of the slide plate plus the added weight is 850 grams ± 1 gram.

[0431] Test Procedure

[0432] Before measurement, equilibrate the absorbent article package at 23°C ± 2°C and 50% ± 5% relative humidity.

[0433] Lift the horizontal slide plate and place the absorbent article package centered below the horizontal slide plate in such a way that the absorbent article within the package is in a horizontal orientation (see Figure 27 ). Fold any handles or other encapsulation features on the surface of the package that contact either plate flat against the surface of the package to minimize their effect on the measurement. Slowly lower the horizontal slide plate until it contacts the top surface of the package and then release. Ten seconds after releasing the horizontal slide plate, measure the gap between the horizontal plates, accurate 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 "in-bag stack height" = (package width / number of absorbent articles per stack) × 10, accurate to within ±0.5 mm.

[0434] Micro - CT Strength Property Measurement Test Method

[0435] The micro-CT strength property measurement method measures basis weight, thickness, and volume density values within a visually distinguishable area of a substrate sample. It is based on the analysis of 3D x-ray sample images obtained on a micro-CT instrument (a suitable instrument is the Scanco μCT 50 purchased from Scanco Medical AG, Switzerland, or an equivalent). The micro-CT instrument is a cone-beam microphotography instrument with a shielded cabinet. A maintenance-free x-ray tube is used as a light source with an adjustable diameter focus. The x-ray beam passes through the sample, and some of the x-rays are attenuated by the sample. The degree of attenuation is related to the mass of the material the x-rays must pass through. The transmitted x-rays continue to strike a digital detector array and produce a 2D projection image of the sample. A 3D image of the sample is generated by collecting several individual projection images of the sample while it rotates, and then it is reconstructed into a single 3D image. The instrument is connected to a computer running software to control image acquisition and save the raw data. Then, image analysis software (a suitable image analysis software is MATLAB purchased from The Mathworks, Inc., Natick, MA, or an equivalent) is used to analyze the 3D image to measure the basis weight, thickness, and volume density strength properties of regions within the sample.

[0436] Sample Preparation :

[0437] To obtain a sample for measurement, a single layer of dry substrate material is laid flat and a circular piece with a diameter of 30 mm is punched out.

[0438] If the substrate material is a layer of an absorbent article, such as a topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer; the absorbent article is fixed to a rigid flat surface in a planar configuration using tape. The individual substrate layer is carefully separated from the absorbent article. If necessary, a surgical scalpel and / or cryogenic spray (such as Cyto-Freeze, Control Company, Houston TX) can be used to remove the substrate layer from the additional underlying layer to avoid any longitudinal and lateral stretching of the material. Once the substrate layer has been removed from the article, the sample is punched out as described above.

[0439] If the substrate material is in the form of a wet wipe, a new wet wipe package is opened and the entire stack is removed from the package. A wipe is removed from the middle of the stack, laid flat, and allowed to dry completely, and then the sample is punched out for analysis.

[0440] The sample can be cut from any position including the visually distinguishable area to be analyzed. In one area, the area to be analyzed is the area associated with the three-dimensional characteristic structure that defines the micro-region. The micro-region includes at least two visually distinguishable areas. Due to changes in texture, height, or thickness, the area, three-dimensional characteristic structure, or micro-region can be visually distinguishable. Areas within different samples obtained from the same base material can be analyzed and compared with each other. When choosing the sampling position, care should be taken to avoid folding, wrinkling, or tearing.

[0441] Image Acquisition :

[0442] Set up and calibrate the micro-CT instrument according to the manufacturer's instructions. Place the sample in a suitable holder between two low-density material rings with an inner diameter of 25 mm. This will allow the central part of the sample to be placed horizontally and scanned without any other material directly adjacent to its upper and lower surfaces. Measurements should be made in this area. The 3D image field of view is approximately 35 mm on each side in the xy plane, the resolution is approximately 5000 by 5000 pixels, and a sufficient number of 7-micron-thick slices in the z direction that fully enclose the sample are collected. The reconstructed 3D image resolution contains isotropic voxels of 7 microns. Images are acquired with a light source of 45 kVp and 133 μA without an additional low-energy filter. These current and voltage settings can be optimized to produce the maximum contrast in the projection data, where sufficient x-rays penetrate the sample, but once optimized, all substantially similar samples remain constant. A total of 1500 projection images are obtained, which have an integration time of 1000 ms and 3 averages. The projection images are reconstructed into a 3D image and saved in 16-bit RAW format to retain the full detector output signal for analysis.

[0443] Image Processing :

[0444] Load the 3D image into image analysis software. Limit the 3D image threshold to a value that separates and removes the background signal due to air, but retains the signal from the sample fibers within the substrate.

[0445] Generate three 2D intensity characteristic images from the threshold 3D image. The first is the basis weight image. To generate this image, the value of each voxel in the xy plane slice is added to all its corresponding voxel values in other z direction slices that include the signal from the sample. This will create a 2D image where each pixel now has a value equal to the cumulative signal of the entire sample.

[0446] To convert the raw data values in the basis weight image to real numbers, a basis weight calibration curve is generated. A substrate is obtained that has a composition that is substantially similar to the sample being analyzed and has a uniform basis weight. At least ten replicate samples of the calibration curve substrate are obtained according to the above protocol. The basis weight is accurately measured by taking the mass of each of the monolayer calibration samples to be near 0.0001 g and dividing by the sample area and converting to grams per square meter (gsm), and calculating the average value, accurate to 0.01 gsm. According to the above protocol, micro-CT images of a monolayer of the calibration sample substrate are acquired. According to the above protocol, the micro-CT images are processed and a basis weight image including the raw data values is generated. The actual basis weight value of the sample is the average basis weight value measured on the calibration sample. Next, two layers of the calibration substrate samples are stacked on top of each other and micro-CT images of the two layers of calibration substrate are acquired. A basis weight raw data image of the two layers is generated together, and its actual basis weight value is equal to twice the average basis weight value measured on the calibration sample. This protocol of stacking monolayer calibration substrates is repeated to obtain micro-CT images of all the layers, generating raw data basis weight images of all the layers, whose actual basis weight value is equal to the number of layers multiplied by the average basis weight value measured on the calibration sample. A total of at least four different basis weight calibration images are obtained. The basis weight values of the calibration samples must include values that are both higher and lower than the basis weight value of the initial sample to be analyzed to ensure accurate calibration. A calibration curve is generated by performing a linear regression on the raw data with the actual basis weight values of the four calibration samples. If the entire calibration protocol is not repeated, this linear regression must have an R2 value of at least 0.95. Now, this calibration curve is used to convert the raw data values to the actual basis weight.

[0447] The second intensity characteristic 2D image is the thickness image. To generate this image, the upper and lower surfaces of the sample are identified and the distance between these surfaces is calculated to arrive at the sample thickness. The upper surface of the sample is identified by starting with the topmost slice in the z-direction and evaluating each slice through the sample to locate all the voxel positions in the xy-plane where the sample signal is first detected. The lower surface of the sample is identified according to the same protocol, except that the located z-direction voxels are all the positions in the xy-plane where the sample signal is last detected. Once the upper and lower surfaces are identified, they are smoothed with a 15x15 median filter to remove signals from stray fibers. Then, a 2D thickness image is generated by counting the number of voxels present between the upper and lower surfaces at each pixel position in the xy-plane. Then, this raw thickness value is converted to an actual distance (in microns) by multiplying the voxel count by the 7 μm slice thickness resolution.

[0448] The third strength characteristic 2D image is the bulk density image. To generate this image, each xy-plane pixel value (in gsm) in the basis weight image is divided by the corresponding pixel in the thickness image, in microns. The unit of the bulk density image is grams per cubic centimeter (g / cc).

[0449] Micro - CT Basis Weight, Thickness, and Volume Density Strength Properties :

[0450] The analysis is started by identifying a region. The region to be analyzed is a region associated with a three-dimensional characteristic structure that defines a micro-region. The micro-region includes at least two visually distinguishable regions. The region, three-dimensional characteristic structure, or micro-region may be visually distinguishable due to variations in texture, height, or thickness. Next, the boundaries of the region to be analyzed are identified. The boundaries of the region are identified by visually discerning differences in the strength characteristics when compared to other regions within the sample. For example, the region boundaries may be identified based on visually discerning differences in thickness when compared to another region in the sample. Any of the strength characteristics can be used to discern the boundaries of the regions of the physical sample itself in any of the micro-CT strength characteristic images. Once the boundaries of the region are identified, an elliptical or circular "region of interest" (ROI) is drawn inside the region. The ROI should have an area of at least 0.1 mm2 and is selected for measuring the region having strength characteristic values representative of the identified region. The average basis weight, thickness, and bulk density within the ROI are calculated from each of the three strength characteristic images. These values are recorded as the basis weight of the region, accurate to 0.01 gsm, the thickness accurate to 0.1 micron, and the bulk density accurate to 0.0001 g / cc.

[0451] Emtec Test Method

[0452] The TS7 and TS750 values are measured using an EMTEC Tissue Softness Analyzer ("Emtec TSA") (Emtec Electronic GmbH, Leipzig, Germany) connected to a computer running Emtec TSA software (version 3.19 or equivalent). According to Emtec, the TS7 value is related to the actual material softness, while the TS750 value is related to the felt smoothness / roughness of the material. The Emtec TSA includes a rotor with a vertical blade that rotates on the test sample at a defined and calibrated rotational speed (set by the manufacturer) and a contact force of 100 mN. The contact between the vertical blade and the test piece generates vibrations that produce sound, which is recorded by a microphone within the instrument. The recorded sound file is then analyzed by the Emtec TSA software. Sample preparation, instrument operation, and test procedures are carried out according to the instructions of the instrument manufacturer.

[0453] Sample Preparation

[0454] Test samples are prepared by cutting square or circular samples from the finished product. In either of these dimensions, the test samples are cut to a length and width (or diameter if circular) of not less than about 90 mm and not more than about 120 mm to ensure that the samples can be properly clamped into the TSA instrument. The test samples are selected to avoid perforations, creases, or wrinkles within the test area. Eight substantially similar replicate samples are prepared for testing. Prior to performing the TSA test, all samples are equilibrated for at least 2 hours at TAPPI standard temperature and relative humidity conditions (23 °C ± 2 °C and 50% ± 2%), and the TSA test is also performed under TAPPI conditions.

[0455] Test Procedure

[0456] Calibrate the instrument using the one-point calibration method of the Emtec reference standard ("ref.2 sample") according to the manufacturer's instructions. If these reference samples are no longer available, use the appropriate reference samples provided by the manufacturer. Calibrate the instrument according to the manufacturer's recommendations and instructions such that the results are comparable to those obtained when using the one-point calibration method of the Emtec reference standard ("ref.2 sample").

[0457] Provide eight replicate samples of the fabric for testing. Mount the test samples into the instrument with the surface side up and perform the test according to the manufacturer's instructions. After completion, the software will display the values of TS7 and TS750. Record each of these values to an accuracy of 0.01 dB V 2 rms. Then remove the test samples from the instrument and discard them. This test is performed on the same surface of four replicate samples and subsequently on the other surface of the other four replicate samples. The first test surface can be either the first surface 12 or the second surface 14 of the formed nonwoven fabric as disclosed herein.

[0458] Average the TS7 and TS750 values of the four test results from the first test surface (using a simple numerical average); also average the TS7 and TS750 values of the four test results from the second test surface. Report the averages of the respective TS7 and TS750 for the first and second test surfaces on a particular test sample to an accuracy of 0.01 dB V 2 rms. Additionally, calculate the TS7 ratio of the first test surface to the second test surface by dividing the average TS7 of the first test surface by the average TS7 of the second test surface.

[0459] Contact Angle and Capillary Rise Time Test Method

[0460] Contact angle and wicking time measurements are determined using the sessile drop experiment. A specified volume of Type II reagent distilled water (as defined in ASTM D1193) is applied to the surface of the test sample using an automated liquid delivery system. A high-speed camera captures timestamped images of the droplet over a 60-second time period at a rate of 900 frames per second. The contact angle between the droplet and the test sample surface for each captured image is determined by image analysis software. The wicking time is determined as the time required for the contact angle of the droplet absorbed into the test sample to decrease to a contact angle of <10°. All measurements are performed at a constant temperature (23 °C ± 2 °C) and relative humidity (50% ± 2%).

[0461] An automated contact angle tester is required to perform this test. The system consists of a light source, a camera, a horizontal sample stage, a liquid delivery system with a pump and a microsyringe, and a computer equipped with software suitable for video image capture, image analysis, and reporting contact angle data. A suitable instrument is the Optical Contact Angle Measuring System OCA 20 (DataPhysics Instruments, Filderstadt, Germany) or an equivalent system. The system must be able to deliver an 8.2-µL droplet and be able to capture images at a rate of 900 frames per second. Unless otherwise specifically stated in this test protocol, the system is calibrated and operated according to the manufacturer's instructions.

[0462] To obtain a test sample for measurement, a single layer of the dry substrate material is laid flat and rectangular test samples are cut, which are 15 mm wide and approximately 70 mm long. The width of the sample can be reduced as needed to ensure that the test area of interest is not obscured by surrounding features during the test. For narrower sample strips, care must be taken that the droplet does not reach the edge of the test sample during the test, otherwise the test must be repeated. Before the test, the samples are pre-conditioned for 2 hours at approximately 23 °C ± 2 °C and 50% ± 2% relative humidity.

[0463] Sample Preparation

[0464] The test sample can be cut from any location that includes a visually distinguishable area to be analyzed. Within one area, the area to be analyzed is the area associated with a three-dimensional feature structure that defines a micro-region. The micro-region includes at least two visually distinguishable areas. The area, three-dimensional feature structure, or micro-region can be visually distinguishable due to variations in texture, height, or thickness. Areas within different test samples obtained from the same substrate material can be analyzed and compared to each other. When selecting the sampling location, care should be taken to avoid folding, wrinkling, or tearing.

[0465] If the substrate material is a layer of an absorbent article, such as a topsheet or backsheet nonwoven, acquisition layer, distribution layer, or other component layer; the absorbent article is secured to a rigid flat surface in a planar configuration. The individual substrate layer is carefully separated from the absorbent article. If desired, a scalpel and / or cryogenic spray (such as Cyto-Freeze, Control Company, Houston TX) can be used to remove the substrate layer from the underlying attached layer to avoid any longitudinal and lateral stretching of the material. Once the substrate layer has been removed from the article, the test sample is then cut. If the substrate material is in the form of a wet wipe, a new wet wipe package is opened and the entire stack is removed from the package. One wipe is removed from the middle of the stack, laid flat, and allowed to dry completely, and then samples are cut for analysis.

[0466] Test Procedure

[0467] Position the test sample on a horizontal sample stage such that the test area is within the camera's field of view beneath the needle of the liquid delivery system and the test side is facing up. Secure the test sample in such a way that it lies flat without strain and any interaction between the droplet and the underlying surface is avoided to prevent excessive capillary forces. Position a 27-gauge blunt-tipped stainless steel needle (ID 0.23 mm, OD 0.41 mm) above the test sample such that at least 2 mm of the needle tip is within the camera's field of view. Adjust the sample stage to achieve a distance of approximately 3 mm between the needle tip and the surface of the test sample. A droplet of 8.2 microliters of reagent grade distilled water is formed at a rate of 1 microliter per second and allowed to free fall onto the surface of the test sample. Video image capture is initiated before the droplet contacts the surface of the test sample and a continuous series of images is then collected for 60 seconds after the droplet contacts the surface of the test sample. Repeat this protocol for a total of five (5) substantially similar repeat test areas. Use fresh test samples or ensure that previously droplet-wetted areas are avoided during subsequent measurements.

[0468] On each image captured by the camera, the surface and profile of the droplet on the test sample are identified and used by image analysis software to calculate the contact angle for each droplet image and record it to the nearest 0.1 degree. The contact angle is the angle formed by the surface of the test sample and the tangent to the surface of the droplet contacting the test sample. For each series of images from the test, time zero is the time when the droplet begins to contact the surface of the test sample. Measure and record the contact angle on the droplet image corresponding to time zero plus five (5) seconds. If the droplet has been completely absorbed by the test sample within 5 seconds, report the contact angle at five seconds as 0°. Repeat this protocol for the five repeat test areas. Calculate the arithmetic mean of the contact angles at time zero plus five seconds for the five repeat test areas and report this value as the contact angle to the nearest 0.1 degree.

[0469] The wicking time is defined as the time required for the contact angle of the liquid droplet absorbed into the test sample to decrease to a contact angle of <10°. The wicking time is measured by identifying the first image of a given series in which the contact angle has decreased to a contact angle of <10°, and then calculating and reporting the length of time elapsed from time zero based on that image. If a contact angle less than 10° is not reached within 60 seconds, the wicking time is reported as 60 seconds. This procedure is repeated for five replicate test areas. The arithmetic mean of the wicking times for the five replicate test areas is calculated and reported, accurate to 0.1 milliseconds.

[0470] Gray - Level Change Test Method within the Article

[0471] The in - article gray - level change test method is used to determine the uniformity of gray - level values in a visually distinguishable area of a non - woven fabric image. An image is acquired using a flatbed scanner with color management manual control that can scan at 150 dpi with at least 24 - bit color (a suitable scanner is the Epson Perfection V750 Pro from Epson America Inc. (Long Beach CA), or equivalent). The scanner is connected to a computer running color calibration software through an interface. The color calibration software can calibrate the scanner for color reflection IT8 targets using a corresponding reference file compliant with ANSI method IT8.7 / 2 - 1993 (a suitable color calibration software is Monaco EZColor or ilStudio from X - Rite Grand Rapids (MI), or equivalent). The color calibration software constructs an International Color Consortium (ICC) color profile for the scanner, which is used to color - correct the output image for an image analysis program using an application that supports ICC profiles (a suitable program is Photoshop CS4 from Adobe Systems Inc. (San Jose, CA), or equivalent). The color - corrected image is then converted to grayscale for subsequent gray - level image analysis (a suitable image analysis software is MATLAB from The Mathworks, Inc. (Natick, MA)).

[0472] To obtain a sample, the absorbent article is secured to a rigid flat surface with tape in a planar configuration. Any leg elastic members present may be cut to facilitate laying the article flat. The outer boundary of the region located above the absorbent core of the article is identified and marked on the outward surface of the layer. The sample is removed from the lower layer of the article by cutting around the outer perimeter of the article with a razor blade. The layer sample is carefully removed such that its longitudinal and lateral extensions are maintained to avoid distortion of the material. If necessary, a cryogenic spray (such as Cyto-Freeze, Control Company (Houston TX) or equivalent) may be used to remove the sample from the underlying layer. Prior to testing, the sample is conditioned for 2 hours at a temperature of about 23 °C ± 2 °C and a relative humidity of about 50% ± 2%.

[0473] Prior to calibration and image acquisition, the scanner is turned on for 30 minutes. Any automatic color correction or color management options that may be included in the scanner software are deselected. If the automatic color management cannot be disabled, the scanner is not suitable for this application. Follow the recommended procedures of the color calibration software to create and export an ICC color profile for the scanner. The color calibration software compares the acquired IT8 target image with the corresponding reference file to create and export an ICC color profile for the scanner, which will be applied within the image analysis program to correct the color of subsequent output images.

[0474] The scanner cover is opened and the sample is carefully laid flat at the center of the scanner glass with the outward surface of the sample oriented towards the glass. Prior to image acquisition, the sample is backlit with a black glass tile (P / N 11-0050-30, purchased from HunterLab (Reston, VA), or equivalent). A 4-inch by 4-inch (101.6 mm by 101.6 mm) scan of the visually distinguishable area is acquired and imported into the image analysis software in the reflective mode at a resolution of 150 dpi (about 5.9 pixels / mm) in 24-bit color. The ICC color profile is assigned to the image that produces a color-corrected RGB image. The RGB image is then converted to an 8-bit grayscale according to the weighted sum of the following R, G, and B components.

[0475] Gray level = 0.2989 × R + 0.5870 × G + 0.1140 × B

[0476] The image is smoothed and blurred by applying a 2D Gaussian filter where the standard deviation of the Gaussian distribution (sigma) is equal to 4 and the boundaries are filled with replicated border elements. The calibrated and blurred grayscale image is saved in an uncompressed format (such as a TIFF file) prior to analysis.

[0477] Open the calibrated and blurred grayscale image in image analysis software and divide it into a 4×4 grid. Measure the arithmetic mean gray level value in each of the 16 regions and record it. Calculate the standard deviation of the recorded means and report it as the gray level variation, accurate to 0.1.

[0478] Haralick Maximum Contrast Test Method

[0479] The Haralick maximum contrast value is based on the Haralick texture features described in R.M. Haralick, K. Shanmugam, and I. Dinstein, "Textural features for image classification", IEEE Transactions on Systems, Man and Cybernetics, Vol. 3, No. 6, pp. 610 - 621, 1973. The contrast texture feature is calculated from the computed gray level co-occurrence matrix (GLCM). The GLCM is a list of the frequencies of the different combinations of pixel brightness values (gray levels) that occur in the image. The GLCM is normalized so that the sum of its elements equals 1. Each element (i,j) in the normalized GLCM is the joint probability occurrence of pixel pairs with gray level values i and j in the image with a defined spatial relationship, orientation, and distance. The contrast texture feature is calculated using the following formula:

[0480]

[0481] where i is the row number, j is the column number, and p(i,j) is the probability value recorded for the element (i,j) in the GLCM.

[0482] The Haralick maximum contrast value is obtained by analyzing the calibrated and blurred grayscale images collected and saved in the in-process grayscale change test method using image analysis software (a suitable image analysis software is MATLAB purchased from The MathWorks, Inc. (Natick, MA)). Using a symmetric grayscale co-occurrence matrix with 256 grayscale levels, Haralick contrast values in the range of 1 to 150 are calculated at each of the integer pixel distances between an interested pixel and its adjacent pixels in the directions of 0° (horizontal), 45°, 90° (vertical), and 135°. For the 150 Haralick contrast values obtained in the 0° direction, the maximum contrast value is identified (rounded to the nearest integer) and reported as the Haralick maximum 0° contrast value. For the 150 Haralick contrast values obtained in the 90° direction, the maximum contrast value is identified (rounded to the nearest integer) and reported as the Haralick maximum 90° contrast value. For each of the 150 integer pixel distances, the arithmetic mean contrast value between all four directions is calculated (i.e., at each specific integer pixel distance, the arithmetic mean is calculated, which is the mean of the following: 1) the 0° Haralick contrast value at that integer pixel distance, 2) the 45° Haralick contrast value at that integer pixel distance, 3) the 90° Haralick contrast value at that integer pixel distance, and 4) the 135° Haralick contrast value at that integer pixel distance). And from those 150 calculated means, the maximum of those means is identified and reported as the Haralick maximum mean contrast value (rounded to the nearest integer).

[0483] Gray - Level Contrast Slope Test Method

[0484] The grayscale contrast slope value is obtained by analyzing the calibrated and blurred grayscale images collected and saved in the in-process grayscale change test method using image analysis software (a suitable image analysis software is ImageJ version 1.52 or equivalent, National Institute of Health, USA).

[0485] Open the image in image analysis software and identify the boundary between two adjacent regions. Identify the boundary between regions either by visual discrimination or by differences in intensity characteristics when compared to other regions within the sample. For example, the region boundary can be identified based on visually discriminable differences when compared to another region in the sample. Or any of the intensity characteristics detailed herein can be used to discriminate region boundaries on the physical sample itself or on a grayscale image, such as changes in basis weight. Once the boundary between two regions is identified, draw the largest circular regions of interest that can be inscribed within each region such that these inscribed circles are adjacent to each other at the boundary between the two regions. Identify the smaller of the two inscribed circles and replace the larger circular region of interest with a circular region of the same size as the smaller region such that the two regions of interest still touch at the point of adjacency. Calculate the arithmetic mean gray level values within these two circular regions of interest. Measure the straight-line distance between the centers of the two circles, accurate to 0.001 mm. Calculate the gray level contrast slope by dividing the absolute difference in the average gray levels of the two regions by the distance between their centers. Record this value as the gray level contrast slope, accurate to 0.01 gray level / mm.

[0486] Gray - Level Change Test Method between Articles

[0487] Use the inter-product gray level variation test method to determine the uniformity of gray level values among six independent, repeated nonwoven fabric images of the same visually distinguishable zone pattern. Use a flatbed scanner with color management manual control that can scan at 150 dpi with at least 24-bit color (a suitable scanner is the Epson Perfection V750 Pro from Epson America Inc. (Long Beach CA), or equivalent) to acquire the images. The scanner is connected to a computer running color calibration software through an interface, and the color calibration software can calibrate the scanner for color reflection IT8 targets using the corresponding reference file compliant with ANSI method IT8.7 / 2-1993 (a suitable color calibration software is Monaco EZColor or i1Studio from X-Rite, Grand Rapids (MI), or equivalent). The color calibration software constructs an International Color Consortium (ICC) color profile for the scanner, and this color profile is used for color correction of the output images by an image analysis program using an application that supports ICC profiles (a suitable program is Photoshop CS4 from Adobe Systems Inc. (San Jose, CA), or equivalent). Then the color-corrected images are converted to grayscale for subsequent gray level image analysis (a suitable image analysis software is MATLAB from The Mathworks, Inc. (Natick, MA)).

[0488] To obtain each of these samples, the absorbent article is taped to a rigid flat surface in a planar configuration. Any leg elastic members present may be cut to facilitate laying the article flat. The outer boundary of the region located above the absorbent core of the article is identified and marked on the outward surface of the layer. The sample is removed from the lower layer of the article by cutting around the outer perimeter of the article with a razor blade. The layer sample is carefully removed such that its longitudinal and lateral extensions are maintained to avoid distortion of the material. If necessary, a cryogenic spray (such as Cyto-Freeze, Control Company (Houston TX) or equivalent) may be used to remove the sample from the underlying layer. Six replicate samples are prepared from six substantially similar absorbent articles from the same package for analysis. Prior to testing, the samples are conditioned for 2 hours at a temperature of approximately 23 °C ± 2 °C and a relative humidity of approximately 50% ± 2%.

[0489] Before calibration and image acquisition, turn on the scanner for 30 minutes. Deselect any automatic color correction or color management options that may be included in the scanner software. If automatic color management cannot be disabled, the scanner is not suitable for this application. Follow the recommended procedures of the color calibration software to create and export an ICC color profile for the scanner. The color calibration software compares the acquired IT8 target image with the corresponding reference file to create and export an ICC color profile for the scanner, which will be applied within the image analysis program to correct the colors of subsequent output images.

[0490] Open the scanner cover and carefully place the sample flat in the center of the scanner glass, with the outer surface of the sample oriented towards the glass. Before acquiring the image, back the sample with a black glass tile (P / N 11-0050-30, purchased from HunterLab (Reston, VA), or equivalent). Acquire an image of the visually distinguishable area and import the image into the image analysis software in 24-bit color at a resolution of 150 dpi (approx. 5.9 pixels / mm) in reflection mode. The ICC color profile is assigned to the image that produces a color-corrected RGB image. Then, the RGB image is converted to 8-bit grayscale according to the weighted sum of the following R, G, and B components.

[0491] Gray level = 0.2989 × R + 0.5870 × G + 0.1140 × B

[0492] Smooth and blur the image by applying a 2D Gaussian filter, where the standard deviation of the Gaussian distribution (sigma) is equal to 4, and the borders are filled with repeating border elements. The calibrated and blurred grayscale image is saved in an uncompressed format (such as a TIFF file) before analysis. Repeat this procedure for each of the six samples to obtain six repeated images of the same visually distinguishable area.

[0493] Open each of the six calibrated and blurred grayscale images in the image analysis software. Measure and record the arithmetic mean grayscale value of each of the six images. Calculate the standard deviation of the recorded mean values and report it as the grayscale variation, accurate to 0.1.

[0494] Example / Combination :

[0495] 1. A nonwoven fabric, the nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable area on at least one of the first surface and the second surface, the first visually distinguishable area having a pattern of three-dimensional feature structures, each of the three-dimensional feature structures defining a micro-region including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different;

[0496] Wherein the first visually distinguishable region has a gray level variation between about 0.1 and about 10.0, as measured according to the method for testing gray level variation within an article as defined herein.

[0497] 2. The nonwoven fabric according to paragraph 1, wherein the gray level variation is between about 0.1 and about 7.0.

[0498] 3. The nonwoven fabric according to paragraph 1, wherein the gray level variation is between about 0.1 and about 4.1.

[0499] 4. The nonwoven fabric according to paragraph 1, wherein the gray level variation is less than 4.2.

[0500] 5. A package comprising a plurality of disposable absorbent articles, wherein each disposable absorbent article comprises a nonwoven fabric, wherein each nonwoven fabric comprises a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, and the values of the intensity characteristics of the first region and the second region being different;

[0501] Wherein the first visually distinguishable regions of the nonwoven fabrics of the plurality of disposable articles of the package have a gray level variation between about 0.1 and about 10.0, as measured according to the method for testing gray level variation between articles as defined herein.

[0502] 6. The package according to paragraph 5, wherein the disposable absorbent article is a diaper, a feminine hygiene pad or an adult incontinence product.

[0503] 7. The package according to paragraph 5, wherein the nonwoven fabric is selected from topsheet and backsheet nonwovens.

[0504] 8. The package according to paragraph 5, wherein the nonwoven fabric is a topsheet.

[0505] 9. The package according to paragraph 5, wherein the gray level variation is between about 0.1 and about 5.0

[0506] Between.

[0507] 10. The package according to paragraph 5, wherein the gray level variation is between about 0.1 and about 3.0

[0508] Between.

[0509] 11. The package according to paragraph 5, wherein the gray level change is less than 1.8.

[0510] 12. A nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional characteristic structure, each three-dimensional characteristic structure in the three-dimensional characteristic structure defining a microzone including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different;

[0511] wherein the first visually distinguishable zone has a Haralick maximum average contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0512] 13. The nonwoven fabric according to paragraph 12, wherein the Haralick maximum average contrast value is between about 100 and about 600.

[0513] 14. The nonwoven fabric according to paragraph 12, wherein the Haralick maximum average contrast value is greater than 80.

[0514] 15. A nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional characteristic structure, each three-dimensional characteristic structure in the three-dimensional characteristic structure defining a microzone including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different;

[0515] wherein the first visually distinguishable zone has a Haralick maximum 90° contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0516] 16. The nonwoven fabric according to paragraph 15, wherein the Haralick maximum 90° contrast value is between about 100 and about 600.

[0517] 17. The nonwoven fabric according to paragraph 15, wherein the Haralick maximum 90° contrast value is greater than 80.

[0518] 18. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a microzone including a first region and a second region, values of intensity characteristics of the first region and the second region having a difference;

[0519] wherein the first visually distinguishable zone has a Haralick maximum 0° contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0520] 19. The nonwoven fabric according to paragraph 18, wherein the Haralick maximum 0° contrast value is between about 100 and about 600.

[0521] 20. The nonwoven fabric according to paragraph 18, wherein the Haralick maximum 0° contrast value is greater than 80.

[0522] 21. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a microzone including a first region and a second region, values of intensity characteristics of the first region and the second region having a difference;

[0523] wherein the first visually distinguishable zone has a gray level variation between about 0.1 and about 10.0, as measured according to the gray level variation test method within the article as defined herein; and

[0524] wherein the first visually distinguishable zone has a Haralick maximum average contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0525] 22. The nonwoven fabric according to paragraph 21, wherein the gray level variation is between about 0.1 and about 7.0.

[0526] 23. The nonwoven fabric according to paragraph 21, wherein the gray level variation is between about 0.1 and about 4.1.

[0527] 24. The nonwoven fabric according to paragraph 21, wherein the gray level variation is less than 4.2.

[0528] 25. The nonwoven fabric according to paragraph 21, wherein the Haralick maximum average contrast value is between about 100 and about 600.

[0529] 26. The nonwoven fabric according to paragraph 21, wherein the Haralick maximum average contrast value is greater than 80.

[0530] 27. A package comprising a plurality of disposable absorbent articles, wherein each disposable absorbent article comprises a nonwoven fabric, wherein each nonwoven fabric comprises a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, and values of intensity characteristics of the first region and the second region being different;

[0531] wherein the first visually distinguishable region of the nonwoven fabric of the plurality of disposable articles of the package has a gray level variation between about 0.1 and about 10.0, as measured by the inter-product gray level variation test method defined herein;

[0532] wherein the first visually distinguishable region on the nonwoven fabric of at least one of the disposable absorbent articles of the package has a Haralick maximum average contrast value between about 80 and about 750, as measured by the Haralick maximum contrast test method defined herein.

[0533] 28. The package according to paragraph 27, wherein the disposable absorbent article is a diaper, a feminine hygiene pad or an adult incontinence product.

[0534] 29. The package according to paragraph 27, wherein the nonwoven fabric is a topsheet.

[0535] 30. The package according to paragraph 27, wherein the nonwoven fabric is a backsheet.

[0536] 31. The package according to paragraph 27, wherein the gray level variation is between about 0.1 and about 5.0.

[0537] 32. The package according to paragraph 27, wherein the gray level variation is between about 0.1 and about 3.0.

[0538] 33. The package according to paragraph 27, wherein the gray level variation is less than 1.8.

[0539] 34. The package according to paragraph 27, wherein the Haralick maximum average contrast value of the first disposable article is between about 100 and about 600.

[0540] 35. The package according to paragraph 27, wherein the Haralick maximum average contrast value of the first disposable article is greater than 80.

[0541] 36. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a microzone including a first region and a second region, values of intensity characteristics of the first region and the second region being different, wherein at least one of the microzones has a gray-level contrast slope between about 5.0 and about 35.0, as measured according to the gray-level contrast slope test method defined herein.

[0542] 37. The nonwoven fabric according to paragraph 36, wherein the gray-level contrast slope is between about 11.0 and about 25.0.

[0543] 38. The nonwoven fabric according to paragraph 36, wherein the gray-level contrast slope is greater than 11.0.

[0544] 39. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a microzone including a first region and a second region, values of intensity characteristics of the first region and the second region being different, wherein the first visually distinguishable zone has a periodic Haralick wave response, as determined according to the Haralick maximum contrast test method defined herein.

[0545] 40. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a microzone including a first region and a second region, values of intensity characteristics of the first region and the second region being different, wherein the intensity characteristic is one or more of the following:

[0546] a. Thickness,

[0547] b. Basis weight, and

[0548] c. Bulk density;

[0549] wherein the first visually distinguishable region has a gray level variation between about 0.1 and about 10.0, as measured according to the method for testing gray level variation within an article as defined herein.

[0550] 41. The nonwoven fabric according to paragraph 40, wherein the gray level variation is between about 0.1 and about 7.0.

[0551] 42. The nonwoven fabric according to paragraph 40, wherein the gray level variation is between about 0.1 and about 4.1.

[0552] 43. The nonwoven fabric according to paragraph 40, wherein the gray level variation is less than 4.2.

[0553] 44. A package, the package comprising a plurality of disposable absorbent articles, wherein each disposable absorbent article comprises a nonwoven fabric, wherein each nonwoven fabric comprises a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a microregion including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristics are one or more of the following

[0554] :

[0555] d. Thickness,

[0556] e. Basis weight, and

[0557] f. Bulk density;

[0558] wherein the first visually distinguishable region of the nonwoven fabrics of the plurality of disposable articles of the package has a gray level variation between about 0.1 and about 10.0, as measured according to the method for testing gray level variation between articles as defined herein.

[0559] 45. The package according to paragraph 44, wherein the disposable absorbent article is a diaper, a feminine hygiene pad or an adult incontinence product.

[0560] 46. The package according to paragraph 44, wherein the nonwoven fabric is a topsheet.

[0561] 47. The package according to paragraph 44, wherein the nonwoven fabric is a backsheet.

[0562] 48. The package according to paragraph 44, wherein the gray level change is between about 0.1 and about

[0563] 5.0.

[0564] 49. The package according to paragraph 44, wherein the gray level change is between about 0.1 and about

[0565] 3.0.

[0566] 50. The package according to paragraph 44, wherein the gray level change is less than 1.8.

[0567] 51. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristics are one or more of the following:

[0568] g. Thickness,

[0569] h. Basis weight, and

[0570] i. Bulk density;

[0571] wherein the first visually distinguishable region has a Haralick maximum average contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0572] 52. The nonwoven fabric according to paragraph 51, wherein the Haralick maximum average contrast value is between about 100 and about 600.

[0573] 53. The nonwoven fabric according to paragraph 51, wherein the Haralick maximum average contrast value is greater than 80.

[0574] 54. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristics are one or more of the following:

[0575] j. Thickness,

[0576] k. Basis weight, and

[0577] l. Bulk density;

[0578] wherein the first visually distinguishable region has a Haralick maximum 90° contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0579] 55. The nonwoven fabric according to paragraph 54, wherein the Haralick maximum 90° contrast value is between about 100 and about 600.

[0580] 56. The nonwoven fabric according to paragraph 54, wherein the Haralick maximum 90° contrast value is greater than 80.

[0581] 57. A nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristic is one or more of the following:

[0582] m. Thickness,

[0583] n. Basis weight, and

[0584] o. Bulk density;

[0585] wherein the first visually distinguishable region has a Haralick maximum 0° contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0586] 58. The nonwoven fabric according to paragraph 57, wherein the Haralick maximum 0° contrast value is between about 100 and about 600.

[0587] 59. The nonwoven fabric according to paragraph 57, wherein the Haralick maximum 0° contrast value is greater than 80.

[0588] 60. A nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristic is one or more of the following:

[0589] p. Thickness,

[0590] q. Basis weight, and

[0591] r. Bulk density;

[0592] wherein said first visually distinguishable region has a gray level variation between about 0.1 and about 10.0, as measured according to the gray level variation test method for articles defined herein; and

[0593] wherein said first visually distinguishable region has a Haralick maximum average contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method defined herein.

[0594] 61. The nonwoven fabric according to paragraph 60, wherein said gray level variation is between about 0.1 and 7.0.

[0595] 62. The nonwoven fabric according to paragraph 60, wherein said gray level variation is between about 0.1 and about 4.1.

[0596] 63. The nonwoven fabric according to paragraph 60, wherein said gray level variation is less than 4.2.

[0597] 64. The nonwoven fabric according to paragraph 60, wherein said Haralick maximum average contrast value is between about 100 and about 600.

[0598] 65. The nonwoven fabric according to paragraph 60, wherein said Haralick maximum average contrast value is greater than 80.

[0599] 66. A package, said package comprising a plurality of disposable absorbent articles, wherein each disposable absorbent article comprises a nonwoven fabric, wherein each nonwoven fabric comprises a first surface and a second surface and at least a first visually distinguishable region on at least one of said first surface and said second surface, said first visually distinguishable region having a pattern of a three-dimensional characteristic structure, each three-dimensional characteristic structure in said three-dimensional characteristic structure defining a micro-region comprising a first region and a second region, values of intensity characteristics of said first region and said second region being different, wherein said intensity characteristics are one or more of the following

[0600] ones:

[0601] a. Thickness,

[0602] b. Basis weight, and

[0603] c. Bulk density;

[0604] The first visually distinguishable region of the nonwoven fabric of the plurality of disposable articles of the package has a gray level change between about 0.1 and about 10.0, as measured by the inter-article gray level change test method as defined herein;

[0605] The first visually distinguishable region on the nonwoven fabric of at least one disposable absorbent article of the disposable absorbent articles of the package has a Haralick maximum average contrast value between about 80 and about 750, as measured by the Haralick maximum contrast test method as defined herein.

[0606] 67. The package according to paragraph 67, wherein the disposable absorbent article is a diaper, a feminine hygiene pad, or an adult incontinence product.

[0607] 68. The package according to paragraph 67, wherein the nonwoven fabric is a topsheet.

[0608] 69. The package according to paragraph 67, wherein the nonwoven fabric is a backsheet.

[0609] 70. The package according to paragraph 67, wherein the gray level change is between about 0.1 and 5.0

[0610] between.

[0611] 71. The package according to paragraph 67, wherein the gray level change is between about 0.1 and about 3.0.

[0612] 72. The package according to paragraph 67, wherein the gray level change is less than 1.8.

[0613] 73. The package according to paragraph 67, wherein the Haralick maximum average contrast value of the first disposable article is between about 100 and about 600.

[0614] 74. The package according to paragraph 67, wherein the Haralick maximum average contrast value of the first disposable article is greater than 80.

[0615] 75. A nonwoven fabric, the nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure of the three-dimensional feature structures defining a microregion including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristic is one or more of the following:

[0616] s. Thickness,

[0617] t. Basis weight, and

[0618] u. Bulk density;

[0619] wherein at least one of the microregions has a gray level contrast slope between about 10.0 and about 30.0, as measured according to the gray level contrast slope test method defined herein.

[0620] 76. The nonwoven fabric according to paragraph 75, wherein the gray level contrast slope is between about 11.0 and about 25.0.

[0621] 77. The nonwoven fabric according to paragraph 75, wherein the gray level contrast slope is greater than 11.0.

[0622] 78. A nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each of the three-dimensional feature structures in the three-dimensional feature structure defining a microregion including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristic is one or more of the following:

[0623] v. Thickness,

[0624] w. Basis weight, and

[0625] x. Bulk density;

[0626] wherein the first visually distinguishable region has a periodic Haralick response

[0627] as measured according to the Haralick maximum contrast test method defined herein. 79. A nonwoven fabric comprising a first surface and a second surface and

[0628] at least a first visually distinguishable region and a second visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region and the second visually distinguishable region having a pattern of a three-dimensional feature structure, each of the three-dimensional feature structures in the three-dimensional feature structure defining a microregion including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different;

[0629] At least one of the first visually distinguishable region and the second visually distinguishable region has a gray scale change between about 0.1 and about 10.0, as measured according to the in - article gray scale change test method defined herein.

[0630] 80. The non - woven fabric according to paragraph 79, wherein the gray scale change is between about 0.1 and 7.0.

[0631] 81. The non - woven fabric according to paragraph 79, wherein the gray scale change is between about 0.1 and about 4.1.

[0632] 82. The non - woven fabric according to paragraph 79, wherein the gray scale change is less than 4.2.

[0633] 83. A package comprising a plurality of disposable absorbent articles, each disposable absorbent article comprising a non - woven fabric, each non - woven fabric comprising a first surface and a second surface and at least a first visually distinguishable region and a second visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region and the second visually distinguishable region having a pattern of a three - dimensional feature structure, each three - dimensional feature structure in the three - dimensional feature structure defining a micro - region including a first region and a second region, and the values of the intensity characteristics of the first region and the second region being different;

[0634] wherein the first visually distinguishable region of the non - woven fabric of the plurality of disposable articles of the package has a gray scale change between about 0.1 and about 10.0, as measured according to the between - article gray scale change test method defined herein; and

[0635] wherein the second visually distinguishable region of the non - woven fabric of the plurality of disposable articles of the package has a gray scale change between about 0.1 and about 10.0, as measured according to the between - article gray scale change test method defined herein.

[0636] 84. The package according to paragraph 83, wherein the disposable absorbent article is a diaper, a feminine hygiene pad or an adult incontinence product.

[0637] 85. The package according to paragraph 83, wherein the non - woven fabric is selected from a topsheet and a backsheet.

[0638] 86. The package according to paragraph 83, wherein the non - woven fabric is a topsheet.

[0639] 87. The package according to paragraph 83, wherein the gray scale change is between about 0.1 and 5.0

[0640] between

[0641] 88. The package according to paragraph 83, wherein the gray level change is between about 0.1 and about 4.1.

[0642] 89. The package according to paragraph 83, wherein the gray level change is less than 4.2.

[0643] 90. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable region and a second visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region and the second visually distinguishable region having a pattern of a three-dimensional characteristic structure, each three-dimensional characteristic structure in the three-dimensional characteristic structure defining a micro-region including a first region and a second region, the values of the intensity characteristics of the first region and the second region having a difference;

[0644] wherein the first visually distinguishable region and the second visually distinguishable region have a Haralick maximum average contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method defined herein.

[0645] 91. The nonwoven fabric according to paragraph 90, wherein the Haralick maximum average contrast value is between about 100 and about 600.

[0646] 92. The nonwoven fabric according to paragraph 90, wherein the Haralick maximum average contrast value is greater than 80.

[0647] 93. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable region and a second visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region and the second visually distinguishable region having a pattern of a three-dimensional characteristic structure, each three-dimensional characteristic structure in the three-dimensional characteristic structure defining a micro-region including a first region and a second region, the values of the intensity characteristics of the first region and the second region having a difference;

[0648] wherein the first visually distinguishable region and the second visually distinguishable region have a Haralick maximum 90° contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method defined herein.

[0649] 94. The nonwoven fabric according to paragraph 93, wherein the Haralick maximum 90° contrast value is between about 100 and about 600.

[0650] 95. The nonwoven fabric according to paragraph 93, wherein the Haralick maximum 90° contrast value is greater than 80.

[0651] 96. A nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable region and a second visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, and the values of the intensity characteristics of the first region and the second region being different;

[0652] wherein the first visually distinguishable region and the second visually distinguishable region have a Haralick maximum 0° contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0653] 97. The nonwoven fabric according to paragraph 96, wherein the Haralick maximum 0° contrast value is between about 100 and about 600.

[0654] 98. The nonwoven fabric according to paragraph 96, wherein the Haralick maximum 0° contrast value is greater than 80.

[0655] 99. A nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable region and a second visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, and the values of the intensity characteristics of the first region and the second region being different;

[0656] wherein the first visually distinguishable region and the second visually distinguishable region have a gray level change between about 0.1 and about 10.0, as measured according to the gray level change test method within the article as defined herein; and

[0657] wherein the first visually distinguishable region and the second visually distinguishable region have a Haralick maximum average contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein.

[0658] 100. The nonwoven fabric according to paragraph 99, wherein the gray level change is between about 0.1 and 7.0.

[0659] 101. The nonwoven fabric according to paragraph 99, wherein the gray level change is between about 0.1 and about 4.1.

[0660] 102. The nonwoven fabric according to paragraph 99, wherein the gray level change is less than 4.2.

[0661] 103. The nonwoven fabric according to paragraph 99, wherein the Haralick maximum average contrast value is between about 100 and about 600.

[0662] 104. The nonwoven fabric according to paragraph 99, wherein the Haralick maximum average contrast value is greater than 80.

[0663] 105. A package comprising a plurality of disposable absorbent articles, wherein each

[0664] disposable absorbent article comprises a nonwoven fabric, and wherein each nonwoven fabric comprises a first surface and a second surface and at least a first visually distinguishable zone and a second visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone and the second visually distinguishable zone having a pattern of three-dimensional feature structures, each of the three-dimensional feature structures in the three-dimensional feature structures defining a microzone comprising a first region and a second region, and the values of the intensity characteristics of the first region and the

[0665] second region having a difference;

[0666] wherein the first visually distinguishable zone of the nonwoven fabric of the plurality of disposable articles of the package has a gray level change between about 0.1 and about 10.0, as measured according to the inter-product gray level change test method defined herein;

[0667] wherein the second visually distinguishable zone of the nonwoven fabric of the plurality of disposable articles of the package has a gray level change between about 0.1 and about 10.0, as measured according to the inter-product gray level change test method defined herein;

[0668] wherein the first visually distinguishable zone on the nonwoven fabric of at least one of the disposable absorbent articles of the package has a Haralick maximum average contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method defined herein.

[0669] 106. The package according to paragraph 105, wherein the disposable absorbent article is a diaper, a feminine hygiene pad or an adult incontinence product.

[0670] 107. The package according to paragraph 105, wherein the nonwoven fabric is a topsheet.

[0671] 108. The package according to paragraph 105, wherein the nonwoven fabric is a backsheet.

[0672] 109. The package according to paragraph 105, wherein the gray level change is between about 0.1 and 7.0.

[0673] 110. The package according to paragraph 105, wherein the gray level change is between about 0.1 and about 4.1.

[0674] 111. The package according to paragraph 105, wherein the gray level change is less than 4.2.

[0675] 112. The package according to paragraph 105, wherein the Haralick maximum average contrast value of the first disposable article is between about 100 and about 600.

[0676] 113. The package according to paragraph 105, wherein the Har

[0677] alick maximum average contrast value of the first disposable article is greater than 80.

[0678] 114. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable region and a second visually distinguishable region on at least one of the first surface and the second surface, the first visually distinguishable region having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a micro-region including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristic is one or more of the following:

[0679] y. Thickness,

[0680] z. Basis weight, and

[0681] aa. Bulk density;

[0682] wherein the nonwoven fabric has one or more of the following:

[0683] 1. The first visually distinguishable region has a gray level change between about 0.1 and about 10.0, as measured by the method for measuring gray level change within an article as defined herein;

[0684] 2. The first visually distinguishable region has a Haralick maximum average contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein;

[0685] 3. The first visually distinguishable region has a Haralick maximum 90° contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein;

[0686] 4. The first visually distinguishable region has a Haralick maximum 0° contrast value between about 80 and about 750, as measured according to the Haralick maximum contrast test method as defined herein; and

[0687] 5. At least one of the micro-regions has a gray-level contrast slope between about 5.0 and about 35.0, as measured according to the gray-level contrast slope test method as defined herein.

[0688] The dimensions and values disclosed herein should not be construed as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to represent the recited value and the range functionally equivalent thereto. For example, a dimension disclosed as "40 mm" is intended to represent "about 40 mm".

[0689] 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 its filing date, 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 invention disclosed or claimed herein, or that it alone or in any combination with any one or more other references teaches, suggests, or discloses any such invention. Further, when any meaning or definition of a term in this invention conflicts with the same term's meaning or definition in a document incorporated by reference, the meaning or definition assigned to the term in this invention shall govern.

[0690] Although specific embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is intended that all such changes and modifications that fall within the scope of the invention be covered by the appended claims.

Claims

1. A nonwoven fabric, the nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a microzone including a first region and a second region, the values of the strength characteristics of the first region and the second region having a difference, wherein, as measured by the Haralick maximum contrast test method, the first visually distinguishable zone has a periodic Haralick wave response, and wherein the periodic Haralick wave response is only applicable to the Haralick maximum 90° or 0° contrast values. Wherein the Haralick maximum contrast test method comprises: Based on Haralick texture features, calculating contrast texture features from a calculated gray-level co-occurrence matrix, where the gray-level co-occurrence matrix is a list of the frequencies of different combinations of pixel brightness values appearing in an image, normalizing the gray-level co-occurrence matrix such that the sum of its elements equals 1, and each element (i,j) in the normalized gray-level co-occurrence matrix is the joint probability occurrence of pixel pairs having gray-level values i and j in the image with a defined spatial relationship, direction, and distance, and calculating the contrast texture features using the following formula: where i is the row number, j is the column number, and p(i,j) is the probability value recorded for the element (i,j) in the gray-level co-occurrence matrix. Obtaining the Haralick maximum contrast value by analyzing a calibrated and blurred gray-level image using image analysis software, using a symmetric gray-level co-occurrence matrix with 256 gray levels, calculating Haralick contrast values in the range of 1 to 150 for each integer pixel distance between an interested pixel and its adjacent pixels in the 0° and 90° directions, for the 150 Haralick contrast values obtained in the 0° direction, the maximum contrast value is identified and rounded to the nearest integer, reported as the Haralick maximum 0° contrast value, and for the 150 Haralick contrast values obtained in the 90° direction, the maximum contrast value is identified and rounded to the nearest integer, reported as the Haralick maximum 90° contrast value.

2. The nonwoven fabric according to claim 1, wherein the strength characteristic is basis weight.

3. The nonwoven fabric according to claim 1, wherein the strength characteristic is bulk density.

4. An absorbent article, the absorbent article comprising the nonwoven fabric according to claim 1.

5. The absorbent article according to claim 4, wherein the nonwoven fabric is a topsheet.

6. The absorbent article according to claim 4, wherein the nonwoven fabric is an outer cover.

7. A nonwoven fabric, the nonwoven fabric comprising a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional feature structure, each three-dimensional feature structure in the three-dimensional feature structure defining a microzone including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different, wherein the intensity characteristic is one or more of the following: a. Thickness; b. Basis weight; and c. Bulk density; wherein, as measured by the Haralick maximum contrast test method, the first visually distinguishable zone has a Haralick maximum 0-degree contrast value between 80 and 750, wherein the Haralick maximum contrast test method comprises: Based on Haralick texture features, calculating contrast texture features from a calculated gray-level co-occurrence matrix, wherein the gray-level co-occurrence matrix is a list of the frequencies of different combinations of pixel brightness values that appear in an image, normalizing the gray-level co-occurrence matrix such that the sum of its elements is equal to 1, each element (i,j) in the normalized gray-level co-occurrence matrix being the joint probability occurrence of pixel pairs having gray-level values i and j with defined spatial relationships, directions, and distances in the image, and calculating the contrast texture features using the following formula: where i is the row number, j is the column number, and p(i,j) is the probability value recorded for the element (i,j) in the gray-level co-occurrence matrix, Obtaining the Haralick maximum contrast value by analyzing a calibrated and blurred gray-level image using image analysis software, using a symmetric gray-level co-occurrence matrix with 256 gray levels, calculating Haralick contrast values in the range of 1 to 150 for each integer pixel distance between an interested pixel and its adjacent pixels in the 0° direction, and for the 150 Haralick contrast values obtained in the 0° direction, the maximum contrast value is identified and rounded to the nearest integer and reported as the Haralick maximum 0° contrast value.

8. The nonwoven fabric according to claim 7, wherein the Haralick maximum 0-degree contrast value is between 100 and 600.

9. The nonwoven fabric according to claim 7, wherein the Haralick maximum 0-degree contrast value is greater than 80.

10. The nonwoven fabric according to claim 7, wherein the intensity characteristic is basis weight.

11. The nonwoven fabric according to claim 7, wherein the intensity characteristic is bulk density.

12. An absorbent article, the absorbent article comprising the nonwoven fabric according to claim 7.

13. A nonwoven fabric, the nonwoven fabric including a first surface and a second surface and at least a first visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional feature structure, each of the three-dimensional feature structures in the three-dimensional feature structure defining a microzone including a first region and a second region, values of intensity characteristics of the first region and the second region having a difference, wherein the intensity characteristic is one or more of the following: a. Thickness; b. Basis weight; and c. Bulk density; wherein, as measured according to the Haralick maximum contrast test method, the first visually distinguishable zone has a periodic Haralick wave response, wherein the periodic Haralick wave response is only applicable to the Haralick maximum 90° or 0° contrast values, wherein the Haralick maximum contrast test method comprises: calculating contrast texture features from a calculated gray-level co-occurrence matrix based on Haralick texture features, wherein the gray-level co-occurrence matrix is a list of the frequencies of different combinations of pixel brightness values appearing in an image, normalizing the gray-level co-occurrence matrix such that the sum of its elements is equal to 1, each element (i,j) in the normalized gray-level co-occurrence matrix being the joint probability occurrence of pixel pairs having gray-level values i and j in the image with a defined spatial relationship, direction, and distance, calculating the contrast texture features using the following formula: where i is the row number, j is the column number, and p(i,j) is the probability value recorded for the element (i,j) in the gray-level co-occurrence matrix, obtaining the Haralick maximum contrast value by analyzing a calibrated and blurred gray-level image using image analysis software, using a symmetric gray-level co-occurrence matrix with 256 gray levels, calculating Haralick contrast values in the range of 1 to 150 for each integer pixel distance between an interested pixel and its adjacent pixels in the 0° and 90° directions, for the 150 Haralick contrast values obtained in the 0° direction, the maximum contrast value is identified and rounded to the nearest integer, reported as the Haralick maximum 0° contrast value, for the 150 Haralick contrast values obtained in the 90° direction, the maximum contrast value is identified and rounded to the nearest integer, reported as the Haralick maximum 90° contrast value.

14. The nonwoven fabric according to claim 13, wherein the intensity characteristic is the basis weight.

15. The nonwoven fabric according to claim 13, wherein the intensity characteristic is the bulk density or the thickness.

16. An absorbent article, the absorbent article including the nonwoven fabric according to claim 13.

17. The absorbent article according to claim 16, wherein the nonwoven fabric is a topsheet.

18. The absorbent article according to claim 16, wherein the nonwoven fabric is an outer cover.

19. A nonwoven fabric, the nonwoven fabric comprising a first surface and a second surface and a first visually distinguishable zone and a second visually distinguishable zone on at least one of the first surface and the second surface, the first visually distinguishable zone having a pattern of a three-dimensional characteristic structure, each three-dimensional characteristic structure in the three-dimensional characteristic structure defining a microzone including a first region and a second region, the values of the intensity characteristics of the first region and the second region being different; wherein, as measured according to the Haralick maximum contrast test method, the first visually distinguishable zone and the second visually distinguishable zone have a Haralick maximum 0-degree contrast value between 80 and 750; wherein the Haralick maximum contrast test method comprises: Based on the Haralick texture features, calculating the contrast texture features from the calculated gray-level co-occurrence matrix, where the gray-level co-occurrence matrix is a list of the frequencies of different combinations of pixel brightness values that appear in the image, normalizing the gray-level co-occurrence matrix such that the sum of its elements is equal to 1, and each element (i, j) in the normalized gray-level co-occurrence matrix is the joint probability occurrence of pixel pairs having gray-level values i and j with defined spatial relationships, directions, and distances in the image, and calculating the contrast texture features using the following formula: where i is the row number, j is the column number, and p(i, j) is the probability value recorded for the element (i, j) in the gray-level co-occurrence matrix; Obtaining the Haralick maximum contrast value by analyzing the calibrated and blurred gray-level image using image analysis software, using a symmetric gray-level co-occurrence matrix with 256 gray levels, calculating the Haralick contrast values in the range of 1 to 150 for each integer pixel distance between the pixel of interest and its adjacent pixels in the 0° direction, and for the 150 Haralick contrast values obtained in the 0° direction, the maximum contrast value is identified and rounded to the nearest integer and reported as the Haralick maximum 0° contrast value.

20. The nonwoven fabric according to claim 19, wherein the Haralick maximum 0-degree contrast value is between 100 and 600.

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