Absorbent article with laminated bond pattern

Abstract

An absorbent article includes first and second waist regions and a crotch region disposed between the first and second waist regions. The absorbent article includes a chassis having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. Comprising a laminate is joined to the chassis. The laminate is an ultrasonically bonded laminate of an elastomeric layer and a nonwoven layer. The bond pattern includes a plurality of discrete primary ultrasonic bonds and a plurality of secondary ultrasonic bonds. The primary bond permanently attaches a layer of the laminate, and the secondary bond releasably attaches a layer of the laminate. The secondary bond is released when the laminate extends in the stretch direction.

Description

Technical Field

[0001] The present disclosure relates to absorbent articles having a stretch laminate with a bond pattern. More particularly, the present disclosure relates to a stretch laminate comprising one or more permanent bonds and one or more releasable bonds. Background Art

[0002] Elastomeric laminates are used in a variety of products, including absorbent articles (e.g., diapers, incontinence products, feminine hygiene pads). Such laminates typically include an elastomeric layer that provides extensibility to the laminate and an outer layer that is less stretchable but suitable for providing durability and desired tactile properties. In this way, the laminate allows the components of the article to intimately and comfortably contact the wearer while providing desired appearance qualities.

[0003] The layers of an elastomeric laminate can be combined in a variety of ways, including, for example, heat bonding to gather the laminate configuration, where wrinkles are present in one or more layers. When bonding the layers, manufacturers must balance considerations such as strength, ductility, and comfort. However, these considerations often offset each other. For example, while more bonding can provide greater laminate strength, it may undermine ductility. Similarly, a more elastic material can provide greater tear resistance, but less softness or breathability.

[0004] Therefore, there is a need to balance the strength, comfort and extensibility of stretch laminates. It is also necessary to provide a bonding pattern that maximizes the desired lamination properties while minimizing undesirable properties. In addition, it is necessary to convey the lamination properties through the bonding pattern. Summary of the invention

[0005] The absorbent article comprises: a top sheet, a back sheet and an absorbent core disposed between the top sheet and the back sheet. The absorbent core comprises at least one elastic ear piece having a laminate. The laminate comprises an elastomeric layer and a nonwoven layer. The laminate may comprise a plurality of discrete primary ultrasonic bonds and a plurality of secondary ultrasonic bonds. The elastomeric layer and the nonwoven layer remain permanently attached by the primary ultrasonic bonds and are releasably attached by the secondary ultrasonic bonds. When the laminate extends in a stretching direction greater than about 5 mm, the secondary ultrasonic bonds are released.

[0006] The absorbent article comprises: a top sheet, a back sheet and an absorbent core arranged between the top sheet and the back sheet. The absorbent core comprises at least one elastic ear piece having a laminate. The laminate comprises an elastomeric layer and a nonwoven layer. The laminate may comprise a plurality of discrete primary ultrasonic bonds and a plurality of secondary ultrasonic bonds. The elastomeric layer and the nonwoven layer remain permanently attached by the primary ultrasonic bonds and are releasably attached by the secondary ultrasonic bonds. When the laminate is extended by a force of at least 0.5 N / in in the stretching direction, the secondary ultrasonic bonds are released.

[0007] The absorbent article comprises: a top sheet, a back sheet and an absorbent core arranged between the top sheet and the back sheet. The absorbent core comprises at least one component having a laminate. The laminate comprises an elastomeric layer and a nonwoven layer. The laminate may comprise a plurality of discrete primary ultrasonic bonds and a plurality of secondary ultrasonic bonds. The elastomeric layer and the nonwoven layer remain permanently attached by the primary ultrasonic bonds and are releasably attached by the secondary ultrasonic bonds. When the laminate extends in a stretching direction greater than about 5 mm, the secondary ultrasonic bonds are released. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above and other features and advantages of the present disclosure and the manner in which they are obtained will become more apparent, and the present disclosure itself will be better understood by referring to the following description of exemplary forms of the present disclosure made in conjunction with the accompanying drawings.

[0009] Figure 1 is an exploded perspective view of an exemplary laminate according to a non-limiting embodiment of the present disclosure.

[0010] Figure 2A is a plan view of an exemplary laminate according to a non-limiting embodiment of the present disclosure.

[0011] Figure 2B is a plan view of an exemplary laminate according to a non-limiting embodiment of the present disclosure.

[0012] Figure 2C is a plan view of an exemplary laminate according to a non-limiting embodiment of the present disclosure.

[0013] Figure 2D is a schematic diagram of a stretch laminate subjected to lateral tension.

[0014] Figure 2E to Figure 2G is a schematic illustration of a stretch laminate having various types of releasable bonds after being subjected to a lateral tensile force.

[0015] FIG. 3A to FIG. 3C is a schematic diagram of an exemplary pattern of a laminate according to a non-limiting embodiment of the present disclosure.

[0016] FIG. 4A to FIG. 4D is a schematic diagram of an exemplary pattern of a laminate according to a non-limiting embodiment of the present disclosure.

[0017] Figure 5A and Figure 5B is a schematic diagram of an exemplary pattern according to a non-limiting embodiment of the present disclosure.

[0018] Figure 6 is a cross-sectional view of a laminate according to a non-limiting embodiment of the present disclosure.

[0019] Figure 7 is a plan view of an exterior surface of a laminate according to a non-limiting embodiment of the present disclosure.

[0020] Figure 8 is a plan view of an exemplary laminate according to a non-limiting embodiment of the present disclosure.

[0021] Fig. 9 is a plan view of another exemplary laminate according to a non-limiting embodiment of the present disclosure.

[0022] Fig.10 is a schematic plan view of an exemplary absorbent article according to one non-limiting embodiment of the present disclosure. The absorbent article is shown in a flat, uncontracted state.

[0023] Fig.11A is a schematic perspective view of an exemplary embodiment of an absorbent pant.

[0024] Fig. 11B is a schematic plan view of an exemplary embodiment of an absorbent pant front body structure prior to the front section and the front section of the joining belt.

[0025] Fig.12 is a schematic perspective view of a package according to one embodiment of the present disclosure.

[0026] Fig.13 is an illustration of a bonding pattern according to one embodiment of the present disclosure.

[0027] Fig.14 is an illustration of a corrugated laminate on a rigid surface according to one embodiment of the present disclosure. DETAILED DESCRIPTION

[0028] definition

[0029] "Absorbent article" refers to devices that absorb and contain body exudates, and more specifically, refers to devices that fit against or in proximity to the wearer's body to absorb and contain the various exudates discharged from the body. Exemplary absorbent articles include diapers, training pants, pull-on diapers (i.e., diapers with preformed waist and leg openings such as shown in U.S. Pat. No. 6,120,487), refastenable diapers or pant diapers, incontinence briefs and undergarments, diaper holders and liners, feminine hygiene undergarments such as panty liners, absorbent inserts, and the like.

[0030] "Elastic", "elastomeric" and "elastically extensible" refer to the ability of a material or portion of a material to stretch at least 50% without rupture or breakage under a given load, and the elastic material or component exhibits at least 70% recovery (i.e., having less than 30% permanent deformation) in one direction of a hysteresis test as described herein when the load is released. Stretching is sometimes referred to as strain, percent strain, engineering strain, stretch ratio, or elongation, which together with recovery and permanent deformation can each be determined according to the "hysteresis test" described in more detail below. Non-elastic materials are referred to as inelastic. As used herein, a laminate is elastic if at least 20% of the area of ​​the laminate meets the elastic definition herein. In this case, the area percentage of the laminate is determined when the laminate is in a fully stretched state.

[0031] "Extensible" means the ability to stretch or elongate (without rupturing or breaking) at least 50% according to step 5(a) of the hysteresis test herein. As used herein, a laminate is extensible if at least 20% of the area of ​​the laminate meets the definition of extensible herein. In this case, the area percentage of the laminate is determined when the laminate is in a fully stretched state. If the laminate does not meet the definition of elasticity above, but does meet the definition of extensible provided in this paragraph, the laminate is an extensible laminate.

[0032] "Fully stretched" with respect to a laminate means that (1) for a corrugated laminate, the laminate is fully stretched when the corrugations are substantially flattened by stretching the laminate while ensuring that the inelastic substrate of the laminate is not plastically deformed, and (2) for a laminate without corrugations, the laminate is considered to be fully stretched without any material extension (i.e., a non-corrugated laminate is fully stretched in its relaxed state). "Relaxed" with respect to a laminate means that at rest, there are substantially no external forces acting on the laminate other than gravity.

[0033] A "unit" is the smallest building block of a pattern, whose geometric arrangement defines the characteristic image of the pattern and whose repetition in space is necessary to reconstruct the pattern. A pattern may be formed from one or more units. A "repeating unit" is a unit that occurs multiple times within a pattern; the unit may be rotated, mirrored, or otherwise reoriented.

[0034] "Closed cell" means a cell having a recognizable shape with a perimeter formed by at least 5 bonds substantially surrounding an area without permanent bonds. The perimeter may be formed by discontinuous bonds. For example, discrete bonds that are small enough and / or close together so that an observer sees a shape that is substantially surrounded by the perimeter. Closed cell cells may share bonding sites with each other to form closed cells.

[0035] "Releasable bond" in relation to a laminate means that the bond will release when the laminate is stretched from a relaxed state of the laminate in the direction of stretch of the application. Releasing includes at least partial separation of the bond. For example, one or more fibers of the nonwoven portion of the laminate may remain bonded at the bond site as the laminate is extended. However, while these one or more fibers remain bonded, the bond site will be considered to be released.

[0036] According to the Laminate Extension Test Method, a "permanent bond" with respect to a laminate means that the bond will remain intact when the laminate is stretched at least 15 mm in the cross direction from the laminate's relaxed state.

[0037] "Joined" refers to configurations in which one element is directly secured to another element by being directly attached to the other element; it also refers to configurations in which one element is indirectly secured to another element by being attached to an intermediate member which is then attached to the other element.

[0038] Overview

[0039] like Figure 1 As shown, laminate 10 includes a first cover layer 12 and an elastomeric layer 14. The laminate may include a second cover layer 16, and the elastomeric layer 14 may be sandwiched between the first cover layer and the second cover layer. The cover layer material may be non-elastic. Additional layers may be included. The layers may be non-woven, non-elastic, elastic, or extensible. The laminate may be extensible. In certain embodiments, the laminate is elastomeric. Two or more laminate layers may be joined by a plurality of bonding portions 30, such as Figure 2A As shown. The bonding portion can be an ultrasonic bond 31, which can join the nonwoven layer through the elastomeric layer. The ultrasonically bonded laminate can be formed by any suitable method, including but not limited to those described in commonly assigned U.S. Patents 10,568,775, 10,568,776 and 10,575,993. The bonding portion can be any suitable shape or size so that two or more laminate layers are joined.

[0040] like Figures 2A to 2C As shown, the laminate may include a plurality of bonds 30, which may be ultrasonic bonds 31. The plurality of bonds may be arranged in a bonding pattern. The bonding pattern may include a plurality of bonds arranged in a grid configuration or a shaped configuration such that a group of bonds form one or more shapes. For example, Figure 2AAs shown, the laminate includes a first bond pattern 200. The first bond pattern 200 includes closed cell cells 204. The laminate may include one or more bond patterns, and the bond patterns may be different.

[0041] According to the bonding size test method of this paper, the bonding of bonding pattern can comprise that about 0.1mm is about 15mm or about 1.2mm is about 10mm or about 1.5mm is about 5mm or is less than the bonding separation distance of about 5mm.According to the bonding size test method, the bonding of each in permanent bonding portion and releasable bonding portion can have the bonding size of 0.5mm to 10mm or about 0.7mm to 3mm in one or more directions.The size of permanent bonding portion can be greater than the size of releasable bonding portion.Permanent bonding portion and releasable bonding portion can have any shape, such as rectangle, circle, hexagon, ellipse, rhombus or any other shape that allows laminate to bond.

[0042] refer to Figure 2B , the bonding pattern 200 may be a plurality of bonding portions 30 arranged in a grid configuration. Figure 2C As shown, the bonding pattern 200 can be a plurality of bonding portions 30 arranged in an offset configuration so that the bonding row is offset from the adjacent row of the bond. It should be understood that the bonding pattern can be an irregular pattern, and the bonding density within the bonding pattern can vary in various areas of the laminate. In addition, multiple bonds may not form a bonding pattern, but may be spaced unevenly on the laminate.

[0043] In addition to the above, the bonding pattern 200 may include a plurality of discrete primary bonds 30 (also referred to herein as permanent bonds) and a plurality of secondary bonds 32 (also referred to herein as releasable bonds). The primary ultrasonic bonds may allow the laminate 10 to be permanently attached in the region of the primary bonds 30. The secondary bonds 32 may allow these bonds to be released when the laminate is extended in the stretching direction, thereby allowing two or more layers of the laminate to be separated. The primary bonds 30 may be permanent bonds 34, and the secondary bonds may be releasable bonds 36. The releasable bonds 36 are configured to bond two or more layers of the laminate 10 together before the bond is released. When the releasable bonds 36 are released, the two or more layers of the laminate are partially or completely separated. The releasable bonds 36 may be configured to release when the laminate is extended in one or more directions. For example, the laminate may be an elastic ear. Before the elastic ear is stretched, the releasable bonds attach each layer of the elastic ear. When the elastic ear is extended, the releasable bond 36 is released, thereby allowing the two or more layers of the laminate of the elastic ear to separate. The releasable bond 36 allows the laminate to be in a relatively flat state before stretching, and then becomes relatively fluffy and pillow-shaped when the releasable bond is extended and released. The permanent bond 34 prevents the laminate from separating when the laminate is extended. Both the permanent bond and the releasable bond can be ultrasonic bonds. The permanent bond and the releasable bond can be different types of bonds.

[0044] These and other features are described in more detail below.The ears 130 and / or the waistband 180 and / or the leg cuffs of the absorbent article may comprise a laminate as described herein.

[0045] Laminated body

[0046] As described above, laminate 10 includes one or more cover layers 12, 16 and an elastomer layer 14. The cover layer material can be selected from nonwovens, films and / or any other type of web-based materials. In various embodiments, one or more cover layers include nonwovens. Any suitable nonwoven can be used in laminate 10. Suitable nonwovens can have a basis weight of at least about 8gsm, or at least about 10gsm, or at least about 15gsm, or about 40gsm or less, or about 30gsm or less, or about 22gsm or less, or about 17gsm or less, or about 10gsm to about 22gsm. Suitable nonwovens include, but are not limited to, spunbond, spunlaid, meltblown, spunmelt, solvent spinning, electrostatic spinning, carded webs, film fibrillation, melt film fibrillation, airlaid, drylaid, wetlaid, spunlace, spunlace, air-through bonding, and other nonwoven web materials partially or completely formed by polymer fibers, as known in the art. In a non-limiting example, the nonwoven includes a meltblown layer. Additionally or alternatively, the nonwoven may include a spunbond layer. In a non-limiting example, the nonwoven includes two or more spunbond layers. In another non-limiting example, one or more nonwovens may include a SMS (spunbond-meltblown-spunbond) configuration. In another non-limiting example, one or more nonwovens may include a SPS (spunbond-pulp-spunbond) configuration. Alternatively, one or more of the nonwovens in the ear piece of the absorbent article may not contain a meltblown layer. Although it has been found that meltblown layers enhance the bonding in the ear pieces that require adhesive (considering that meltblown layers inhibit adhesive diffusion through porous nonwoven structures), meltblown layers lack strength generally.In some embodiments, nonwoven is substantially composed of spunbond layers.In some non-limiting examples, the first nonwoven and the second nonwoven both comprise at least 2 spunbond layers or 3 or more spunbond layers.The fiber of nonwoven can be engaged by a plurality of hot spot bonding portions as known in the art.In non-limiting examples, nonwoven can comprise about 20% or less bonding area (relative to their hot spot bonding portions).

[0047] The nonwoven web may be formed mainly of polymer fibers. In some examples, suitable nonwoven fiber materials may include, but are not limited to, polymer materials, such as polyolefins, polyesters, polyamides, nylons, or specifically polypropylene (PP), polyethylene (PE), polylactic acid (PLA), polyethylene terephthalate (PET), and / or blends thereof. In some examples, the fiber may be formed of a PP / PE blend, such as described in U.S. Patent No. 5,266,392. The nonwoven fiber may be formed of or may include components as additives or modifiers, such as aliphatic polyesters, thermoplastic polysaccharides, or other biopolymers. Additional available nonwovens, fiber compositions, fiber and nonwoven formation and related methods are described in the following documents: U.S. Patent Nos. 6,645,569, 6,863,933 and 7,112,621, and U.S. Patent Application Serial Nos. 10 / 338,603, 10 / 338,610 and 13 / 005,237. The single fiber of nonwoven layer can be monocomponent or multicomponent (comprising bicomponent).Multicomponent fiber can be bicomponent, has with for example core-skin arrangement or different polymer components arranged side by side.Single component can comprise polyolefin such as polypropylene or polyethylene or their copolymer or polyester, thermoplastic polysaccharide or other biopolymer or recycling or recovery polymer resin.In addition, nonwoven fabric can comprise the blend of different fibers of the type that is for example selected from above-mentioned polymer fiber.

[0048] The individual fibers of the nonwoven fabric may also include natural fibers. Natural fibers may be fibers derived from vegetable or naturally occurring sources (such as plants and / or trees). Suitable sources for this application include wood pulp, cotton, rice, wheat, bamboo, and seaweed. The fiber web may include fibers, fiber components (cotton linters, seed hairs, trichomes, straw), or spun fibers from any of these naturally occurring sources, or combinations thereof. The most common and suitable spun fibers for this application are made from spun wood pulp and bamboo.

[0049] The nonwoven fabric may include a combination of plant-based fibers and non-plant-based synthetic fibers. For example, the nonwoven fabric may include both polypropylene fibers and cotton fibers; see, for example, U.S. Patent Application Publication US 2017 / 0203542. The cotton content may be in the range of about 3%, 5%, 10%, or 15% to about 50% by weight of the nonwoven fabric. When synthetic fibers such as polypropylene are used, it is preferred that the polypropylene is a non-phthalate catalyst polypropylene fiber.

[0050] In some examples, at least a portion of the fiber may exhibit a spiral curl with a spiral shape. According to one example, the fiber may include a bicomponent fiber, which is a single fiber that contains different materials (usually a first polymer material and a second polymer material) respectively. It is believed that the use of a side-by-side bicomponent fiber is beneficial to imparting a spiral curl to the fiber. Examples of potential suitable curling or "curled" bicomponent fibers and nonwovens formed by them are described in U.S. Patents 5,382,400, 5,418,045, 5,707,468, 6,454,989, 6,632,386, 5,622,772 and 7,291,239. For the purposes of this article, it may be desirable to use a nonwoven formed by a crimped bicomponent or multicomponent fiber as one or two nonwoven layers, such as described in the patents and / or patent applications just cited above, because they can feel particularly soft to the touch (to achieve comfort of wear on the inside and to achieve a sense of beauty on the outside), and are generally quite flexible. In other non-limiting examples, the nonwoven may be free of crimped fibers.

[0051] Where the laminate 10 includes more than one nonwoven, the nonwovens may have the same basis weight or different basis weights. Likewise, the nonwovens may include the same layer configuration (eg, SSS) or different layer configurations (eg, SMS, SPS).

[0052] The elastomeric layer 14 includes one or more elastomeric materials that provide elasticity to at least a portion of the layer 14. Non-limiting examples of elastomeric materials include films (e.g., polyurethane films, films derived from rubber and / or other polymeric materials), elastomeric coatings applied to another substrate (e.g., hot melt elastomers, elastomeric adhesives, printed elastomers, or elastomers coextruded to another substrate), elastomeric nonwovens, scrims, strands (including one or more strands), etc. The elastomeric material can be formed from an elastomeric polymer, including polymers having the following substances: styrene derivatives (e.g., styrene block copolymer materials), polyesters, polyurethanes, polyetherimides, polyolefins, combinations thereof, or any suitable known elastomers, including but not limited to coextruded VISTAMAXX ®Exemplary elastomers and / or elastomeric materials are disclosed in U.S. Patents 8,618,350, 6,410,129, 7,819,853, 8,795,809, 7,806,883, 6,677,258, and U.S. Patent Publication No. 2009 / 0258210. Commercially available elastomeric materials include KRATON (styrene block copolymer; available from Kraton Chemical Company, Houston, TX); SEPTON (styrene block copolymer; available from Kuraray America, Inc., New York, NY); VECTOR (styrene block copolymer; available from TSRC Dexco Chemical Company, Houston, TX); ESTANE (polyurethane; available from Lubrizol, Inc., Ohio); PEBAX (polyether block amide; available from Arkema Chemicals, Philadelphia, PA); HYTREL (polyester; available from DuPont, Wilmington, DE), VISTAMAXX (homopolyolefins and random copolymers, and blends of random copolymers, available from EXXON Mobile, Spring, TX), VERSIFY (homopolyolefins and random copolymers, and blends of random copolymers, available from Dow Chemical Company, Midland, Michigan), and INFUSE (block copolymers, available from Dow Chemical Company).

[0053] In a non-limiting example, the elastomer layer 14 includes a film 15. The film can be a single layer or multiple layers. The film can be extensible or elastic in the lateral and / or longitudinal directions. The film can be pre-treated, such as by pre-activation, as disclosed in, for example, U.S. Pat. No. 9,533,067. Additionally or alternatively, the elastomer layer 14 can be apertured.

[0054] The elastomeric layer may be shorter than the laminate itself in one or more dimensions of the laminate. For example, the elastomeric layer may include a maximum dimension Y along the stretch direction, and the laminate may include a maximum dimension W along the stretch direction, such as in FIG. 2A to FIG. 2CAs shown in . In various embodiments, the stretching direction is the lateral direction. The maximum dimension is measured when the laminate is in a relaxed state. In a non-limiting example, Y may be at least about 10 mm smaller than W. In certain embodiments, Y is at least about 20%, or about 25% to about 100%, or about 35% to about 85%, or about 80% or less of W. In various embodiments, the stretching direction is the lateral direction. Additionally or alternatively, the elastomer layer may have a scale equal to one or more scales of the laminate. For example, the elastomer layer may have substantially the same longitudinal length of the laminate over the entire lateral width of the laminate. In some embodiments, the elastomer layer may have a basis weight of about 5 gsm to about 150 gsm, or about 10 gsm to about 100 gsm, or less than about 150 gsm.

[0055] Go to FIG. 2A to FIG. 2C , the laminate 10 may include a primary region 18 defined by the periphery of the elastomeric material 14 and one or more inelastic regions 20, 22. The primary region 18 includes an elastic region 26 and one or more unstretched regions 28. In the elastic region 26, the laminate 10 is elastically extensible. In the unstretched region 28, despite the presence of the elastomeric layer, the laminate 10 may not be elastic. In some embodiments, the area of ​​the primary region 18 accounts for at least about 20%, or about 30% to about 100%, or about 80% or less of the total area of ​​the laminate. The laminate 10 may include one or more inelastic regions 20, 22. In certain embodiments, the laminate 10 includes a first inelastic region 20 that extends laterally outward from a first laminate edge 9 of the laminate and is adjacent to the elastic region 18 at the first elastomeric material edge 17. The laminate may include a second inelastic region 22 which may extend laterally inwardly from the second laminate edge 11 and may be adjacent to the elastic region 18 at the second elastomeric material edge 19. The first inelastic region and the second inelastic region may be made of the same or different materials.

[0056] In certain embodiments, the laminate 10 includes a gathered laminate 24 in which one of the layers is strained to a greater extent than the remaining layers during lamination. In this way, when the gathered laminate 24 is in a relaxed state, the less extensible layers (such as the cover layers 12, 16) will form a gathered portion. In some embodiments, during lamination, at least a portion of the elastomeric layer is strained when the cover layer (including one or more nonwovens) is in a relaxed state. The elastomeric layer can be stretched in one or more directions. Then, when the subsequently formed laminate 24 is in a relaxed state, wrinkles are formed in the multiple nonwoven layers. The laminate can have a wrinkle regularity greater than about 50%, such that when measured perpendicular to a flat surface of the laminate, about 50% of the wrinkles have substantially the same amplitude, such as Fig.14The laminate may have a wrinkle regularity of greater than about 75%, such that about 75% of the wrinkles have substantially the same amplitude when measured perpendicular to a planar surface of the laminate, as shown in FIG. Fig.14 When preparing the gathered laminate, the elastomeric layer is extended in the stretch direction (i.e., the intended stretch direction in the final product). The stretch direction may be lateral. In a non-limiting example, the elastomeric layer is stretched in a direction corresponding to the lateral direction of the article. In other words, when the laminate is joined to the base structure after lamination, the laminate will be oriented so that the laminate can be stretched in the lateral direction of the article (i.e., the laminate is laterally extensible).

[0057] like Figure 2A As shown, for example, the laminate layers are joined by one or more bonding portions 30. The bonding portion can be any suitable shape, and a variety of shapes can be utilized in the laminate. In various embodiments, the bonding portion can be an ultrasonic bonding portion 31. The bonding portion can be arranged in one or more patterns 200. Each pattern may include one or more closed-cell units 204. Repeating closed-cell units form one or more repeating units 202. The repeating unit is the same or substantially the same closed-cell unit repeated in a bonding pattern. Therefore, the first repeating unit includes a first closed-cell unit having substantially the same shape, and the second repeating unit includes a second closed-cell unit having substantially the same shape; however, the first closed-cell unit and the second closed-cell unit are different shapes. It should be understood that the closed-cell units of different repeating units may differ in at least one aspect of shape and size. The bonding pattern may include closed-cell units, wherein each closed-cell unit has the same or substantially the same shape and / or size. The bonding pattern may include closed-cell units, wherein the closed-cell units are different, such as different shapes and / or sizes. In the bonding pattern, some closed-cell units may be the same or substantially the same as some other closed-cell units, and some other closed-cell units may be different. For example, the bonding pattern may include closed-cell units having only hexagonal shapes, or the bonding pattern may include a plurality of closed-cell units having hexagonal shapes and a plurality of closed-cell units having triangular shapes. The laminate may include a first bonding pattern 200a having one or more repeatable closed-cell units 204. The first bonding pattern may overlap at least partially with the primary region 18.

[0058] In addition, the bonding pattern 200 may include permanent bonds 34. The permanent bonds 34 allow the laminate to remain bonded in the area of ​​the permanent bonds 34 when the laminate is stretched. The bonding pattern 200 may also include releasable bonds 36. The permanent bonds 34 may be referred to as primary bonds 29, and the releasable bonds 36 may be referred to as secondary bonds 32. Releasable bonds refer to ultrasonic bonds that are breakable (or releasable) when stretched. Figure 2Dis a schematic diagram of a stretch laminate 10 that includes an elastomeric film layer 14 sandwiched between a first cover layer 12 and a second cover layer 16. The layers are held together with a plurality of ultrasonic bonds 31. The stretch laminate 10 can withstand lateral tension in the direction of stretch. Figure 2E to Figure 2G It is a kind of releasable bonding area 36 after being subjected to lateral tension. Figure 2D A schematic diagram of a stretch laminate 10 is shown. Figure 2E In FIG. 5 , the releasable bond 36 is separated from both the first cover layer 12 and the second cover layer 14 at the separation area 702. Figure 2F In FIG. 7 , the releasable bonding area 36 is separated from the first cover layer 12 or the second cover layer 14 at the separation area 702. Figure 2G In the embodiment shown in FIG. 7 , the releasable bond 36 is only partially separated from the first cover layer 12 or the second cover layer 14 at the separation area 702 .

[0059] The releasable adhesive portion 36 may be disposed within the closed cell (e.g. Figure 2A 36 is releasable. For example, when at least one layer in the adhesive layer in the releasable bonding area is separated from one or more other layers or at least partially separated from one or more layers in the releasable bonding area, the bonding is released. In certain embodiments, according to the laminate extension test method, when the laminate extends from about 5mm to about 12mm or from about 5mm to about 10mm or from about 5mm to about 8mm, the releasable bonding portion is released. When the laminate extends to 15mm, the permanent bonding portion keeps bonding.

[0060] According to the Peel Force Test Method, when the laminate peel force (peel force applied to the laminate) is greater than or equal to 0.3N / cm, the secondary releasable adhesive portion can be released. In another embodiment, according to the Peel Force Test Method, when a single adhesive portion is subjected to a force of 0.06N / bond or less, the permanent adhesive portion can remain bonded, while the releasable adhesive portion is released. In another embodiment, according to the Laminate Extension Test Method, when the laminate is extended in the tensile direction by a force of 0.5N / in or more, the permanent adhesive portion can remain bonded, while the releasable adhesive portion is released. In some embodiments, according to the Laminate Extension Test Method, when the laminate is extended by a force of about 0.4N / in to about 0.7N / in or about 0.4N / in to about 0.5N / in, the releasable adhesive portion of the laminate can be released.

[0061] It should be understood that one or more of the releasable adhesive portion can be released before the laminate extends 5mm in the stretching direction.For example, secondary or releasable adhesive portion can be configured to make when the laminate is stretched less than the first extension of 5mm in the stretching direction, one or more of the releasable adhesive portion releases, and when the laminate is stretched more than or equal to the second extension of 5mm in the stretching direction, the second multiple releasable adhesive portions release.For example, the laminate of the first extension of about 5mm in the stretching direction causes the first part of the releasable adhesive portion to be partially or completely released, and the laminate of the second extension of about 10mm in the stretching direction causes the remainder or the second part of the releasable adhesive portion to be partially or completely released.Similarly, one or more releasable adhesive portions can be released before the laminate extends in the stretching direction by the power of 0.5N / in, and other adhesive portion can not be released until the laminate is subjected to the power of being more than or equal to 0.5N / in and extends in the stretching direction. It should also be understood that, according to the peel force test method, when single releasable bonding portion was subjected to 0.06N / bonding or less peel force, one or more of the releasable bonding portion may not be released.Therefore, when more power was applied on releasable bonding, additional releasable bonding portion could be released.For example, when single releasable bonding was subjected to 1.2N / bonding or less power, all releasable bonding portions were released.In a preferred embodiment, substantially all releasable bonding portions are configured to be released when single releasable bonding was subjected to about 0.06N / bonding or less power, and this power is about the power applied by the user when utilizing the absorbent article comprising laminate as disclosed herein.

[0062] The release of releasable bonding portion allows the bonding area to experience the change from the relative compression zone to the more pillow-like district.For example, releasable bonding portion or secondary bonding portion may be present in the ear piece of disposable absorbent article, and when absorbent article is applied to the wearer, secondary or releasable bonding may be released.When absorbent article is in use or is placed on the wearer, the release of releasable bonding portion may allow the ear piece to have the more pillow-like feeling, larger air permeability and / or the air flow that increases relatively.In addition, the release of releasable bonding portion may cause the variation of opacity, figure visibility and / or color intensity.The release of releasable bonding portion may also cause the increase of laminate thickness.

[0063] In order to realize a more pillow-like region, the number of primary bonding portions 29 is greater than the number of secondary bonding portions 32. In other words, the number of permanent bonding portions 34 can be greater than the number of releasable bonding portions. Permanent bonding portions 34 and releasable bonding portions 36 can have a bonding ratio. Bonding ratio is the ratio of permanent bonding portions 34 to releasable bonding portions 36. The number of permanent bonding portions and releasable bonding portions can be determined by a bonding ratio test method (Bond Ratio Test Method). According to the bonding ratio test method, the bonding ratio of laminate is 1, or greater than about 1, or greater than about 1.1, or greater than about 1.3, or greater than about 1.5, or greater than about 1.7, or greater than about 2, or greater than about 5, or greater than about 8, or greater than about 10. Having a bonding ratio greater than 1 allows laminate to remain fully attached for use, wherein the releasable bonding portion is separated during use. In addition, the bonding ratio allows laminate to be fully compressed before use, such as when in a packaging state, and becomes relatively pillow-shaped while maintaining sufficient attachment amount between layers during use after extension.

[0064] like Figure 2A As shown, releasable bonding portion 36 can be arranged in the closed-cell unit composed of permanent bonding portion 34. Releasable bonding portion 36 can allow the closed-cell unit to maintain a more compressed state before using or stretching the laminate. When releasing the releasable bonding portion 36, the laminate in the releasable bonding portion 36 area can be released, causing the laminate in the releasable bonding portion 36 area to separate, so that the releasable bonding portion 36 no longer bonds the laminate or only partially bonds the laminate, such as one or more fibers thereof remain bonded. When releasing the releasable bonding portion, the permanent bonding portion can still be discerned by the user.

[0065] The releasable bond 36 may be a portion of a bond pattern that does not include closed cells, such as Figure 2B and Figure 2C The secondary bonds or releasable bonds may be evenly or unevenly distributed on the laminate. Figure 2A , Figure 2B and Figure 2C As shown, the releasable bonding portion can be formed on the secondary bonding pattern of the laminate. It should be understood that the first bonding pattern formed by the permanent bonding portion may not be fully recognized by the user until the second bonding pattern formed by the releasable bonding portion is released. In addition, the first bonding pattern formed by the permanent bonding portion and the second bonding pattern formed by the releasable bonding portion can form a cooperative bonding pattern before the releasable bonding portion is released, and the first bonding pattern can become visible when the second bonding pattern is released.

[0066] Each of the primary bonding portion and the secondary bonding portion (also referred to as welding in this article) can be formed by one or more methods, and the one or more methods include ultrasonic bonding, adhesive bonding, mechanical bonding (such as heat and pressure or a combination of heat and pressure) and electrostatic bonding. The primary bonding portion can be formed by a first bonding method, and the secondary bonding portion can be formed by a second bonding method. The first bonding method may be different from the second bonding method. In some embodiments, the primary bonding portion and the secondary bonding portion can be formed by the same bonding method, but have different bond strengths. For example, in order to change the bond strength, bonding can be different sizes, including different materials, and different shapes. In addition, bonding can be formed by the same method, but due to the different structures of nonwoven fibers (such as the cross-sectional area of ​​the fiber and / or elastic film properties or coatings) have different bond strengths.

[0067] As previously mentioned, permanent bonding and releasable bonding can form one or more bonding patterns. These bonding patterns may include bondings that are evenly or unevenly distributed. These bonding patterns may also form one or more closed-cell units. In addition, the permanent bonding may form a first bonding pattern, and the releasable bonding may form a second bonding pattern. When the releasable bonding is released, the second bonding pattern may be removed from the laminate and the first bonding pattern may be retained. In addition, the permanent bonding may form a first bonding pattern, and the releasable bonding may form a second bonding pattern. When the releasable bonding is released, the second bonding pattern may be removed from the laminate, and the permanent bonding may form a third bonding pattern that is different from the first bonding pattern.

[0068] FIG. 3A to FIG. 5B Embodiments of bonding patterns having permanent bonds and releasable bonds are provided. For example, FIG. 3A to FIG. 3C A bond pattern having closed-cell cells is shown that includes a perimeter 206 formed by one or more permanent bonds 34 and releasable bonds 36. For example, Figure 3A and Figure 3B A plurality of closed cell units 204 are shown forming the first bonding pattern 200 and the second bonding pattern 201. The first bonding pattern 200 and the second bonding pattern 201 may be formed from one or more permanent bonds 34 and one or more releasable bonds 36. Figure 3B Shown Figure 3A206 is a portion of a bonding pattern shown in FIG. 20 and a perimeter 206 formed by each of these closed-cell units. For illustrative purposes and to better understand the present disclosure, the perimeter 206 is shown as a dashed line; however, the dashed line does not form a part of the bonding pattern. The perimeter 206 is formed by connecting adjacent single bonds. It should be understood that the perimeter of a first closed-cell unit may form a portion of the perimeter of a second closed-cell unit. In addition, the perimeter 206 may be formed by connecting one or more permanent bonds and releasable bonds.

[0069] refer to Figure 3C , when the laminate is extended in the stretching direction, the releasable bonds 36 are released and permanent bonds 34 are left. The permanent bonds 34 that remain after the release of the releasable bonds 36 show a third bonding pattern that is different from both the first bonding pattern and the second bonding pattern. In addition, the release of the releasable bonds 36 leaves a larger area of ​​the laminate free from bonding, which results in a more pillow-like or cushion-like appearance of the laminate.

[0070] The closed-cell unit can be any shape so that it can be identified as having a shape having a perimeter that substantially surrounds a certain area. For example, the closed-cell unit can be a variety of shapes, including polygonal, heart-shaped, circular, oval, and combinations thereof. The bonding pattern may include closed-cell units each having the same shape. The bonding pattern may include closed-cell units having different shapes. Some bonding patterns may include more than one closed-cell unit having different shapes. For example, as Figure 3A and Figure 3B As shown, the bonding pattern may include a first closed-cell unit 204a and a second closed-cell unit 204b. The first closed-cell unit 204a may be a hexagonal closed-cell unit, and the second closed-cell unit 204b may be a triangular closed-cell unit. It should also be understood that the various closed-cell units may be substantially the same shape, but have different sizes. The closed-cell units may form a pattern, such as discussed previously.

[0071] As discussed herein, when the laminate is in a contracted state, the bonding pattern with closed-cell units allows a relatively large area of ​​the nonwoven to gather without the risk of having an uncontrolled area of ​​unbonded areas that can, for example, tear. In addition, these bonding patterns with closed-cell units allow for a more cushion-like feel to the wearer's skin and may produce less pressure and skin markings on the wearer. The bonding patterns discussed herein may also allow for relatively greater breathability.

[0072] FIG. 4A to FIG. 4D Another bonding pattern of the laminate is shown. The bonding pattern includes permanent bonds 34 and releasable bonds 36. Figure 4A and Figure 4BThe laminate is shown before being extended in the stretching direction, including both permanent bonds 34 and releasable bonds 36 that bond two or more layers of the laminate. The permanent bonds 34 and the releasable bonds 36 can be positioned to form a closed-cell unit. In addition, the permanent bonds 24 and the releasable bonds 36 can be positioned to form a first bonding pattern 200 and a second bonding pattern 201, the first bonding pattern forming a hexagonal area and the second bonding pattern forming a triangular shape. Once the laminate is extended in the stretching direction, the releasable bonds 36 can be released, causing the two or more layers of the laminate to separate from each other. Figure 4C and Figure 4D As shown in , the release of the releasable bonding portion causes additional closed-cell units of the laminate to appear. The laminate includes a first closed-cell unit of a first size and a second closed-cell unit of a second size that is different from the first size. It should be understood that in some embodiments, the shape of the first closed-cell unit and the shape of the second closed-cell unit can be the same size. In other words, the shape of the pattern formed by the bonding can be the same shape and different sizes.

[0073] It is also contemplated that the first bonding pattern may include closed-cell cells and unclosed areas of the bonding pattern. Figure 5A As shown, the bonding pattern may include discrete closed-cell cells 204. Each of the discrete closed-cell cells has a perimeter that does not share the perimeter of another closed-cell cell. Figure 5A For example, the bonding pattern may include closed-cell elements and individual bonds arranged in rows. It should also be understood that the bonding pattern may include one or more closed-cell elements that share a perimeter with each other and unenclosed areas of the bonding pattern. The closed-cell elements may be formed with permanent bonds. A single linear bond may be formed with a releasable bond 36. Thus, when the releasable bond is released, as in Figure 5B As shown, the closed-cell cells are independent of each other such that a bond from a first closed-cell cell does not share that bond with another closed-cell cell.

[0074] In some embodiments, the laminate may have a first cover layer 12 including a first exterior surface 210 and a second cover layer 16 including a second exterior surface 212, such as Figure 6As shown. The first cover layer and the second cover layer can be made of different materials and have different basis weights, layer configurations, and ductility. For example, the first cover layer includes a nonwoven, and the second cover layer includes a nonwoven. Alternatively, the first cover layer includes a first nonwoven, and the second cover layer includes a second nonwoven, so that the first nonwoven and the second nonwoven are different in at least one of basis weight, layer configuration (e.g., SS, SMS, SPS, etc.), and ductility. In another non-limiting example, the first cover layer and the second cover layer have the same constituent materials, but one of the two layers includes a surface treatment or coating that causes a change in material properties (such as ductility, tensile strength, softness, or a combination thereof). In embodiments where the first cover layer and the second cover layer are different, the same bonding pattern 200 may result in different appearances and / or different bonding strengths. As Figure 7 As shown, for example, the bond appears relatively darker and more visually apparent on the second exterior surface 212 than on the first exterior surface 210 .

[0075] According to the Hysteresis Test Method of the present invention, the area of ​​the laminate including the bond pattern may have an unload force at 50% of about 0.2 N / in or greater, or about 0.3 N / in or greater, or about 0.35 N / in to about 1 N / in, with each increment of 0.01 N / in listed for the range.

[0076] The laminate may include a first bonding pattern 200a and a second bonding pattern 200b, such as Figure 8 and Fig. 9 The second bonding pattern differs from the first bonding pattern in at least one of the shape of the bonding portion, the number of bonding portions, the number of closed-cell units (or the absence of closed-cell units), the shape of the repeating unit, the closed area of ​​the closed-cell units, the bonding density, the bonding area, and combinations thereof. The second bonding pattern may be positioned outside the first bonding pattern so that the two patterns may be in a non-overlapping relationship. Figure 8 and Fig. 9 As shown, the second bonding pattern can be disposed along one or more edges of the laminate. Thus, the second bonding pattern can at least partially surround or enclose at least a portion of the first bonding pattern or the entire first bonding pattern. The second bonding pattern can at least partially overlap the unstretched region 34, the inelastic region 20, the fastening system 148, and / or the reinforcing layer 160 (e.g., a folded substrate or additional substrate added to the laminate to enhance integrity).

[0077] The first bonding pattern and the second bonding pattern may overlap in the transition zone.The overlap of the first bonding pattern and the second bonding pattern in the transition zone may be less than about 5 mm, or less than about 3 mm, or less than about 1 mm.

[0078] The bond pattern may include one or more releasable bonds and one or more permanent bonds. Figure 8 and Fig. 9 As shown, the first bonding pattern 200a includes a releasable bonding portion 36 and a permanent bonding portion 34. The releasable bonding portion 34 can be arranged in the closed-cell unit of the first bonding pattern 200a. The second bonding pattern 200b can also include at least one of the permanent bonding portion 34 and the releasable bonding portion 36 in a grid-like pattern.

[0079] The second bonding pattern 200b may be free of closed-cell cells. Alternatively, the second bonding pattern may include one or more closed-cell cells having any of the features described herein.

[0080] In certain embodiments, the laminate may have a permeability of at least about 1 m / s according to the Air Permeability Test Method herein. 3 / m 2 / min, or about 1m 3 / m 2 / min to about 125m 3 / m 2 / min, or about 2m 3 / m 2 / min to about 50m 3 / m 2 / min air permeability value.

[0081] The bonding pattern of the laminate can be coordinated with other parts of the absorbent article. For example, the bonding pattern of the laminate can be coordinated with the bonding pattern on the infrastructure such as the top sheet and / or back sheet, ear piece, fastener and / or waist feature. The coordination pattern can be a pattern formed by mechanically changing the structure of the material or adding material to form a pattern (e.g., by printing). The bonding pattern of the laminate can be coordinated with the bonding pattern included in another part of the absorbent article so that the bonding pattern is the same, or the bonding pattern can be different in size so that one bonding pattern is larger or smaller than another bonding pattern. The bonding pattern can be coordinated so that the bonding pattern has the same geometry.

[0082] The laminate can include added materials such as inks, color change indicators, and skin components such as moisturizers, fragrances, lubricants, antimicrobial substances, insect repellent substances, and ultraviolet protection substances. The added materials can be disposed on one or more layers of the laminate. The added materials can be disposed on the surface of one or more layers of the laminate. For example, the ink can be applied to the laminate by printing. The ink can provide a visual signal to the user, such as the location of the releasable bond or a bonding pattern or graphic.

[0083] As mentioned above, various methods can be used to manufacture laminates. For example, the method for manufacturing an elastic laminate may include the following steps. A first substrate and a second substrate may be provided. The first substrate and the second substrate may be any material as mentioned above, such as a nonwoven material. The first substrate and the second substrate may each include a first surface and a relative second surface, and limit the width along the transverse direction. The first surface of the first substrate may be encapsulated on the outer circumferential surface of the anvil. The elastic film or other elastomeric substrates may be advanced in the longitudinal direction.

[0084] The elastic film can be preactivated in the longitudinal direction, in a transverse direction substantially perpendicular to the longitudinal direction, or in both. For the preactivation process, the elastomeric film can be guided through a system of intermeshing profile rollers, each roller comprising a disc pack having a plurality of intermeshing discs located on an axle. This method is generally referred to as a ring rolling method. In this case, the elastomeric film is stretched transversely by the intermeshing disc pack.

[0085] The stretching may be uniform or variable across the width of the film. The preactivation process may be performed with varying pitches and / or varying depths of engagement. The preactivation process may also be performed in the longitudinal direction or in any other direction. Preactivation by ring rolling forms visible lines on the film due to local mechanical deformation caused by the intermeshing discs, and these lines are also referred to as activation stripes. The activation stripes formed on the elastic film may be visible to the naked eye.

[0086] Pre-activation of the elastomeric film has a positive effect on the tensile force distribution and helps to allow easy stretching action of the manufactured stretch laminate over a large expansion area. In addition, the recovery of the stretch laminate can also be improved by pre-activating the elastomeric film. Recovery is the ability of the stretch laminate to return to its original size after it has been stretched to its expansion limit. The increased recovery of the elastomeric film after the pre-activation process is due to the removal of a certain amount of hardener from the film. Pre-activation of elastomeric films is disclosed in U.S. Patent No. 11135100, which is incorporated by reference.

[0087] The elastomeric film may also include at least one skin layer disposed on an elastically extensible material, the skin layer forming at least one of the surfaces of the film. Such a skin layer is an extensible material and provides an outer surface for the elastomeric film, the outer surface having less adhesion than the elastically extensible material below. In some embodiments, the skin layer may also serve as an elastically extensible material, but will be less elastic than the elastically extensible material below. Therefore, when compared with an elastically extensible material, the skin layer will have less recovery from the same amount of extension. In other words, when compared with an elastically extensible material, the skin layer will have a higher percentage group starting from the same percentage strain. The skin layer may contribute to the processability of the elastomeric film, and the thickness is between about 1 μm and about 10 μm, or between about 3 μm and about 7 μm, or about 5 μm in some embodiments. In certain embodiments, the skin layer covering the elastically extensible material in the elastomeric film is a polyolefin. Non-limiting examples of available surface materials include metallocene polyethylene, low density polyethylene, high density polyethylene, linear low density polyethylene, very low density polyethylene, polypropylene homopolymer, plastic atactic polypropylene (olefin / olefin) copolymer, syndiotactic polypropylene, metallocene polypropylene, polybutene, impact copolymer, polyolefin wax, and combinations thereof. Exemplary elastomeric films (i.e., elastically extensible materials having at least one surface layer disposed on the surface of an elastically extensible material) that can be used for the stretch 5 laminate described in detail herein include M18-1117 and M18-1361 elastomeric films commercially available from Clopay Corporation (Cincinnati, Ohio); K11-815 and CEX-826 10 elastomeric films commercially available from Tredegar Film Products (Richmond, Va.); and elastomeric films commercially available from Mondi Gronau GmbH (Gronau, Germany). These exemplary elastomeric films include a single-layer elastically extensible material having a 15um surface layer disposed on both surfaces of the material.

[0088] Films suitable for this application will have a skin layer providing a first surface and a second skin layer providing a second surface. During pre-activation, the skin layer and the elastically extensible material are stretched similarly (i.e., placed under similar strains). However, after stretching, the skin layer and the elastically extensible material will retract and recover differently (i.e., have different set points). Compared with the elastically extensible material, the skin layer is less elastic and therefore has less recovery after stretching, also known as a higher set point. The skin layer is also much thinner than the elastically extensible material, so when the thicker elastically extensible material retracts and recovers after stretching before activation, it will force the attached skin layer to retract with it. But because the skin layer cannot recover as much as the elastically extensible material, the skin layer shrinks and wrinkles. In the absence of pre-activation, the skin layer and therefore the outer surface of the elastomeric film is substantially smooth in a cross-sectional view. In the pre-activated condition, the skin layer, and therefore the outer surface of the elastic film, is substantially wrinkled in cross-sectional view, such as disclosed in US Pat. No. 10,485,713, which is incorporated herein by reference.

[0089] The preactivated elastic film may be advanced to an expander mechanism including an engagement portion. The elastic film may be stretched to a first elongation in a transverse or longitudinal direction at the expander mechanism. The elastic film is then advanced from the expander mechanism to an anvil. The anvil may include an effective vacuum zone having a maximum width in a transverse direction. The elastic film is positioned to contact the second surface of the first substrate on the anvil, and the second substrate is advanced to position the first surface of the second substrate to contact the second surface of the first substrate on the elastic film and the anvil. The first substrate is ultrasonically bonded to the second substrate, wherein the elastic material is positioned between the first substrate and the second substrate. A sonotrode may be used to ultrasonically bond the laminate. The ultrasonic bonding of the laminate imparts one or more bonding patterns, such as previously discussed herein. Methods of making laminates are disclosed in commonly owned publications, which are incorporated herein by reference: U.S. Patent No. 10,561,537; U.S. Patent No. 10,568,776; U.S. Patent Publication No. 2021 / 0401638; and U.S. Application No. 17 / 493,098, filed on October 4, 2021.

[0090] Releasable bonds can be formed in a variety of ways, including reducing the bond size, reducing the bond pressure, reducing the bond bump height, reducing energy transfer through the bump shape or geometry. Variations in the bond bump height can be achieved by laser metal deposition, such as disclosed in U.S. Patent Publication No. 2020 / 0180025.

[0091] Articles including laminates

[0092] refer to Fig.10, the laminate 10 of the present disclosure can be incorporated into an absorbent article 100, such as a disposable absorbent article. The laminate can be attached to one or more layers of a chassis 120 via a chassis attachment bond 102. The chassis attachment bond can include an ultrasonic bond, an adhesive bond, a mechanical bond, or a combination thereof.

[0093] Fig.10 1 is a plan view of an exemplary non-limiting embodiment of an absorbent article 100 in a flat, uncontracted state. The body-facing surface 115 of the absorbent article 100 faces the viewer. The absorbent article 100 includes a longitudinal centerline 105 and a lateral centerline 110.

[0094] The absorbent article 100 includes a chassis 120. The absorbent article 100 and chassis 120 are shown as having a first waist region 114, a second waist region 118 opposite the first waist region 114, and a crotch region 116 located between the first waist region 114 and the second waist region 118. The waist regions 114 and 118 generally include those portions of the absorbent article that surround the waist of the wearer when worn. The waist regions 114 and 118 may include elastic members 155 so that they gather around the waist of the wearer to provide improved fit and restraint. The crotch region 116 is the portion of the absorbent article that is generally positioned between the legs of the wearer when the absorbent article is worn.

[0095] The outer periphery of the chassis 120 is defined by the longitudinal edges 112 and the waist edges (the first waist edge 113 in the first waist region 114 and the second waist edge 119 in the second waist region 118). The chassis 120 can have opposite longitudinal edges 112 oriented generally parallel to the longitudinal centerline 105. However, to achieve a better fit, the longitudinal edges 112 can be bent or angled to produce, for example, an "hourglass" shaped article when viewed in a plan view, such as Fig.10 The chassis 120 may have opposing lateral edges 113 , 119 (ie, a first waist edge 113 and a second waist edge 119 ) oriented generally parallel to the lateral centerline 110 .

[0096] The chassis 120 may include a liquid permeable topsheet 124, a backsheet 126, and an absorbent core 128 positioned between the topsheet 124 and the backsheet 126. The topsheet 124 may be joined to the core 128 and / or the backsheet 126. The backsheet 126 may be joined to the core 128 and / or the topsheet 124. It should be appreciated that other structures, elements, or substrates may also be positioned between the core 128 and the topsheet 124 and / or the backsheet 126. In some embodiments, an acquisition-distribution system 127 is disposed between the topsheet 126 and the absorbent core 128.

[0097] In certain embodiments, the chassis 120 comprises the main structure of the absorbent article 100, which together with other features added form a composite absorbent article structure. Although the top sheet 124, the back sheet 126 and the absorbent core 128 can be assembled in a variety of well-known configurations, the configuration of absorbent articles is generally described in the following patents: U.S. Patents 3,860,003, 5,151,092, 5,221,274, 5,554,145, 5,569,234, 5,580,411 and 6,004,306.

[0098] The components of the disposable absorbent article may include at least in part the bio-source content as described in U.S. Patent Publications 2007 / 0219521A1, 2011 / 0139658A1, 2011 / 0139657A1, 2011 / 0152812A1, and 2011 / 0139659A1. These components include, but are not limited to, topsheet, backsheet film, backsheet nonwoven, ear / ear sheet laminate, leg lining system, superabsorbent, acquisition layer, core wrap material, adhesive, fastener system, and landing zone. In at least one embodiment, the disposable absorbent article component includes a bio-based content value of about 10% to about 100%, or about 25% to about 75%, or about 50% to about 60% measured using ASTM D6866-10 Method B. In order to apply the method of ASTM D6866-10 to determine the bio-based content of any component, a representative sample of the component must be obtained for testing. In at least one embodiment, known milling methods (e.g., WILEY ® The disposable absorbent article components are ground into particles smaller than about 20 mesh using a grinder and a representative sample of suitable mass is obtained from the randomly mixed particles.

[0099] The laminate 10 of the present disclosure may form or be a portion of one or more components of an article including, but not limited to, ears, waist features, belts, and combinations thereof.

[0100] Top sheet

[0101] The top sheet 124 is typically a portion of the absorbent article 100 that can be positioned to at least partially contact or be in close proximity to the wearer. Suitable top sheets 124 can be made of a wide range of materials, such as porous foams; reticulated foams; open-cell plastic films; or woven or nonwoven webs of natural fibers (e.g., wood fibers or cotton fibers), synthetic fibers (e.g., polyester fibers or polypropylene fibers), or a combination of natural and synthetic fibers. The top sheet 124 is typically compliant, soft-feeling, and non-irritating to the wearer's skin. Generally speaking, at least a portion of the top sheet 124 is liquid permeable, thereby allowing liquid to easily penetrate through the thickness of the top sheet 124. The top sheet 124 can be perforated. The top sheet can be perforated by over-bonding the material and then breaking the over-bonding by ring rolling, such as disclosed in U.S. Patent No. 5,628,097.

[0102] Any part of the top sheet may be coated with a skin care composition, antimicrobial agent, surfactant and / or other benefit agent. The top sheet may be hydrophilic or hydrophobic or may have hydrophilic and / or hydrophobic parts or layers. If the top sheet is hydrophobic, there will typically be holes so that body exudates can pass through the top sheet.

[0103] Absorbent core

[0104] The absorbent core 128 may include a variety of liquid-absorbent materials commonly used in disposable diapers and other absorbent articles. Examples of suitable absorbent materials include comminuted wood pulp, which is commonly referred to as air felt crepe cellulose filler; meltblown polymers, including co-formed meltblown polymers; chemically hardened, modified or cross-linked cellulose fibers; tissue, including tissue wrappers and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; or any other known absorbent material or combination of materials. In one embodiment, at least a portion of the absorbent core is substantially free of cellulose and contains less than 10% by weight of cellulose fibers, less than 5% by weight of cellulose fibers, less than 1% by weight of cellulose fibers, no more than a non-significant amount of cellulose fibers or no cellulose fibers. It should be understood that a non-significant amount of cellulose material will not substantially affect at least one of the thinness, flexibility and absorbency of the portion of the absorbent core that is substantially free of cellulose. Among other benefits, it is believed that when at least a portion of the absorbent core is substantially free of cellulose, the portion of the absorbent core is significantly thinner and more flexible than a similar absorbent core containing more than 10% by weight of cellulose fibers. The amount of absorbent material such as absorbent particulate polymer material present in the absorbent core can vary, but in certain embodiments, the absorbent particulate polymer material is present in the absorbent core in an amount greater than about 80% by weight of the absorbent core, or greater than about 85% by weight of the absorbent core, or greater than about 90% by weight of the absorbent core, or greater than about 95% by weight of the core.

[0105] The absorbent material may be deposited as an absorbent layer having a generally rectangular outline. The absorbent material layer may also have a non-rectangular perimeter (a "shaped" core), in particular the absorbent material may define a taper (or "dog bone" shape) along its width towards a central region of the core. In this way, the absorbent material deposition area may have a relatively narrow width in the region of the core intended to be placed in the crotch region of the absorbent article. This may provide, for example, better wearing comfort. Other shapes such as a "T" or "Y" or "hourglass" shape may also be used for the area of ​​absorbent material.

[0106] In some embodiments, the absorbent core may include one or more grooves 129, wherein the grooves are substantially free of absorbent granular polymer material. The grooves 129 may extend longitudinally or laterally. The absorbent core may also include two or more grooves. The grooves may be straight, curved, angled, or any feasible combination thereof. In a non-limiting example, two grooves are symmetrically arranged about the longitudinal axis.

[0107] Negatives

[0108] Backsheet 126 is usually positioned so that it can be at least a portion of the surface facing clothes of absorbent article 100. Backsheet 126 can be joined to the top sheet 124 of absorbent article, absorbent core 128 and / or the part of any other layer by any attachment method known to those skilled in the art. Backsheet 126 can be designed to prevent the outflow that is absorbed by absorbent article 100 and contained in absorbent article from soiling the products that may contact absorbent article 100, such as bed sheet and underwear. In certain embodiments, backsheet 126 is water impermeable basically. Backsheet can be for example or include thin plastic film, such as thermoplastic film, and it has the thickness of about 0.012mm to about 0.051mm. Other suitable backsheet materials can include breathable material, and it allows steam to escape from absorbent article, while still preventing or at least suppressing body outflow to see through backsheet.

[0109] Backsheet 126 may also be composed of more than one layer. Backsheet 126 may include an outer cover and an inner layer. The outer cover material 40 may include a bonding pattern, holes and / or three-dimensional features. The outer cover material 40 may be a nonwoven material, such as a spunlace nonwoven material. The inner layer may be made of a substantially liquid-impermeable film such as a polymer film. The outer cover and the inner layer may be joined together by an adhesive or any other suitable material or method.

[0110] Ears / Fasteners

[0111] Absorbent article 100 may include one or more ear pieces 130, which include, for example, a front ear piece 132 disposed in the first waist region and / or a back ear piece 134 disposed in the second waist region. Ear piece 130 may be integrated with base structure 120 or a discrete element attached to the base structure at base structure attachment bonding portion 102, and the base structure attachment bonding portion may attach one or more layers of ear piece to the base structure. It should be understood that front ear piece 132 and back ear piece 134 may be attached to different layers of base structure. Ear piece 130 may be extensible or elastic. Ear piece 130 may be formed by one or more of the following materials: nonwoven web, woven web, knitted fabric, polymer film and elastomeric film, apertured film, sponge, foam, scrim, or a combination and / or laminate of any of the foregoing materials.

[0112] In some embodiments, ear piece 130 may include elastomer, so that ear piece is stretchable.In certain embodiments, ear piece 130 may be formed by stretch laminate, such as nonwoven / elastomeric material laminate or nonwoven / elastomeric material / nonwoven laminate, which also causes ear piece to be stretchable.Ear piece 120 is extensible in the lateral direction of article.In some embodiments, ear piece is elastic in the lateral direction.In other embodiments, ear piece 130 may extend more than longitudinally in the lateral direction.Alternatively, ear piece may extend more than laterally in the longitudinal direction.In some non-limiting examples, ear piece may include one or more inelastic zones and independent elastic zones.

[0113] In some embodiments, the ears include a laminate of one or more nonwovens and one or more elastic materials, such as laminate 10 having any of the features or laminate layers described herein.

[0114] Can use any suitable nonwoven in ear piece 130.Suitable nonwoven can have at least about 8gsm or be less than about 30gsm or about 17gsm or less or about 10gsm to about 17gsm basis weight.Usually, the nonwoven of lower basis weight reduces the overall strength of ear piece.Yet, although use the nonwoven of lower basis weight, can obtain high strength according to the ear piece of this paper principle design.In the situation that ear piece 130 comprises more than a kind of nonwoven, these nonwoven can have the same basis weight or different basis weight.Equally, nonwoven can have the same layer structure or different layer structures.In addition, the nonwoven in ear piece can have the same or different nonwoven feature portion in backsheet, top sheet, leg gasket system and / or waist feature portion.

[0115] The ear can be an ultrasonically bonded ear, such as disclosed in, for example, U.S. Patent Application No. 15 / 674,559. The ear can be a gathered laminate 24. Alternatively, the ear can be activated by methods disclosed in, for example, U.S. Patent Publication No. 2013 / 0082418, U.S. Patent Nos. 5,167,897, 5,993,432, 5,156,793, 5,167,897, 7,062,983, and 6,843,134.

[0116] The ear may be joined to the chassis at a chassis attachment bond 102. In some non-limiting examples, the chassis attachment bond is located in an inelastic region of the ear.

[0117] The absorbent article 100 may also include a fastening system 148. When fastened, the fastening system 148 interconnects the first waist region 116 and the rear waist region 118, thereby obtaining a waist circumference that can be around the wearer during the wear of the absorbent article 100. The fastening system 148 may include fastening elements 150, such as a belt insert, a hook-and-loop fastening component, an interlocking fastener such as an insert and a slot, a buckle, a button, a snap, and / or an androgynous fastening component, but any other known fastening member is generally acceptable. The absorbent article may also include a landing zone where the fastening element can engage and / or a peeling tape that protects the fastening element from being violated before use. Some exemplary surface fastening systems are disclosed in the following U.S. Patents: 3,848,594, 4,662,875, 4,846,815, 4,894,060, 4,946,527, 5,151,092, and 5,221,274. An exemplary interlocking fastening system is disclosed in US Patent No. 6,432,098. In some embodiments, the fastening system 148 and / or fastening elements 150 are foldable.

[0118] The fastening system 148 may be joined by any suitable means to any suitable portion of the article 100. The fastening system may be joined to the ears between the layers.

[0119] Leg collar system

[0120] The absorbent article 100 may include a leg gasketing system 170 attached to the chassis 120, which may include one or more cuffs. The leg gasketing system may include a pair of barrier leg cuffs 172. Each barrier leg cuff may be formed by a piece of material that is bonded to the absorbent article so that it can extend upward from the wearer-facing surface of the absorbent article and provide improved containment of fluids and other body exudates near the junction of the wearer's torso and legs. The barrier leg cuff is defined by a proximal edge that is directly or indirectly joined to the top sheet 124 and / or the back sheet 126 and a free end edge 175, which is intended to contact the wearer's skin and form a seal. In some embodiments, the free end edge 175 includes a folded edge. The barrier leg cuff 172 extends at least partially between the front waist edge 113 and the rear waist edge 119 of the absorbent article on opposite sides of the longitudinal centerline 105, and is present at least in the crotch region. The barrier leg cuffs may be joined to the chassis of the article at the proximal edges by bonds, which may be made by gluing, fusion bonding, or a combination of other suitable bonding techniques.

[0121] The barrier leg cuffs may be integral with the topsheet 124 or backsheet 126, or may be a separate material joined to the chassis of the article. Each barrier leg cuff 172 may include one, two or more elastic elements 155 near the free end edge 175 to provide a better seal.

[0122] In addition to the barrier leg cuffs 172, the article may also include a gasketing cuff 176 that is joined to the chassis of the absorbent article, specifically to the topsheet 124 and / or the backsheet 126, and is placed externally relative to the barrier leg cuffs 172. The gasketing cuffs 176 may provide a better seal around the wearer's thighs. The gasketing cuffs may include a proximal edge and a free end edge 177. The free end edge 177 may include a folded edge. Each gasketing cuff may include one or more elastic elements 155 located between the topsheet 124 and the backsheet 126 in the leg opening area in the chassis of the absorbent article. All or a portion of the barrier leg cuffs and / or the gasketing cuffs may be treated with a lotion or another skin care composition.

[0123] In other embodiments, the leg gasketing system includes barrier leg cuffs integral with the gasketing cuffs. Suitable leg gasketing systems that may be part of an absorbent article are disclosed in US Patent Applications 62 / 134,622, 14 / 077,708; US Patents 8,939,957, 3,860,003, 7,435,243, 8,062,279.

[0124] Elastic waist feature

[0125] The absorbent article 100 may include at least one elastic waist feature 180 that helps provide improved fit and restraint, such as Fig.10As shown. The elastic waist feature 180 is generally intended to stretch and contract to dynamically fit the waist of the wearer. The elasticized waist feature includes a waistband, a waist cuff having a pocket formed by a portion of the waist feature 180 detached from the base structure 120, and a waist piece designed to be fixedly fitted around the abdomen of the wearer. Non-limiting examples of elasticized waist features are disclosed in U.S. patent applications 13 / 490,543, 14 / 533,472, and 62 / 134,622. The waist feature 180 may be incorporated into the base structure 120 in the first waist region 114 and / or the second waist region 118. The waist feature may be used with the ear piece 130 to provide the desired stretch and flexibility for a product that fits the wearer appropriately. The waist feature may include a laminate 10 having any of the features described herein. The waist feature may be extensible or elastic in the lateral direction and / or the longitudinal direction. In some embodiments, waist feature 180 includes a belt 220. The waist feature can be attached to the chassis at waist feature bonds 182.

[0126] Adult or baby pant-type absorbent products

[0127] In some embodiments, the article 100 may include Fig.11A and Fig. 11B An absorbent pant 300 is shown. The absorbent pant may include a chassis 120, a belt 320 positioned about the waist of the wearer, and optionally a leg gasketing system 170. Fig. 11B Shows Fig.11A 324, and the front body structure of the pants of the embodiment of the present invention is an exemplary front body structure of the pants in the embodiment of the present invention, which is in a flat open configuration and is stretched laterally to resist elastic induced contraction. In the final assembly of the pants, the front belt portion 322 is joined to the back belt portion 323 at the seam 324, and the seam can be permanent or refastenable. In order to form the pants 300, the front body structure can be folded at or around the lateral centerline 110, wherein the top sheet 124 faces inward, and the longitudinal edges of the front belt portion 322 and the back belt portion 323 can be joined at the seam 324, thereby forming a pants structure with leg openings, a front waist edge and a rear waist edge. In this way, the pants 300 may include a preformed continuous waist opening and a preformed continuous leg opening for the wearer when wearing the pants 300.

[0128] The front belt portion 322 and the back belt portion 323 may be the outermost structures forming the front and back regions of the pants 300. The pants may include an outer wrap 326 that wraps around the entire front region, crotch region, and back region and forms the outermost pants-shaped structure. In some embodiments, the outer cover of the backsheet forms the outer wrap. The outer wrap 326 may be formed from one or more sections of a nonwoven web and may be cut to provide a contour that provides a properly customized leg opening edge contour as desired.

[0129] The belt 320 may include a laminate 10 of the present disclosure having any of the aforementioned features, including one or more nonwoven layers and one or more elastomeric layers. The laminate layers may be joined by ultrasonic bonding.

[0130] According to some non-limiting examples, the nonwoven used for the belt portion may include a material that provides good recovery when external pressure is applied and removed.

[0131] The elastomeric layer of the waist features, such as the band portion, may include one or more elastic members 155. The elastic members 155 may be elastomeric fibers, such as LYCRA® available from INVISTA (Wichita, KS) in various decitex levels. ® Fiber. Elastic member 155 may also include any heat-shrinkable elastic material as known in the art. Other suitable elastic members may be made of various other materials, including but not limited to: rubber, styrene ethyl butylene styrene, styrene ethylene propylene styrene, styrene ethylene propylene styrene, styrene butadiene styrene, styrene isoprene styrene, polyolefin elastomers, elastomeric polyurethanes, and other elastomeric materials known in the art, and combinations thereof. In some non-limiting examples, the elastic member may be an extruded strand elastic component with any number of strands (or filaments). In some embodiments, the elastic member may have a decitex within the range of 50 to 2000, or any integer value of any decitex value within the range. However, the technician may select appropriate decitex based on the desired contraction and other principles discussed herein. In other embodiments, the elastic member may be in the form of a film. Examples of films have been described in previous patent applications (see, for example, U.S. Patent Application Publication 2010 / 0040826). The film may be formed by combining a plurality of resins in at least one layer in several sublayers, the latter providing different beneficial effects to the film.

[0132] In addition, the elastic member 155 may also take on a variety of configurations. For example, the width may vary; a single strand or several parallel or non-parallel strands of elastic material may be used; or a variety of shapes may be used, including straight and curved lines; or a variety of cross-sectional shapes may be used (circular, rectangular, square, etc.).

[0133] The layers of the waist features (e.g., band portions) and / or chassis 120 may be joined together around the elastic strands 155 by an adhesive deposited between the layers, by heat bonds, by compression bonds, or by a combination thereof. In other examples, one or more elastic members may be a strip or a length of film formed from an elastomeric material. In the case of an elastic member that is elongated, it is desirable that the longer dimension be oriented laterally, or even substantially aligned with the lateral direction, such as, for example, Fig. 11B The strand 155 is shown in FIG.

[0134] The band portion or other form of waist feature may include at least 3 waist elastic members, at least 5 elastic members, at least 10 waist elastic members, or at least 15 waist elastic members, or from about 2 to about 35 waist elastic members, or from about 5 to about 25 waist elastic members.

[0135] In one embodiment, adjacent elastic members 155 are spaced at least 3.5 mm longitudinal distance from one edge of the member to the other edge of the member, optionally spaced at least 4 mm; optionally spaced at least 4.5 mm; optionally spaced at least 5 mm; optionally spaced at least 5.5 mm; optionally spaced at least 6 mm; optionally spaced at least 6.5 mm; optionally spaced at least 7 mm; optionally spaced at least 7.5 mm; optionally spaced at least 8 mm; optionally spaced at least 8.5 mm; optionally spaced at least 9 mm; optionally spaced at least 9.5 mm; optionally spaced at least 10 mm; optionally spaced at least 10.5 mm; optionally spaced at least 11 mm; optionally spaced at least 11.5 mm; optionally spaced at least 12 mm. The spacing between the elastic members may be the same or different in the longitudinal length of the waist feature. For example, the spacing between adjacent elastic members may be uniformly 7 mm, or may be a variable spacing (i.e., two adjacent elastic members are separated by 3 mm, the other two are separated by 6.5 mm, etc.).

[0136] During manufacture of the waist features, the elastic members 155 may be pre-strained a desired amount when they are incorporated into the waist features. When the waist features are subsequently relaxed, the elastic members will contract laterally toward their unstrained lengths. This may cause the layers of the waist features to gather and form hems or gathers having ridges and valleys that are generally transverse to the length of the elastic members 155 and extend in the z-direction.

[0137] In other embodiments, in order to adhere components of the waist feature laminate, the elastic member may be separately coated with an adhesive ("strand coated") prior to incorporation into the waist laminate. Various coating methods and techniques, including strand coating methods and techniques, are shown, for example, in U.S. Pat. Nos. 5,340,648, 5,501,756, 5,507,909, 6,077,375, 6,200,635, 6,235,137, 6,361,634, 6,561,430, 6,520,237, 6,582,518, 6,610,161, 6,613,146, 6,652,693, 6,719,846, and 6,737,102. The adhesive used may be a hot melt adhesive that is elastic and flexible, making it suitable for attaching pre-strained elastic materials to substrates, such as OMNIMELT BLOCKS 22 H2401F, or a ZEROCREEP brand, such as AVANCÉ available from Bostik, Inc., Wauwatosa, Wisconsin.

[0138] In some embodiments, the corners of the front and / or rear band portions may be trimmed off, such as Fig. 11B As shown. The corners may be trimmed along a straight line, or may be trimmed along a curved and concave or convex trimming path relative to the remaining area of ​​the band portion, which may be expected to impart a specific curved leg edge profile. In conjunction with such trimming and configuration of the elastic strands described above, it is expected that bonding is imparted between the layers along the edges of the corresponding band portions 322, 323. Such bonding may be used to prevent any separation of the layers along the edges, which may contribute to a rough appearance, and may also help to more effectively pull the rear band portion laterally inwardly toward the central infrastructure 120 under the action of the contraction forces of the elastic strands under the seam 324. Bonding may be achieved by mechanical / compression bonding as described in, for example, U.S. Patents 4,854,984 and 4,919,738, by thermal bonding or welding, or by adhesive deposits between the layers. In a non-limiting example, such bonding may be patterned along the edges. Such bonding may supplement any bonding between the layers that typically hold the corresponding band portions 322, 23 together as a laminated structure.

[0139] The side seam 324 can be permanent or refastenable. A permanent seam can be formed between the front belt portion and the rear belt portion by any bonding mechanism, wherein the front belt portion and the rear belt portion can be separated without forcibly causing significant damage to one or both of the front belt portion and the rear belt portion, or can not affect any included mechanism of substantially reattaching or refastening. The bonding forming the permanent seam can include compression bonding, thermal bonding / welding, ultrasonic bonding or adhesive bonding. A refastenable seam can be formed between the front belt portion and the rear belt portion by any mechanism, any mechanism being configured to allow the front belt portion and the rear belt portion to be forcibly separated substantially without loss, and then substantially reattached or refastened at the same position. An example of this mechanism is a hook and loop fastening system, such as a VELCRO fastening system. Hook components of appropriate size and shape may be bonded along their longitudinal edges to one of the front or rear belt portions, and loop components of appropriate size and shape may be bonded along their longitudinal edges to the other of the front or rear belt portions, where they may be brought together and joined to form seam 224. Examples are shown in U.S. Patent Application Serial Nos. 61 / 787,416, 61 / 787,332, 61 / 666,065.

[0140] Exemplary belt and absorbent pant constructions are disclosed in US Patent Applications 14 / 598,783 and 14 / 032,595.

[0141] Packaging

[0142] The absorbent article 100 of the present disclosure can be placed in a package. The package can include polymer films, paper materials and / or other materials. Graphics and / or marks related to the characteristics of the absorbent article can be formed, printed, positioned, and / or placed on the outer portion of the package. Each package can include a plurality of absorbent articles. The absorbent articles can be piled up under compression to reduce the size of the package while still providing a sufficient amount of absorbent articles for each package. By packaging the absorbent articles under compression, the caregiver can easily handle and store the package, while also providing the manufacturer with savings in distribution due to the size of the package.

[0143] The package may include a polymer film including recycled materials, such as about 20% to about 100%, about 30% to about 90%, about 30% to about 80%, about 40% to about 60%, or about 50% recycled materials. The recycled materials may include post-industrial recycled materials (PIR) and / or post-consumer recycled materials (PCR). In some cases, the polymer film for packaging may include two outer layers and one or more inner layers. The one or more inner layers may include recycled materials or may contain more recycled materials than the outer layers. The recycled materials may include recycled polyethylene. The recycled materials may include recycled polyethylene PIR trimmed from packaging operations.

[0144] The packaging material may include paper, paper-based material, paper with one or more barrier layers, or paper / film laminates. The packaging material may be in the range of about 50 gsm to about 100 gsm or about 70 gsm to about 90 gsm, and one or more barrier layers may be in the range of about 3 gsm to about 15 gsm. The paper-based packaging material with or without one or more barrier layers may exhibit a longitudinal tensile strength of at least 5.0 kN / m, a longitudinal stretch of at least 3%, a transverse tensile strength of at least 3 kN / m, and a transverse tensile break stretch of at least 4%, each measured via ISO 1924-3.

[0145] The paper-based packaging material or the paper-based packaging material including a barrier layer or a film can be recyclable or recyclable in normal paper recycling operation. The recyclable degree of the paper-based packaging can be determined by a recyclable percentage. The paper-based packaging of the present disclosure can show a recyclable percentage of 70% or greater, 80% or greater, or 90% or greater. The paper-based packaging of the present disclosure can have a recyclable percentage between 70% and approximately 99.9%, between approximately 80% and approximately 99.9%, or between approximately 90% and approximately 99.9%. In one embodiment, the paper-based packaging of the present disclosure can show a recyclable percentage of approximately 95% to approximately 99.9%, approximately 97% to approximately 99.9%, or most approximately 98% to approximately 99.9%. The recyclability percentage of the paper-based package can be determined via test PTS-RH:021 / 97 (draft October 2019) under category II, as performed by Papiertechnische Stiftung located at Pirnaer Strasse 37, 01809 Heidenau, Germany. In another case, the paper-based package of the present disclosure can show an overall "pass" test result, as determined by PTS-RH:021 / 97 (draft October 2019) under the category II method. Any paper-based package may have an opening feature, such as a perforation line, and may also have a handle.

[0146] Thus, according to the In-Bag Stack Height Test described herein, the packages of absorbent articles of the present disclosure may have an In-Bag Stack Height of less than about 110 mm, less than about 105 mm, less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm, less than about 74 mm, less than about 72 mm, or less than about 70 mm. Alternatively, according to the In-Bag Stack Height Test described herein, the packages of absorbent articles of the present disclosure may have an In-Bag Stack Height of about 70 mm to about 110 mm, about 70 mm to about 105 mm, about 70 mm to about 100 mm, about 70 mm to about 95 mm, about 70 mm to about 90 mm, about 70 mm to about 85 mm, about 72 mm to about 80 mm, or about 74 mm to about 78 mm.

[0147] Fig.12 An exemplary package 1000 is shown that includes a plurality of absorbent articles 1004. The package 1000 defines an interior space 1002 in which the plurality of absorbent articles 1004 are located. The plurality of absorbent articles 1004 are arranged in one or more stacks 1006.

[0148] Test Method

[0149] Adhesion Scale Test Method

[0150] The Bond Size test method is used to measure various dimensions of permanent and releasable bonds in a laminate. The test measures the size of a bond (bond size) and the distance between adjacent bonds (bond separation distance), such as Fig.13 As shown. For the purpose of this method, bonding is the intentional joining of two or more layers, and the bonding is the deformation area caused during the bonding process (e.g., the thickness reduced at the bonding site or at the melted fiber or at the thermoplastic material). The dimensional measurements are determined from the image of the bonded laminate and obtained using an image capture tool (microscope, camera or similar image capture tool) and image analysis software. When the laminate is fully stretched, the image of the bonded laminate is captured. For wrinkled laminates, when the wrinkles are substantially flattened by extending the laminate, the sample is fully stretched while ensuring that the non-elastic substrate of the laminate is not plastically deformed. For laminates without wrinkles, when placed flat, the sample is considered to be fully stretched without such extension. Prior to testing, the sample / sample is pre-conditioned for 2 hours at a temperature of about 23°C ± 2°C and about 50% ± 2% relative humidity under the same environmental conditions.

[0151] In this method, a "cell" is the smallest pattern containing both permanent and releasable bonds that, when repeated through a combination of translation, reflection, and rotation, forms the entire bond pattern being interrogated. The cells are identified within the captured image, and both permanent and releasable bonds are discerned and identified within the cell pattern. If permanent and releasable bonds cannot be discerned by detection, similar cells are interrogated using a bonding ratio test method to discern permanent and releasable bonds.

[0152] The bonding dimensions of the selected unit area in the stretching direction and the longitudinal direction are measured. The bonding dimensions in the stretching direction or transverse direction and the longitudinal direction perpendicular to the transverse direction are defined as the shortest (minimum) straight-line distance of the bonding area (i.e., deformation area) in the transverse direction and the longitudinal direction, respectively.

[0153] For permanent bonding position, use the captured image of cell, measure and record the bonding dimension measured value in the stretching direction, and measure and record the bonding dimension measured value in the longitudinal direction.Similarly, for releasable bonding position, use the captured image of cell, measure and record the bonding dimension measured value in the stretching direction, and measure and record the bonding dimension in the longitudinal direction.Repeat this process for 3 cells altogether.Calculate and report the arithmetic mean of recorded value, and be reported as the bonding dimension of permanent bonding portion and releasable bonding portion.Report value, be accurate to 0.1mm.

[0154] The bond separation distance is defined as the shortest (minimum) straight-line distance between any two individual bonds (permanent or releasable). Fig.13 As shown, locate the perimeter of the first bond site and the perimeter of the different second bond site and measure the shortest straight-line distance between the perimeters. Record the value and repeat for a total of 3 cells. Calculate and report the arithmetic mean of the recorded values ​​and report it as the bond separation distance to the nearest 0.1 mm.

[0155] Peel force test method

[0156] The peel force test method is used to determine the force associated with separating the top and bottom layers of a peel laminate sample. ®The tester is a suitable tensile tester of MTS model Alliance RT / 1 or equivalent with software. The tensile tester is located in a temperature-controlled room at 23°C ± 2°C and 50% ± 10% relative humidity. The instrument is calibrated according to the manufacturer's instructions. The data acquisition rate is set to at least 50 Hz. The grips used for testing are wider than the sample. For example, a grip with a width of 50.8 mm can be used. These grips are pneumatic grips or equivalent grips designed to concentrate all the clamping force along a single line perpendicular to the direction of the test stress and have a flat surface and an opposite face protruding into a semicircle (radius = 6 mm, for example, part number: 56-163-827, obtained from MTS Systems Corp.) to minimize the slippage of the sample. The load sensor is selected so that the measured force is between 5% and 95% of the range of the load sensor used. The initial distance (gauge length) between the clamping force lines is adjusted according to the needs of the sample group. The load reading on the instrument is zeroed to deduct the mass of the grip and the chuck.

[0157] Identify the wrinkled or stretched portion on the absorbent product, which has a bonding pattern containing releasable or secondary bonding. Collect and cut at least four samples containing releasable bonding parts from the same part of the same absorbent product so that the sample is not damaged during the separation process. The stretching direction of the sample is the direction in which the sample is intended to stretch in the product. Cut a sample that is measured as 25mm in the stretching direction and at least 40mm in the direction perpendicular to the stretching direction, or as close to 40mm as possible if at least 40mm cannot be obtained. Finely cut the sample from the wrinkled or stretched portion of the laminate from the absorbent article. Before testing, under the same environmental conditions, the sample is pre-conditioned for 2 hours at a temperature of about 23°C ± 2°C and about 50% ± 2% relative humidity. Starting from one end of the sample, the sample is peeled off by separating the first substrate layer from the remaining layers of the laminate at the bonding connection so as not to damage the layer until a sufficient amount of the sample is separated to allow the sample to be installed in the clamp. The first substrate can be the top or bottom substrate layer of the laminate. The first substrate is mounted on one of the holders and the remaining layers are mounted on the other holder.

[0158] The sample is mounted in the chuck in a certain way so that there is no relaxation and the measured load is between 0.00N and 0.02N. The sample is mounted in the center of the chuck so that the sample peeling direction perpendicular to the tensile direction is parallel to the applied tensile stress. The sample is placed between the clamps so that the first clamp holds the first substrate and the second clamp holds the second substrate, thereby peeling the first substrate from the second substrate in the 180° peeling direction. Those skilled in the art will recognize that if the sample size is smaller or larger, other sizes of bonding samples can be used in the peeling force test method; however, the effective bonding area should be kept centered on the sample. Start the peel test and extend the sample at 127mm / min, with a data acquisition rate of at least 50 Hz until the sample is completely separated. The peeling force in N is the average value of 5mm from the beginning of the chuck stroke to at least 5mm before the end of the chuck stroke, and is reported as the sample peeling force in N. The peeling force in N is usually the average value of at least 30mm of the stroke. The sample peeling force in N / cm is calculated using the following formula.

[0159]

[0160] For specimens tested according to the sized method, the width of the specimen is 1 inch or 2.54 cm.

[0161] The arithmetic mean of the sample peel forces in N / cm of the four samples was recorded as the Average Peel Force (N / cm) for the top or bottom layer.

[0162] The peeling procedure was performed on the top and bottom layers of the laminate. The larger value between the average peel force of the top layer and the average peel force of the bottom layer was reported as the peel force of the laminate to the nearest 0.01 N / cm.

[0163] In order to calculate the releasable adhesive peeling force, the cutting width is wider than the releasable adhesive portion width, only contains the releasable adhesive portion, and is long enough to allow the sample of the 40mm travel distance required for the above-mentioned peeling test method. The top layer and bottom layer of the laminate are also subjected to the peeling procedure. The smaller value between the average peeling force of the top layer and the average peeling force of the bottom layer is reported as the peeling force of the releasable adhesive, accurate to 0.01N. For the releasable adhesive peeling force, the peeling force is normalized and recorded as N (per average number of bonds). The number of bonds per width in the sample is calculated as follows. Draw a straight line from the bonding site on the sample in the primary stretching direction (sample width direction and within 5 degrees of angle). Count the number of bonding sites intersecting with the line. Repeat three times, each time draw a line from different bonding sites. Record the number of bonds intersecting with each line, and record the arithmetic mean as the average number of bonds per width to the nearest 0.1 bond. The releasable adhesive peeling force is calculated using the following formula:

[0164]

[0165] The arithmetic mean of the releasable bond peel forces in N / bond from the four specimens is reported as the Average Releasable Bond Peel Force (N / bond) to the nearest 0.01 N / bond.

[0166] Hysteresis Test Method

[0167] The hysteresis test method is used to characterize the strain or load value of a specific purpose after being subjected to an extension cycle. A commercial tensile tester (e.g., obtained from Instron Engineering Corp. (Canton, MA), SINTECH-MTS Systems Corporation (Eden Prairie, MN) or equivalent) is used to perform the "hysteresis test". The test is performed under laboratory conditions of 23°C ± 2°C and 50% ± 2% relative humidity. Prior to testing, the sample is conditioned for 24 hours.

[0168] Identify the wrinkled or stretched portion on the absorbent article product that has a bond pattern that includes releasable bonds and permanent bonds. Cut samples from this area of ​​the absorbent article product to the dimensions listed in the table below for testing.

[0169] Test plan

[0170] 1. Select appropriate grips and load cells. The grips must have a flat surface and must be wide enough to clamp the sample along its full width. In addition, the grips should provide sufficient force and suitable surface area to ensure that the sample does not slip during the test. These grips are pneumatic grips or equivalent grips designed to concentrate the entire clamping force along a single line perpendicular to the direction of the test stress and have a flat surface and opposing faces that protrude into a semicircle (radius = 6 mm, e.g., part number: 56-163-827, from MTS Systems Corp.) to minimize slippage of the sample. Select the load cell so that the tension response of the sample being tested is between 5% and 95% of the range of the load cell used. Calibrate the tester according to the manufacturer's instructions.

[0171] 2. Set the distance between the grips (gauge length) according to the test being performed (table below).

[0172] 3. Place the sample in the flat surface of the grips so that the uniform width is along the direction perpendicular to the gauge length. Mount the sample in such a way that the direction of sample tension is the test direction. Secure the sample in the upper grips so that the sample hangs loosely, and then close the lower grips.

[0173] 4. Preload: Set the slack preload to 0.05 N / in and the preload chuck speed to 13 mm / min. This means that data collection begins when slack is removed with a force of 0.05 N / in (at a constant chuck speed of 13 mm / min). Based on the adjusted gauge length (l ini ), the adjusted gauge length is the sample length between the grips of the tensile tester at a force of 0.05 N / in. The adjusted gauge length is taken as the initial sample length, and it corresponds to 0% strain. In this test, the percentage strain at any point is defined as the change in length relative to the adjusted gauge length divided by the adjusted gauge length, multiplied by 100%.

[0174] 5(a). First cycle loading: The sample is pulled to a given endpoint (load or strain) at a constant grip speed as defined for the test in the following table. The tensile sample length between the grips is reported as l max .

[0175] 5(b). First cycle unloading: Hold the sample at the endpoint of step 5(a) for 30 seconds, and then return the crosshead to its starting position (0% strain or initial sample length, l) at the constant crosshead speed defined in step 5(a) above. ini ).

[0176] 5(c). The sample is maintained at zero strain for 1 minute.

[0177] 5(d). Second cycle: Repeat steps 5(a) and 5(b). :

[0178]

[0179] During the test, the force applied to the sample is recorded as a function of the applied strain. From the resulting data generated, the following quantities are collected and reported.

[0180] i. Specimen length between the grips at a relaxed preload of 0.05 N / in (l ini ), accurate to 0.01mm.

[0181] ii. Sample length between the grips on the first cycle at a given strain or a given force (l max ), accurate to 0.01mm.

[0182] iii. Sample length between the grips at the second cycle load force of 0.05 N / in (l ext ), accurate to 0.001mm.

[0183] iv. For the Laminate Properties test setup, the force at 50% strain during the first load cycle, accurate to 0.01 N / in (reported as the force at 50% load).

[0184] iv. For the Laminate Properties test setup, the force at 50% strain during the second unloading cycle, accurate to 0.01 N / in (reported as the Unloading Force at 50%).

[0185] Permanent deformation % is defined as (l ext - l ini ) / (l max - l ini ) * 100%, accurate to 0.01%.

[0186] The test was repeated for three independent samples and the arithmetic mean was reported.

[0187] Laminate extension test method

[0188] The extension of the laminate (ears, waist, cuffs or other) is measured using a constant rate extension tester such as the MTS Alliance. The equipment is set up and the samples are preconditioned according to the hysteresis test method described above. The test is conducted under laboratory conditions of 23°C ± 2°C and 50% ± 2% relative humidity. The samples are conditioned for 24 hours prior to testing.

[0189] Identify the wrinkled or stretched portion on the absorbent product that has a bond pattern that includes releasable bonds and permanent bonds. Cut the sample from this area of ​​the absorbent product to the dimensions listed in the table below. The sample dimensions, gauge lengths, and test speeds listed in the table below are used to measure laminate extension.

[0190]

[0191] Test plan :

[0192] 1) Select appropriate grips and load cells. The grips must have a flat surface and must be wide enough to clamp the sample along its full width. In addition, the grips should provide sufficient force and suitable surface area to ensure that the sample does not slip during the test. These grips are pneumatic grips or equivalent grips designed to concentrate all clamping forces along a single line perpendicular to the direction of the test stress and have a flat surface and opposing faces that protrude into a semicircle (radius = 6 mm, e.g., part number: 56-163-827, from MTS Systems Corp.) to minimize slippage of the sample. Select the load cell so that the tension response of the sample being tested is between 5% and 95% of the range of the load cell used. Calibrate the tester according to the manufacturer's instructions.

[0193] 2) Set the distance between the clamps (gauge length) as described in the table.

[0194] 3) Place the sample in the flat surface of the clamps so that the uniform width is along the direction perpendicular to the gauge length. Mount the sample in such a way that the direction of sample stretching is the test direction. Secure the sample in the upper clamps, allowing the sample to hang loosely, and then close the lower clamps.

[0195] 4) Preload: The slack preload was set to 0.05 N per inch and the preload chuck speed was 13 mm / min. This means that data collection begins when the slack is removed with a force of 0.05 N per inch (at a constant chuck speed of 13 mm / min). Based on the adjusted gauge length (l ini ), the adjusted gauge length is the sample length between the grips of the tensile tester at a force of 0.05 N per inch. The adjusted gauge length is taken as the initial sample length, and it corresponds to 0% strain. In this test, the percent strain at any point is defined as the change in length relative to the adjusted gauge length divided by the adjusted gauge length, multiplied by 100.

[0196] 5) If specified, the specimen is pulled to the end point at the test speed, or the specimen is pulled to rupture at the test speed. Rupture is defined as a sudden drop in force of at least 50%.

[0197] From the data, determine the extension at 0.5 N / in, the extension at 1.5 N / in, the extension at 4 N / in, the extension at break, and the load at break. The extension is defined as (at a given force - l ini The length of the lower sample between the grips) is recorded to the nearest 0.1 mm. The breaking load is recorded to the nearest 0.01 Newton.

[0198] Run five (5) replicates for each product example. Report the average extension at 0.5 N / in force, average extension at 1.5 N / in force, average extension at 4 N / in force, average extension at break, average load at break for each of the 4 samples.

[0199] Bond Ratio Test Method

[0200] Prepare specimens according to the Laminate Extension Test Method. Identify the areas containing permanent bonds and releasable bonds.

[0201] The specimens were tested according to the Laminate Extension Test Method described above, where the endpoint of Step 5 of the method is defined in the table below.

[0202]

[0203] After the sample is pulled to the desired extension or desired force, the sample is held in that condition. The bonds in the stretched sample are visually observed. The number of bonds that have been released as releasable bonds is recorded, and the number of bonds that have not been released as permanent bonds is recorded.

[0204] Test four (4) samples. For each sample, record the number of releasable bonds and the number of permanent bonds. The bonding ratio of each sample is calculated by dividing the number of permanent bonds by the number of releasable bonds. The average bonding ratio is determined by calculating the mean value (arithmetic mean) of the bonding ratios of the four samples respectively. Record the bonding ratio and the average bonding ratio to the nearest 0.1.

[0205] Air permeability test method

[0206] The air permeability of a laminate or substrate (e.g., film, nonwoven, or article component) is determined by measuring the flow rate of standard conditioned air through a test specimen driven by a specified pressure drop. This test is particularly useful for materials that have a high permeability to gases, such as nonwovens, apertured ear laminates, etc. ASTM D737 was used, modified as follows.

[0207] Use a TexTest FX 3300 instrument from Textest AG, Switzerland or Advanced Testing Instruments ATI, Spartanburg SC, USA or equivalent. Follow the procedures described in the operating instructions of the Textest FX 3300 Air Permeability Tester manual for air tightness testing and functional and calibration checks. If a different instrument is used, perform similar settings for air tightness and calibration according to the manufacturer's instructions.

[0208] Cut a sample from the portion of the absorbent article containing the releasable bonds and the permanent bonds. Test the sample in a relaxed state and the test area should contain the releasable bonds and the permanent bonds.

[0209] Use 5cm 2 The test head with the same area is tested, while adjusting the pressure drop to obtain a stable reading. The result is recorded to three significant figures. The average value (arithmetic mean) of the five samples is calculated and recorded as the air permeability value (m 3 / m 2 / min).

[0210] Test method for stacking height in bags

[0211] The in-bag stack height of the absorbent article package is determined as follows:

[0212] equipment

[0213] A thickness tester with a flat, rigid, horizontal slide is used. The thickness tester is configured so that the horizontal slide is free to move in a vertical direction, wherein the horizontal slide is always maintained in a horizontal orientation directly above a flat, rigid, horizontal substrate. The thickness tester includes a device suitable for measuring the gap between the horizontal slide and the horizontal substrate, accurate to within ±0.5 mm. The horizontal slide and the horizontal substrate are larger than the surface of the absorbent article package that contacts each plate, i.e., each plate extends beyond the contact surface of the absorbent article package in all directions. The horizontal slide applies a downward force of 850 g ± 1 gram-force (8.34 N) to the absorbent article package, which can be achieved by placing a suitable weight on the center of the top surface of the horizontal slide that does not contact the package, so that the total mass of the slide plus the added weight is 850 g ± 1 gram.

[0214] Test procedures

[0215] Prior to measurement, the absorbent article packages were equilibrated at 23°C ± 2°C and 50% ± 5% relative humidity.

[0216] The horizontal slide is raised and the absorbent article package is placed centrally underneath the horizontal slide in such a way that the absorbent articles in the package are in a horizontal orientation (see Fig.12 ). Any handles or other packaging features on the surface of the package that touches either of the plates are folded flat against the surface of the package to minimize their effect on the measurement. Slowly lower the horizontal slide until it contacts the top surface of the package, and then release. Ten seconds after releasing the horizontal slide, measure the gap between the horizontal plates to within ±0.5 mm. Measure five identical packages (packages of the same size and the same number of absorbent articles) and report the arithmetic mean as the package width. Calculate and report "stack height in bag" = (package width / number of absorbent articles per stack) × 10 to within ±0.5 mm.

[0217] The dimensions and values ​​disclosed herein are not to be construed as being strictly limited to the exact numerical values ​​cited. Instead, unless otherwise specified, each such dimension is intended to represent the stated value and a functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm." In addition, for all numerical ranges specified in this application, it is to be understood that the range includes all numerical increments within the stated range and all ranges formed therein or thereby. For example, numerical increments may be 0.1 mm, 1 gsm, and / or 0.1 mm. 2 .

[0218] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or patent application and any patent application or patent to which this application claims priority or the benefit of, is hereby incorporated by reference in its entirety. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein, nor is it an admission that it alone or in any combination with any other reference or references teaches, suggests or discloses any such invention. In addition, when any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0219] Although specific embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that many other changes and modifications may be made without departing from the spirit and scope of the present invention. Therefore, it is intended that all such changes and modifications within the scope of the present invention be covered in the appended claims.

Claims

1. An absorbent article, comprising: Top sheet; negative film; An absorbent core disposed between the top sheet and the back sheet; as well as at least one elastic ear comprising a laminate having an elastomeric layer and a nonwoven layer, wherein the laminate has a plurality of discrete primary ultrasonic bonds and a plurality of secondary ultrasonic bonds, wherein the elastomeric layer and the nonwoven layer remain permanently attached by the primary ultrasonic bonds and are releasably attached by the secondary ultrasonic bonds, and wherein the secondary ultrasonic bonds release when the laminate is extended by more than about 5 mm in a stretch direction.

2. The absorbent article of claim 1, wherein the bonding ratio is greater than about 1.

3. The absorbent article of claim 1, wherein the number of said plurality of primary discrete ultrasonic bonds is greater than the number of said plurality of secondary ultrasonic bonds.

4. The absorbent article according to any one of the preceding claims, wherein the laminate peel force is greater than or equal to 0.3 N / cm.

5. An absorbent article according to any one of the preceding claims 1, wherein the at least one elastic ear comprises a first portion and a second portion opposite to the first portion, wherein the first portion of the at least one elastic ear is bonded to at least one of the top sheet and the back sheet at a chassis attachment bond.

6. The absorbent article of claim 5, wherein the plurality of secondary ultrasonic bonds do not overlap with the chassis attachment bonds.

7. The absorbent article according to any one of the preceding claims, wherein at least a portion of the plurality of secondary ultrasonic bonds are released when the absorbent article is first applied to a wearer.

8. The absorbent article according to any one of the preceding claims, wherein the plurality of secondary ultrasonic bonds are evenly distributed on the laminate.

9. The absorbent article of any one of the preceding claims, wherein the plurality of primary ultrasonic bonds form one or more closed-cell units, and wherein at least a portion of the secondary ultrasonic bonds are disposed within the one or more closed-cell units.

10. The absorbent article according to any one of the preceding claims, wherein the primary ultrasonic bonds form a bond pattern upon release of the plurality of secondary ultrasonic bonds.

11. The absorbent article according to any one of the preceding claims, wherein the elastomeric layer is pre-activated.

12. The absorbent article according to any one of the preceding claims, wherein the laminate comprises one or more openings.

13. The absorbent article according to any one of the preceding claims, wherein the nonwoven layer of the laminate comprises at least one of a spunbond nonwoven, a carded nonwoven, a hydroentangled nonwoven, a through-air bonded nonwoven, and a spunlaced nonwoven.

14. The absorbent article of any one of the preceding claims, wherein the laminate has a plurality of pleats.

15. An absorbent article, comprising: Top sheet; negative film; An absorbent core disposed between the top sheet and the back sheet; as well as at least one elastic ear comprising a laminate having an elastomeric layer and a nonwoven layer, wherein the laminate has a plurality of discrete primary ultrasonic bonds and a plurality of secondary ultrasonic bonds, wherein the elastomeric layer and the nonwoven layer remain permanently attached by the primary ultrasonic bonds and are releasably attached by the secondary ultrasonic bonds, and wherein the secondary ultrasonic bonds release when the laminate is extended in a stretch direction by a force of at least 0.5 N / in.

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