Nonwoven material with shaped perforated regions

Abstract

A nonwoven material includes a plurality of fibers forming a nonwoven web having a perforated region with a plurality of pores. A width of the perforated region is defined between side portions of the perforated region, and the width of the perforated region tapers at a first end portion of the perforated region.

Description

Background Art

[0001] Nonwoven materials are often used in personal care absorbent articles, such as diapers or incontinence briefs. In addition, the liner of such articles faces and contacts the wearer's skin. The contact between body exudates (such as semi-solid fecal materials) captured in the article and the wearer's skin can cause discomfort. Allowing body exudates to move through the liner and away from the wearer's skin can reduce or limit this discomfort. Therefore, a nonwoven material having features that facilitate the movement of body exudates through the nonwoven material would be useful.

[0002] Nonwoven materials are subjected to various manufacturing processes to form personal care absorbent articles with nonwoven materials. For example, a roll of nonwoven material can be unrolled and cut to form the inner liner of such articles. Registration can help to accurately cut nonwoven materials from a roll. Some registration systems measure the light passing through the nonwoven material. However, this registration is affected by the holes in the nonwoven material. Therefore, a nonwoven material having the characteristics of facilitating the movement of body exudates through the nonwoven material while also being convenient for the registration of the nonwoven material will be useful. Summary of the invention

[0003] Generally speaking, the present disclosure relates to a nonwoven material having a feature that facilitates the movement of body exudates through the nonwoven material. The nonwoven material may include a plurality of fibers that form a nonwoven web. The perforated area of ​​the nonwoven web may advantageously allow body exudates to pass through the nonwoven material via a plurality of holes. The size and / or shape of the perforated area may be designed to facilitate the registration of the nonwoven material. For example, the perforated area may taper, for example, at the leading edge of the tapered area, to facilitate the registration of the nonwoven material. The nonwoven material with the perforated area may be incorporated into an absorbent article, such as a panty liner, a diaper, a disposable underwear, etc.

[0004] In an exemplary embodiment, the nonwoven material includes a plurality of fibers that form a nonwoven web that defines a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The nonwoven web includes a perforated area having a plurality of holes. The perforated area of ​​the nonwoven web has a first side portion and a second side portion spaced apart in the transverse direction, and also has a first end portion and a second end portion spaced apart in the longitudinal direction. The central portion of the perforated area is disposed between the first side portion and the second side portion of the perforated area in the transverse direction. The width of the perforated area is defined in the transverse direction, and the length of the perforated area is defined in the longitudinal direction. The width of the perforated area at the first end portion of the perforated area is less than the width of the perforated area at the central portion of the perforated area, and the length of the perforated area at the first side portion and the second side portion of the perforated area is less than the length of the perforated area at the central portion of the perforated area. A width of the perforated area at the first end portion of the perforated area is greater than twenty percent and less than ninety percent of a width of the perforated area at the center portion of the perforated area.

[0005] In another exemplary embodiment, the nonwoven material includes a plurality of fibers that form a nonwoven web that defines a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The nonwoven web includes a perforated area having a plurality of holes. The perforated area of ​​the nonwoven web has a first side portion and a second side portion spaced apart in the transverse direction, and also has a first end portion and a second end portion spaced apart in the longitudinal direction. The central portion of the perforated area is disposed between the first side portion and the second side portion of the perforated area in the transverse direction. The width of the perforated area defined in the transverse direction tapers gradually at the first end portion of the perforated area, so that the width of the perforated area at the first end portion of the perforated area is not less than 20 percent and not more than 80 percent of the width of the perforated area at the central portion of the perforated area.

[0006] In additional exemplary embodiments, a nonwoven material may include a plurality of fibers that form a nonwoven web that defines a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The nonwoven web includes a perforated area having a plurality of holes. The perforated area of ​​the nonwoven web has a first side portion and a second side portion spaced apart in the transverse direction, and also has a first end portion and a second end portion spaced apart in the longitudinal direction. The plurality of holes are distributed in a plurality of rows spaced apart in the longitudinal direction in the perforated area. A leading row in the plurality of rows is positioned at the first end portion of the perforated area. A second row in the plurality of rows is positioned adjacent to and continuous with the leading row in the plurality of rows. The total area of ​​the plurality of holes in the leading row is less than the total area of ​​the plurality of holes in the second row. The total area of ​​the leading row has a density in the longitudinal direction of greater than about four and nine-tenths square millimeters per millimeter.

[0007] These and other features, aspects and advantages of the present disclosure will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and together with the description serve to explain the principles of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A full and enabling disclosure of the present invention, including the best mode thereof, for those of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings.

[0009] Figure 1 is a top plan view of an absorbent article according to an exemplary embodiment of the present disclosure and in a stretched, flat, relaxed state.

[0010] Figure 2 is a process diagram depicting a manufacturing method including a registration process for registering a mesh according to example aspects of the present disclosure.

[0011] Figure 3 is a top plan view of a nonwoven material according to an example embodiment of the present disclosure.

[0012] Figure 4 yes Figure 3 A top plan view of a perforated area of ​​an example nonwoven material.

[0013] Figure 5 is a graph of a registration signal of a perforated area of ​​a nonwoven material according to example aspects of the present disclosure.

[0014] Repeated use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0015] In one embodiment, the present disclosure is generally directed to a nonwoven material having perforated areas.One of ordinary skill in the art will appreciate that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0016] When introducing elements of the present disclosure or preferred embodiments thereof, the articles "a", "an", "the" and "said" are intended to indicate that there are one or more of the elements. As used herein, the term "includes / including" is intended to be inclusive in a manner similar to the term "comprising". Similarly, the term "or" is generally intended to be inclusive (i.e., "A or B" is intended to mean "A or B or both"). Approximate language as used herein throughout the specification and claims is used to modify any quantitative representation that is permitted to vary without resulting in a change in the basic function associated therewith. Therefore, values ​​modified by one or more terms such as "about", "approximately" and "substantially" are not limited to the exact values ​​specified. In at least some cases, approximate language may correspond to the accuracy of the instrument used to measure the value. For example, approximate language may refer to within a limit of ten percent (10%).

[0017] definition:

[0018] The term "absorbent article" herein refers to an article that can be placed against or close to the wearer's body (i.e., adjacent to the body) to absorb and contain various liquid, solid and semi-solid exudates discharged from the body. Such absorbent articles as described herein are intended to be discarded after a limited period of use, rather than being washed or otherwise restored for reuse. It should be understood that the present disclosure is applicable to various disposable absorbent articles, including but not limited to diapers, diapers, training pants, older children's pants, swim trunks, feminine hygiene products (including but not limited to menstrual pads or menstrual pants), incontinence products, medical garments, surgical pads and bandages, other personal care or health care garments, etc., without departing from the scope of the present disclosure.

[0019] The term "acquisition layer" herein refers to a layer capable of accepting and temporarily holding liquid body exudates to decelerate and diffuse a gush or burst of liquid body exudates and subsequently release the liquid body exudates therefrom into another layer or layers of the absorbent article.

[0020] The term "bonded" or "coupled" herein refers to the joining, adhering, connecting, attaching, etc. of two elements. Two elements will be considered to be bonded or coupled together when they are joined, adhered, connected, attached, etc. directly to each other or indirectly to each other, such as when each element is directly bonded to an intermediate element. The joining or coupling of one element to another element can be performed by continuous or intermittent bonding.

[0021] The term "carded web" herein refers to a web containing natural or synthetic staple length fibers, typically less than about 100 mm in fiber length. The staple fiber bundles may be subjected to an opening process to separate the fibers, after which the fibers are sent to a carding process, where the fibers are separated and combed to align them in the machine direction, after which the fibers are deposited on a moving wire for further processing. Such webs typically undergo some bonding process, such as thermal bonding using heat and / or pressure. Additionally or alternatively, the fibers may undergo an adhesion process to bond the fibers together, for example, by using a powdered adhesive. The carded web may undergo fluid entanglement, such as hydroentanglement, to further entangle the fibers and thereby improve the integrity of the carded web. Since the fibers are aligned in the machine direction, the carded web, once bonded, typically has a machine direction strength greater than the cross machine direction strength.

[0022] The term "film" herein refers to thermoplastic films produced using extrusion and / or forming processes such as cast film or blown film extrusion processes. This term includes apertured films, slit films, and other porous films that constitute liquid transfer films, as well as films that do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.

[0023] The term "gsm" herein means grams per square meter.

[0024] The term "hydrophilic" herein refers to fibers or fiber surfaces that are wetted by aqueous liquids in contact with the fibers. The degree of wettability of a material can also be described in terms of the contact angle and surface tension of the liquids and materials involved. Equipment and techniques suitable for measuring the wettability of a particular fiber material or fiber material blend can be provided by a Cahn SFA-222 Surface Force Analyzer System, or a substantially equivalent system. When measured using this system, fibers having a contact angle of less than 90 are identified as "wettable" or hydrophilic, and fibers having a contact angle of greater than 90 are identified as "non-wettable" or hydrophobic.

[0025] The term "liquid-impermeable" herein refers to one or more layers of laminated materials wherein, under normal use conditions, liquid body exudates such as urine will not pass through the layer or laminated material in a direction generally perpendicular to the plane of the layer or laminated material at the point of liquid contact.

[0026] The term "liquid permeable" is used herein to refer to any material that is not liquid impermeable.

[0027] The term "meltblown" herein refers to fibers formed by extruding molten thermoplastic material through a plurality of fine, usually circular die capillaries as molten strands or filaments into a converging high velocity heated gas (e.g., air) stream, which attenuates the filaments of molten thermoplastic material to reduce their diameter, which may be a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and deposited on a collecting surface to form a web composed of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin et al., which is incorporated herein by reference. Meltblown fibers are microfibers that may be continuous or discontinuous, are typically less than about 0.6 denier, and may be tacky and self-adhesive when deposited on a collecting surface.

[0028] The term "nonwoven" herein refers to a material or web of material that is formed without the aid of a fabric weaving or knitting process. The material or web of material may have a structure of individual fibers, filaments, or threads (collectively referred to as "fibers") that may be interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven materials or webs may be formed by many processes, such as, but not limited to, meltblowing processes, spunbonding processes, carded web processes, and the like.

[0029] The term "flexible" herein refers to materials that are compliant and will readily conform to the general shape and contours of the wearer's body.

[0030] The term "spunbond" herein refers to small diameter fibers formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinning head having a circular or other configuration and then rapidly reducing the diameter of the extruded filaments by conventional processes such as draw-off drawing and the processes described in the following patents: U.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No. 3,502,538 to Peterson, and U.S. Pat. No. 3,542,615 to Dobo et al., each of which is incorporated herein by reference in its entirety. Spunbond fibers are substantially continuous and generally have an average denier greater than about 0.3, and in one embodiment between about 0.6, 5 and 10 and about 15, 20 and 40. Spunbond fibers are generally not tacky when deposited onto a collecting surface.

[0031] The term "superabsorbent" herein refers to a water-swellable, water-insoluble organic or inorganic material that is capable of absorbing at least about 15 times its weight, and in one embodiment at least about 30 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride under most favorable conditions. Superabsorbent materials can be natural, synthetic, and modified natural polymers and materials. Additionally, superabsorbent materials can be inorganic materials such as silica gel or organic compounds such as cross-linked polymers.

[0032] The term "thermoplastic" refers herein to a material that is softenable and shapeable when exposed to heat and that substantially returns to a non-softened state when cooled.

[0033] The term "user" or "caregiver" refers herein to a person who fits an absorbent article such as, but not limited to, a diaper, diapers, training pants, older children's pants, incontinence products or other absorbent articles around the wearer of one of these absorbent articles. The user and the wearer may be the same person.

[0034] Absorbent products:

[0035] Figure 1 is a top plan view of an absorbent article 10 in accordance with an exemplary embodiment of the present disclosure and in a stretched, flat, relaxed state. Figure 1 The exemplary embodiment shown in the drawings is shown as a diaper, but it should be understood that in other exemplary embodiments, the absorbent article 10 can be configured as other types of absorbent articles, such as training pants, larger children's pants, adult incontinence garments, and feminine hygiene products, etc. Although the exemplary embodiments and illustrations described herein can generally be applied to absorbent articles manufactured in the longitudinal direction of the product (hereinafter referred to as the longitudinal or machine direction of the product), it should be noted that without departing from the spirit and scope of the present disclosure, one of ordinary skill in the art can apply the information herein to absorbent articles manufactured in the latitudinal direction of the product, which is hereinafter referred to as the cross-machine direction of the product.

[0036] Figure 1The absorbent article 10 shown may include a backsheet 11. The absorbent article 10 may also include a front waist region 12, a back waist region 14, and a crotch region 16, wherein the crotch region is disposed between the front waist region 12 and the back waist region 14, and the front waist region 12 and the back waist region 14 are interconnected, respectively. The front waist region 12 may be referred to as a front end region, the back waist region 14 may be referred to as a back end region, and the crotch region 16 may be referred to as a middle region. For articles manufactured in a transverse manufacturing process, such as in a three-piece construction, such an absorbent article may have a backsheet, which includes a front waist piece defining a front waist region, a back waist piece defining a back waist region, and an absorbent piece defining a crotch region. The absorbent piece may extend between the front waist piece and the back waist piece. In some exemplary embodiments, the absorbent piece may overlap with the front waist piece and the back waist piece. The absorbent piece may be bonded to the front waist piece and the back waist piece to define a three-piece construction. However, it is conceivable that the absorbent article may be manufactured in the lateral direction without being a three-piece construction garment.

[0037] The absorbent article 10 can have a pair of longitudinal side edges 18, 20 and a pair of opposing waist edges, which are respectively designated as a front waist edge 22 and a rear waist edge 24. The front waist region 12 can be adjacent to the front waist edge 22, and the rear waist region 14 can be adjacent to the rear waist edge 24. The longitudinal side edges 18, 20 can extend from the front waist edge 22 to the rear waist edge 24. The longitudinal side edges 18, 20 can extend in a direction parallel to the longitudinal direction 30 throughout their length, such as for the absorbent article 10. In other exemplary embodiments, the longitudinal side edges 18, 20 can be curved between the front waist edge 22 and the rear waist edge 24.

[0038] The front waist region 12 may include a portion of the absorbent article 10 that is at least partially positioned on the front of the wearer when worn, and the back waist region 14 may include a portion of the absorbent article 10 that is at least partially positioned on the back of the wearer when worn. The crotch region 16 of the absorbent article 10 may include a portion of the absorbent article 10 that is positioned between the legs of the wearer when worn and may partially cover the lower body of the wearer. The waist edges 22 and 24 of the absorbent article 10 may be configured to surround the waist of the wearer and together define a central waist opening of the wearer's waist. When the absorbent article 10 is worn, the portions of the longitudinal side edges 18, 20 in the crotch region 16 may generally define the leg openings of the wearer's legs.

[0039] The absorbent article 10 may include an outer cover 26 and a body side liner 28. The outer cover 26 and the body side liner 28 may form part of the backsheet 11. In an exemplary embodiment, the body side liner 28 may be bonded to the outer cover 26 in an overlying relationship by any suitable mechanism, such as, but not limited to, adhesives, ultrasonic bonds, thermal bonds, pressure bonds, or other conventional techniques. The outer cover 26 may define a length in the longitudinal direction 30 and a width in the transverse direction 32, which in the exemplary embodiment shown may correspond to the length LAA and the width WAA of the absorbent article 10. As shown in FIG. Figure 1 As shown, the absorbent article 10 can have a longitudinal axis 29 extending in a longitudinal direction 30 and a transverse axis 31 extending in a transverse direction 32 .

[0040] The backsheet 11 may include an absorbent body 34. The absorbent body 34 may be disposed between the outer cover 26 and the body side liner 28. The absorbent body 34 may have longitudinal edges 36 and 38, which, in exemplary embodiments, may form portions of the longitudinal side edges 18 and 20 of the absorbent article 10, respectively. The absorbent body 34 may have a first end edge 40, respectively opposite to a second end edge 42, which, in exemplary embodiments, may form portions of the waist edges 22 and 24 of the absorbent article 10, respectively. In some exemplary embodiments, the first end edge 40 may be in the front waist region 12. In some exemplary embodiments, the second end edge 42 may be in the back waist region 14. In exemplary embodiments, the absorbent body 34 may have a length and width that are equal to or less than the length LAA and the width WAA of the absorbent article 10. The body side liner 28, the outer cover 26, and the absorbent body 34 may form a portion of an absorbent assembly 44. In exemplary embodiments of articles according to aspects of the present disclosure manufactured in a transverse manufacturing process, the absorbent body 34 may form the absorbent assembly 44. As is known in the art, the absorbent assembly 44 may further include a fluid transfer layer (not shown) and / or a fluid acquisition layer (not shown) positioned between the bodyside liner 28 and the absorbent chassis 34. The absorbent assembly 44 may further include a spacer layer (not shown) positioned between the absorbent chassis 34 and the outer cover 26.

[0041] The absorbent article 10 can be configured to contain and / or absorb liquid, solid and semi-solid body exudates discharged from the wearer. In some exemplary embodiments, the leakage-proof flaps 50, 52 can be configured to provide a barrier to the lateral flow of body exudates. In order to further enhance the leakage-proof and / or absorption of body exudates, the absorbent article 10 can appropriately include an elastic waist member 54. In some exemplary embodiments, the elastic waist member 54 can be disposed in the rear waist region 14 of the absorbent article 10. However, it is conceivable that the elastic waist member 54 can be additionally or alternatively disposed in the front waist region 12 of the absorbent article 10.

[0042] An elastic waist feature 54 may be disposed on the body-facing surface 19 of the backsheet 11 to help contain and / or absorb body exudates. Figure 1 In the absorbent article 10 depicted in , the elastic waist feature 54 can be disposed on the body-facing surface 45 of the absorbent assembly 44. In some exemplary embodiments, the elastic waist feature 54 can be at least partially disposed on the body-facing surface 56 of the bodyside liner 28.

[0043] The absorbent article 10 may also include leg elastic members 60, 62 known to those skilled in the art. The leg elastic members 60, 62 may be attached to the outer cover 26 and / or the bodyside liner 28 along the opposite longitudinal side edges 18 and 20 and positioned in the crotch region 16 of the absorbent article 10. The leg elastic members 60, 62 may be parallel to the longitudinal axis 29, such as Figure 1 or may be curved, as is known in the art. The leg elastic members 60, 62 may provide elasticized leg cuffs.

[0044] The outer cover 26 and / or portions thereof may be breathable and / or liquid impermeable. The outer cover 26 and / or portions thereof may be elastic, stretchable, or non-stretchable. The outer cover 26 may be constructed of a single layer, multiple layers, laminates, spunbond fabrics, films, meltblown fabrics, elastic netting, microporous webs, bonded carded webs, or foams provided by elastomeric or polymeric materials. In an exemplary embodiment, for example, the outer cover 26 may be constructed of a microporous polymer film such as polyethylene or polypropylene.

[0045] In an exemplary embodiment, the outer cover 26 can be a single layer of liquid-impermeable material, such as a polymer film. In an exemplary embodiment, the outer cover 26 can be appropriately stretchable at least in the transverse direction 32 of the absorbent article 10, and more appropriately elastic. In an exemplary embodiment, the outer cover 26 can be stretchable in both the transverse direction 32 and the longitudinal direction 30, and more appropriately elastic. In an exemplary embodiment, the outer cover 26 can be a multilayer laminate, at least one of which is liquid-impermeable. In some exemplary embodiments, the outer cover 26 can be a two-layer structure, which includes an outer layer (not shown) and an inner layer (not shown) that can be bonded together such as by a laminate adhesive. Suitable laminate adhesives can be applied in a continuous or intermittent manner as beads, spraying, parallel vortices, etc., but it should be understood that the inner layer can be bonded to the outer layer by other bonding methods including but not limited to ultrasonic bonding, thermal bonding, pressure bonding, etc.

[0046] The outer layer of the outer cover 26 can be any suitable material and can be a material that provides a generally cloth-like texture or appearance to the wearer. An example of such a material can be a 100% polypropylene bonded carded web with a diamond bond pattern available from Sandler AG of Germany, for example, 30 gsm Sawabond Or equivalent. Another example of a material suitable for use as the outer layer of the outer cover 26 can be a 20 gsm spunbond polypropylene nonwoven web. The outer layer can also be constructed of the same materials as the body side liner 28 can be constructed as described herein.

[0047] The liquid-impermeable inner layer of the outer cover 26 (or the liquid-impermeable outer cover 26, in which case the outer cover 26 has a single layer construction) can be vapor-permeable (i.e., "breathable") or vapor-impermeable. The liquid-impermeable inner layer (or the liquid-impermeable outer cover 26 when the outer cover 26 has a single layer construction) can be made of a thin plastic film. The liquid-impermeable inner layer (or the liquid-impermeable outer cover 26, in which case the outer cover 26 has a single layer construction) can inhibit liquid body exudates from leaking out of the absorbent article 10 and wetting articles such as bed sheets and clothing, as well as the wearer and caregiver.

[0048] In some exemplary embodiments, where the outer cover 26 has a single layer construction, it may be embossed and / or matte finished to provide a more cloth-like texture or appearance. The outer cover 26 may allow vapor to escape from the absorbent article 10 while preventing liquid from passing therethrough. Suitable liquid-impermeable, vapor-permeable materials may be composed of microporous polymer films or nonwoven materials that have been coated or otherwise treated to impart a desired level of liquid impermeability.

[0049] The absorbent body 34 may be appropriately constructed to be substantially compressible, conformable, flexible, non-irritating to the wearer's skin, and capable of absorbing and retaining liquid body exudates. The absorbent body 34 may be made into a variety of sizes and shapes (e.g., rectangular, trapezoidal, T-shaped, I-shaped, hourglass-shaped, etc.), and made of a variety of materials. The size and absorptive capacity of the absorbent body 34 should be compatible with the body shape of the intended wearer (infant to adult) and the liquid load applied by the intended use of the absorbent article 10. The absorbent body 34 may have a length and width that may be less than or equal to the length LAA and the width WAA of the absorbent article 10.

[0050] In an exemplary embodiment, the absorbent body 34 may be composed of hydrophilic fibers, cellulose fibers (e.g., wood pulp fibers), natural fibers, web materials of synthetic fibers, woven or nonwoven sheets, scrims or other stable structures, superabsorbent materials, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, lotions, odor control agents, etc., and combinations thereof. In an exemplary embodiment, the absorbent body 34 may be a matrix of cellulose fluff and superabsorbent materials. In another exemplary embodiment, the absorbent body 34 may mainly include superabsorbent materials, or even more than 80% superabsorbent materials, more than 90% superabsorbent materials, or 100% superabsorbent materials by weight of the absorbent material of the absorbent body 34. However, in other exemplary embodiments, the absorbent body 34 may not contain superabsorbent materials. In an exemplary embodiment, the absorbent body 34 may be constructed of a single layer of material, or in an alternative, may be constructed of two or more layers of material.

[0051] Various types of wettable, hydrophilic fibers can be used in the absorbent body 34. Examples of suitable fibers include: natural fibers; cellulosic fibers; synthetic fibers composed of cellulose or cellulose derivatives, such as rayon fibers; inorganic fibers composed of essentially wettable materials, such as glass fibers; synthetic fibers made of essentially wettable thermoplastic polymers, such as certain polyester or polyamide fibers, or synthetic fibers composed of non-wettable thermoplastic polymers, such as polyolefin fibers that have been hydrophilized by suitable means. For example, the fibers can be hydrophilized by treatment with a surfactant, treatment with silica, treatment with a material having a suitable hydrophilic portion that is not easily removed from the fibers, or by coating non-wettable hydrophobic fibers with a hydrophilic polymer during or after fiber formation. Suitable superabsorbent materials can be selected from natural, synthetic, and modified natural polymers and materials. Superabsorbent materials can be inorganic materials such as silica gel or organic compounds such as cross-linked polymers.

[0052] If a spacer layer is present, the absorbent body 34 may be disposed on the spacer layer and superimposed on the outer cover 26. The spacer layer may be bonded to the outer cover 26, for example, by an adhesive. In some exemplary embodiments, there may be no spacer layer, and the absorbent body 34 may be in direct contact with the outer cover 26 and may be directly bonded to the outer cover 26. However, it should be understood that the absorbent body 34 may be in contact with the outer cover 26 but not bonded thereto and remain within the scope of the present disclosure. In an exemplary embodiment, the outer cover 26 may be composed of a single layer, and the absorbent body 34 may be in contact with the single layer of the outer cover 26. In some exemplary embodiments, at least a portion of a layer such as, but not limited to, a fluid transfer layer and / or a spacer layer may be positioned between the absorbent body 34 and the outer cover 26. The absorbent body 34 may be bonded to the fluid transfer layer and / or the spacer layer.

[0053] The body side liner 28 of the absorbent article 10 may overlie the absorbent body 34 and the outer cover 26 and may isolate the wearer's skin from waste fluids held by the absorbent body 34. In various exemplary embodiments, a fluid transfer layer may be positioned between the body side liner 28 and the absorbent body 34. In various exemplary embodiments, an acquisition layer (not shown) may be positioned between the body side liner 28 and the absorbent body 34 or the fluid transfer layer (if present). In various exemplary embodiments, the body side liner 28 may be bonded to the acquisition layer or the fluid transfer layer (if an acquisition layer is not present) via an adhesive and / or by point fusion bonding. The point fusion bonding may be selected from ultrasonic bonding, thermal bonding, pressure bonding, and combinations thereof.

[0054] In an exemplary embodiment, the body-side liner 28 may extend beyond the absorbent body 34 and / or the fluid transfer layer (if present) and / or the acquisition layer (if present) and / or the spacer layer (if present) to overlie a portion of the outer cover 26 and may be bonded to that portion by any method deemed suitable (e.g., by bonding to that portion by an adhesive) to substantially enclose the absorbent body 34 between the outer cover 26 and the body-side liner 28. It is contemplated that the body-side liner 28 may be narrower than the outer cover 26. However, in other exemplary embodiments, the body-side liner 28 and the outer cover 26 may have the same width and length dimensions, for example, as may be seen in Figure 1 In the exemplary embodiment shown, it can be seen that the body side liner 28 can be wider than the outer cover 26. It is also conceivable that the body side liner 28 may not extend beyond the absorbent body 34 and / or may not be fixed to the outer cover 26. In some exemplary embodiments, the body side liner 28 can wrap at least a portion of the absorbent body 34, including wrapping around the longitudinal edges 36, 38 and / or one or more end edges 40, 42 of the absorbent body 34. It is further conceivable that the body side liner 28 can be composed of more than one material section. The body side liner 28 can have different shapes, including rectangular, hourglass or any other shape. The body side liner 28 can be appropriately conformable, soft and comfortable and non-irritating to the wearer's skin, and can be the same or lower than the hydrophilicity of the absorbent body 34 to allow body exudates to easily penetrate into the absorbent body 34 and provide a relatively dry surface for the wearer.

[0055] The body side liner 28 can be made of various types of materials, such as synthetic fibers (e.g., polyester fibers or polypropylene fibers), natural fibers (e.g., wood fibers or cotton fibers), combinations of natural and synthetic fibers, porous foams, cellular foams, perforated plastic films, etc. Examples of suitable materials include, but are not limited to, rayon, wood, cotton, polyester, polypropylene, polyethylene, nylon or other heat-bondable fibers, polyolefins, such as, but not limited to, copolymers of polypropylene and polyethylene, linear low-density polyethylene and aliphatic esters such as polylactic acid, perforated film webs, mesh materials, etc., and combinations thereof.

[0056] Various woven and nonwoven fabrics can be used for the body side liner 28. The body side liner 28 can include woven fabrics, nonwoven fabrics, polymer films, film-fabric laminates, etc., and combinations thereof. Examples of nonwoven fabrics can include spunbond fabrics, meltblown fabrics, coformed fabrics, carded webs, bonded carded webs, bicomponent spunbond fabrics, spunlace fabrics, etc., and combinations thereof. The body side liner 28 is not necessarily a single layer structure, and therefore can include more than one layer of fabric, film and / or web, and combinations thereof. For example, the body side liner 28 can include a support layer and a protruding layer that can be hydroentangled. The protruding layer can include hollow protrusions, such as those disclosed in U.S. Pat. No. 9,474,660 to Kirby, Scott SC et al.

[0057] For example, the body side liner 28 can be composed of a meltblown or spunbond web of polyolefin fibers. Alternatively, the body side liner 28 can be a bonded carded web composed of natural fibers and / or synthetic fibers. The body side liner 28 can be composed of a substantially hydrophobic material, and the hydrophobic material can optionally be treated with a surfactant or otherwise treated to impart a desired degree of wettability and hydrophilicity. The surfactant can be applied by any conventional mechanism such as spraying, printing, brushing, etc. The surfactant can be applied to the entire body side liner 28, or the surfactant can be selectively applied to specific sections of the body side liner 28.

[0058] In an exemplary embodiment, the body side liner 28 can be constructed of a nonwoven bicomponent web. The nonwoven bicomponent web can be a spunbond bicomponent web or a bonded carded bicomponent web. Examples of bicomponent tufted fibers include polyethylene / polypropylene bicomponent fibers. In this particular bicomponent fiber, the polypropylene forms the core and the polyethylene forms the sheath of the fiber. Fibers with other orientations, such as multi-lobed, side-by-side, end-to-end, can be used without departing from the scope of the present disclosure. In an exemplary embodiment, the body side liner 28 can be a spunbond substrate having a basis weight of about 10 or 12 to about 15 or 20 gsm. In an exemplary embodiment, the body side liner 28 can be a 12 gsm spunbond-meltblown-spunbond substrate with 10% meltblown content applied between the two spunbond layers.

[0059] Although the outer cover 26 and the body side liner 28 can include elastomeric materials, it is contemplated that the outer cover 26 and the body side liner 28 can be constructed of substantially non-elastomeric materials. In example embodiments, the body side liner 28 can be stretchable, and more suitably elastic. In example embodiments, the body side liner 28 can be suitably stretchable, and more suitably elastic, at least in the lateral or circumferential directions of the absorbent article 10. In other example aspects, the body side liner 28 can be stretchable, and more suitably elastic, in both the transverse direction 32 and the longitudinal direction 30, respectively.

[0060] In an exemplary embodiment, the absorbent article 10 may include a pair of anti-leakage flaps 50, 52. The anti-leakage flaps 50, 52 may be formed separately from the absorbent backsheet 11 and attached to the backsheet 11, or may be formed integrally with the backsheet 11. In some exemplary embodiments, the anti-leakage flaps 50, 52 may be fixed to the backsheet 11 of the absorbent article 10 in a generally parallel and spaced relationship from each other laterally from the leg openings to provide a barrier to prevent body exudates from flowing. One anti-leakage flap 50 may be on a first side of the longitudinal axis 29, and another anti-leakage flap 52 may be on a second side of the longitudinal axis 29. In an exemplary embodiment, the anti-leakage flaps 50, 52 may extend generally in the longitudinal direction 30 from the front waist region 12 of the absorbent article 10 through the crotch region 16 to the back waist region 14 of the absorbent article 10. In some exemplary embodiments, the containment flaps 50, 52 may extend in a direction substantially parallel to the longitudinal axis 29 of the absorbent article 10, but in other exemplary embodiments, the containment flaps 50, 52 may be curved as is known in the art.

[0061] In example embodiments where the containment flaps 50, 52 are attached to the backsheet 11, the containment flaps 50, 52 can be bonded to the body-side liner 28 using a barrier adhesive, wherein the barrier adhesive connects the tabs 66 to the body-facing surface 19 of the backsheet 11, or in some example embodiments where the body-side liner 28 does not extend to the entire lateral width of the outer cover 26, the containment flaps 50, 52 can be bonded to the outer cover 26 using a barrier adhesive. Of course, the containment flaps 50, 52 can be bonded to other components of the backsheet 11 and can be bonded using other suitable mechanisms other than a barrier adhesive. The containment flaps 50, 52 can be constructed of a fibrous material that can be similar to the material forming the body-side liner 28. Other conventional materials, such as polymer films, can also be used.

[0062] The leakage-proof flaps 50, 52 can each include a base portion 64 and a protruding portion 66. The base portion 64 can be bonded to the backsheet 11, for example, bonded to the body side liner 28 or the outer cover 26 as described above. The base portion 64 can include a proximal end 64a and a distal end 64b. The protruding portion 66 can be separated from the base portion 64 at the proximal end 64a of the base portion 64. As used in this context, the protruding portion 66 can be separated from the base portion 64 at the proximal end 64a of the base portion 64, because the proximal end 64a of the base portion 64 defines the transition between the protruding portion 66 and the base portion 64. The proximal end 64a of the base portion 64 can be located near the barrier adhesive. In some exemplary embodiments, the distal end 64b of the base portion 64 can extend laterally to the corresponding longitudinal side edges 18, 20 of the absorbent article 10. In other exemplary embodiments, the distal end 64b of the base portion 64 can terminate laterally inwardly of the respective longitudinal side edges 18, 20 of the absorbent article 10. The containment flaps 50, 52 can also each include a protruding portion 66 configured to extend away from the body-facing surface 19 of the backsheet 11 at least in the crotch region 16 when the absorbent article 10 is in a relaxed configuration. The containment flaps 50, 52 can include a pinning area 71 in either or both of the front waist region 12 and the back waist region 14, where the protruding portion 66 is coupled to the body-facing surface 19 of the backsheet 11.

[0063] It is contemplated that the containment flaps 50, 52 may have a variety of configurations and shapes and may be constructed in a variety of ways. For example, Figure 1The containment flaps 50, 52 of the embodiment of the present invention depict longitudinally extending containment flaps 50, 52 having pinned areas 71 in both the front waist region 12 and the back waist region 14, where the protruding portion 66 of each containment flap 50, 52 is pinned into the body side liner 28 toward or away from the longitudinal axis 29 of the absorbent article 10. However, the containment flaps 50, 52 may include pinned areas 71 where the protruding portion 66 of each of the containment flaps 50, 52 is folded back on itself and coupled to itself and the body side liner 28 in a "C-shaped" configuration, as known in the art and described in U.S. Pat. No. 5,895,382 to Robert L. Popp et al. As yet another alternative, it is contemplated that the containment flaps 50, 52 may be constructed in a "T-shaped" configuration, such as described in U.S. Pat. No. 9,259,362 to Robert L. Popp et al. Such a configuration may also include pinning areas 71 in either or both of the front waist region 12 and the back waist region 14. Of course, other configurations of containment flaps 50, 52 may be used in the absorbent article 10 and still be within the scope of the present disclosure.

[0064] The containment flaps 50, 52 may include one or more flap elastic members 68, such as Figure 1 . Suitable elastic materials for the flap elastic members 68 may include sheets, strands or strips of natural rubber, synthetic rubber or thermoplastic elastomer materials. Of course, although two elastic members 68 are shown in each containment flap 50, 52, it is contemplated that the containment flaps 50, 52 may be constructed with one or three or more elastic members 68. Alternatively or in addition, the containment flaps 50, 52 may be constructed of a material that exhibits elastic properties itself.

[0065] like Figure 1 The flap elastic member 68 shown in the figure can have two strands of elastomeric material that extend longitudinally in a generally parallel and spaced relationship with each other in the protruding portion 66 of the containment flaps 50, 52. The elastic member 68 can be located within the containment flaps 50, 52 when in an elastically contractible state so that contraction of the strands gathers and shortens the protruding portion 66 of the containment flaps 50, 52 in the longitudinal direction 30. Therefore, when the absorbent article 10 is in a relaxed configuration, in the generally upright orientation of the containment flaps 50, 52, the elastic member 68 can bias the protruding portion 66 of the containment flaps 50, 52 to extend away from the body-facing surface 45 of the absorbent assembly 44, particularly in the crotch region 16 of the absorbent article 10.

[0066] During the manufacture of the containment flaps 50, 52, at least a portion of the elastic member 68 may be bonded to the containment flaps 50, 52 when the elastic member 68 is stretched. The elongation percentage of the elastic member 68 may be, for example, about 110% to about 350%. Before attaching the elastic member 68 to the containment flaps 50, 52, the elastic member 68 may be coated with an adhesive when it is stretched to a specified length. In the stretched state, the length of the elastic member 68 with the adhesive attached thereto may provide an active flap elastic region 70 in the containment flaps 50, 52, such as Figure 1 , which will gather when the absorbent article 10 relaxes. The active flap elastic area 70 of the containment flaps 50, 52 can have a longitudinal length that is less than the length LAA of the absorbent article 10. In this exemplary method of bonding the elastic members 68 to the containment flaps 50, 52, the un-adhesive-coated portions of the elastic members 68 will retract after the elastic members 68 and the absorbent article 10 are cut to form individual absorbent articles 10 during the manufacturing process. As described above, the relaxation of the elastic members 68 in the active flap elastic area 70 when the absorbent article 10 is in a relaxed state can cause each containment flap 50, 52 to gather and cause the protruding portion 66 of each containment flap 50, 52 to extend away from the body-facing surface 19 of the backsheet 11 (e.g., the body-facing surface 45 of the absorbent assembly 44, or the body-facing surface 56 of the bodyside liner 28).

[0067] Of course, the elastic members 68 can be bonded to the containment flaps 50, 52 in a variety of other ways known to those skilled in the art to provide the active flap elastic zones 70, which are within the scope of the present disclosure. In addition, the active flap elastic zones 70 can be shorter or longer than depicted herein, including extending to the front waist edge 22 and the back waist edge 24, which are still within the scope of the present disclosure.

[0068] The leg elastic members 60, 62 can be fixed to the outer cover 26, such as, at the longitudinal side edges 18 and 20 of the absorbent article 10, generally laterally inward, by being bonded to the outer cover with a laminate adhesive. The leg elastic members 60, 62 can form elasticized leg cuffs to further help contain body exudates. In an exemplary embodiment, the leg elastic members 60, 62 can be arranged between the inner layer and the outer layer (not shown) of the outer cover 26 or between other layers of the absorbent article 10, for example, between the base portion 64 of each containment flap 50, 52 and the body side liner 28, between the base portion 64 of each containment flap 50, 52 and the outer cover 26, or between the body side liner 28 and the outer cover 26. The leg elastic members 60, 62 can be one or more elastic components near each longitudinal side edge 18, 20. For example, the leg elastic members 60, 62 as shown herein can each include two elastic strands. A wide variety of elastic materials can be used for the leg elastic members 60, 62. Suitable elastic materials can include sheets, strands or strips of natural rubber, synthetic rubber or thermoplastic elastic materials. The elastic material can be stretched and fixed to the substrate, fixed to the gathered substrate, or fixed to the substrate and then elasticized or shrunk, such as by applying heat, so that the elastic retractive force is imparted to the substrate. In addition, it is contemplated that in some exemplary embodiments, the leg elastic members 60, 62 can be formed with anti-leakage flaps 50, 52 and then attached to the backsheet 11. Of course, the leg elastic members 60, 62 can be omitted from the absorbent article 10 without departing from the scope of the present disclosure.

[0069] In an exemplary embodiment, the absorbent article 10 may have one or more elastic waist features 54. The elastic waist feature 54 may be as follows: Figure 1 14, or in both the rear waist region 14 and the front waist region 12. Although generally described in the present disclosure with reference to a single elastic waist member, it should be understood that this description is equally applicable to each elastic waist member in the exemplary embodiment containing multiple elastic waist members 54. As will be discussed in more detail below, the elastic waist member 54 can help to accommodate and / or absorb body exudates (especially low viscosity feces), and thus can be preferably located in the rear waist region 14. The elastic waist member 54 in the front waist region 12 can help to accommodate and / or absorb body exudates, such as urine, in the front waist region 12. Although not as common as in the rear waist region 14, in some cases, feces may also spread to the front waist region 12, and therefore, the elastic waist member 54 arranged in the front waist region 12 can also help to accommodate and / or absorb body exudates.

[0070] The elastic waist member 54 can be composed of a variety of materials. In a preferred exemplary embodiment, the elastic waist member 54 can be composed of a spunbond-meltblown-spunbond ("SMS") material. However, it is conceivable that the elastic waist member 54 can be composed of other materials, such as spunbond-film-spunbond ("SFS") material, bonded carded web ("BCW") material or any nonwoven material. In some exemplary embodiments, the elastic waist member 54 can be composed of more than one laminate or other material in these exemplary materials. In some exemplary embodiments, the elastic waist member 54 can be composed of a liquid-impermeable material, such as a film material. In some exemplary embodiments, the elastic waist member 54 can be composed of a material coated with a hydrophobic coating. The basis weight of the material forming the elastic waist member 54 can vary, but in a preferred exemplary embodiment, when the elastic member 86 is not included in the elastic waist member 54, the basis weight can be between about 8gsm and about 120gsm. The basis weight of the material comprising the elastic waist feature 54 may more preferably be between about 10 gsm and about 40 gsm, and even more preferably between about 15 gsm and about 25 gsm.

[0071] The elastic waist member 54 may include a first longitudinal side edge 72, a second longitudinal side edge 74, a first end edge of the waist member that joins the first longitudinal side edge 72 with the second longitudinal side edge 74, and a second end edge of the waist member. The first longitudinal side edge 72 may be opposite to the second longitudinal side edge 74. The distance between the first longitudinal side edge 72 and the second longitudinal side edge 74 may define the width of the elastic waist member 54 in the transverse direction 32. Although not depicted, in some exemplary embodiments, the first longitudinal side edge 72 may be substantially aligned with the first longitudinal side edge 18 of the absorbent article 10. Similarly, in some exemplary embodiments, the second longitudinal side edge 74 may be aligned with the second longitudinal side edge 20 of the absorbent article 10. As shown in FIG. Figure 1 , the elastic waist member 54 can be configured so that the first longitudinal side edge 72 can be disposed laterally outward from the proximal end 64a of the base portion 64 of the containment flap 50. Similarly, the elastic waist member 54 can be configured so that the second longitudinal side edge 74 can be disposed laterally outward from the proximal end 64a of the base portion 64 of the containment flap 52.

[0072] In preferred example embodiments, the elastic waist member 54 may include at least one elastic member 86. In some example embodiments, the elastic waist member 54 may include a plurality of elastic members 86, such as five elastic members 86. Of course, it is contemplated that the elastic waist member 54 may include other numbers of elastic members 86, such as three, four, six, eight, or ten elastic members, and in some example embodiments, the elastic waist member may not include an elastic member 86. The elastic member 86 may span substantially from the first longitudinal side edge 72 to the second longitudinal side edge 74 of the elastic waist member 54. In some example embodiments, the elastic members 86 may be evenly spaced apart in the longitudinal direction 30. At least one of the elastic members 86 may be disposed proximate to the waist member second end edge of the elastic waist member 54.

[0073] A wide variety of elastic materials can be used for the elastic member 86 in the elastic waist member 54. Suitable elastic materials can include sheets, strands or strips of natural rubber, synthetic rubber, thermoplastic elastomeric materials or elastic foams. The elastic material can be stretched and fixed to the substrate forming the elastic waist member 54, fixed to the gathered substrate, or fixed to the substrate and then elasticized or contracted, such as by applying heat, so that an elastic retractive force is imparted to the substrate forming the elastic waist member 54.

[0074] In some exemplary embodiments, the elastic waist feature 54 can be disposed on the body-facing surface 45 of the absorbent assembly 44. In some exemplary embodiments, such as Figure 1 In the exemplary embodiment shown in , the elastic waist feature 54 can be disposed on the body-facing surface 56 of the bodyside liner 28.

[0075] In various exemplary embodiments, the elastic waist member 54 may also include a proximal portion (not shown) and a distal portion (not shown). The proximal portion may be coupled to the body-facing surface 19 of the backsheet 11 (e.g., the body-facing surface 45 of the absorbent assembly 44, or the body-facing surface 56 of the body-side liner 28), while the distal portion of the elastic waist member 54 or at least a portion of the distal portion may be freely movable relative to the backsheet 11 and the absorbent assembly 44 when the absorbent article 10 is in a relaxed configuration. A first fold (not shown) may separate the proximal portion from the distal portion in various exemplary embodiments of the elastic waist member 54 discussed herein. As used in this context, the first fold separates the proximal portion from the distal portion because the first fold defines a transition between the proximal portion and the distal portion in the elastic waist member material and the elastic waist member 54 as a whole. In alternative exemplary embodiments (not shown), the proximal portion and the distal portion may be made of separate materials that are attached to each other, such as in the region of the first fold or replace the first fold. The physical form of attachment may be by way of a butt seam or a lap seam, for example.

[0076] The proximal portion of such an elastic waist feature 54 may be coupled to the body-facing surface 19 of the backsheet 11 using adhesive, and in some exemplary embodiments, the proximal portion may be coupled to the body-facing surface 45 of the absorbent assembly 44. In some exemplary embodiments, the proximal portion of the elastic waist feature 54 may be coupled to the body-facing surface 56 of the body-side liner 28. However, in some exemplary embodiments, the proximal portion of the elastic waist feature 54 may be coupled to the body-facing surface 58 of the back waist panel 15. The proximal portion may be coupled to the body-facing surface 45 of the absorbent assembly 44 using adhesive along the entire length of the proximal portion in the longitudinal direction 30. However, it is contemplated that only a portion of the proximal portion in the longitudinal direction 30 may be coupled to the body-facing surface 45 of the absorbent assembly 44. Of course, it is contemplated that the proximal portion of the elastic waist feature 54 may be coupled to the body-facing surface 19 of the backsheet 11 or the body-facing surface 45 of the absorbent assembly 44 by means other than adhesive, such as by pressure bonding, ultrasonic bonding, thermal bonding, and combinations thereof. In a preferred exemplary embodiment, the proximal portion is connected to the body-facing surface 19 of the backsheet 11 along the transverse axis 31 in the transverse direction 32 in a continuous manner as opposed to an intermittent manner, such that a barrier to body exudates is formed between the proximal portion and the body-facing surface 19 of the backsheet 11.

[0077] The proximal portion of the elastic waist member 54 may include a longitudinal length, measured along the longitudinal axis 29 in the longitudinal direction 30, that is shorter than a longitudinal length of a distal portion (not shown) of the elastic waist member 54. However, in some exemplary embodiments, the longitudinal length of the proximal portion may be substantially equal to or greater than the longitudinal length of the distal portion of the elastic waist member 54. It will be appreciated that the relative longitudinal lengths of the proximal and distal portions may vary between exemplary embodiments of the elastic waist member 54 without departing from the scope of the present disclosure.

[0078] In this type of exemplary embodiment of elastic waist member 54, because when absorbent article 10 is in a relaxed configuration, the distal portion of elastic waist member 54 can move freely relative to absorbent assembly 44, so when absorbent article 10 is in a relaxed configuration, when worn by the wearer, the distal portion can help provide a leakproof bag. The leakproof bag can help provide a barrier to accommodate and / or absorb body exudates. The first longitudinal side edge 72 can be arranged laterally outward from the proximal end 64a of the base portion 64 of the leakproof flap 50, so that the bag can extend laterally outward from the proximal end 64a of the leakproof flap 50. Similarly, the second longitudinal side edge 74 can be arranged laterally outward from the proximal end 64a of the base portion 64 of the leakproof flap 52, so that the bag can extend laterally outward from the proximal end 64a of the leakproof flap 52. This configuration provides an elastic waist member 54 with a spacious leakproof bag to accommodate and / or absorb body exudates. To help prevent the lateral flow of body exudates contained in the leak-proof pocket of the elastic waist member 54, the distal portion of the elastic waist member 54 can be bonded to the proximal portion of the elastic waist member 54 and / or the body-facing surface 19 of the backsheet 11 near the first longitudinal side edge 72 and the second longitudinal side edge 74, respectively. Figure 1 Pinning areas 84 are depicted where the distal portion of the elastic waist member 54 can be bonded to the proximal portion of the elastic waist member 54 and / or the body-facing surface 19 of the backsheet 11 near the first and second longitudinal side edges 72, 74, respectively.

[0079] like Figure 1 As depicted in FIG. 1 , in some exemplary embodiments, the elastic waist member 54 can be disposed on the body-facing surface 19 of the backsheet 11 so that a gap is provided between the second end edge 42 of the absorbent body 34 and the second end edge of the waist member of the distal portion of the elastic waist member 54. By providing a gap, the leak-proof pocket can have a larger void volume to accommodate body exudates. In addition, it is believed that the gap can help body exudates enter the leak-proof pocket of the elastic waist member 54.

[0080] The elastic waist member 54 may be arranged to be coupled to the chassis 11 by being placed above or below the containment flaps 50, 52. More specifically, as Figure 1 As shown in the figure, the elastic waist member 54 can be arranged on the body-facing surface 19 of the backsheet 11 so that the proximal portion of the elastic waist member 54 is arranged above the corresponding base portions 64 of the first and second containment flaps 50, 52. Alternatively, the elastic waist member 54 can be arranged on the body-facing surface 19 of the backsheet 11 so that the proximal portion of the elastic waist member 54 is arranged below the corresponding base portions 64 of the first and second containment flaps 50, 52. Both configurations can provide advantages that facilitate the elastic waist member 54 to function to contain and / or absorb body exudates.

[0081] The exemplary embodiment in which the proximal portion of the elastic waist member 54 is disposed above the base portion 64 of the containment flaps 50, 52 may provide the following advantages: the containment flaps 50, 52 may help the distal portion of the elastic waist member 54 to extend away from the body-facing surface 45 of the absorbent assembly 44 when the absorbent article 10 is applied to the wearer. This is particularly important in the case where the proximal portion of the elastic waist member 54 has a shorter longitudinal length than the distal portion of the elastic waist member 54. For example, when the proximal portion is shorter than the distal portion, the flap elastics 68 in the protruding portions 66 of the containment flaps 50, 52 may provide an opening force to the distal portion of the elastic waist member 54 when the absorbent article 10 is in a relaxed configuration and applied to the wearer, thereby helping the distal portion to extend away from the body-facing surface 45 of the absorbent assembly 44 and open the containment pocket. In some exemplary embodiments, in addition or as an alternative, the containment pocket can be opened by configuring the containment flaps 50, 52 to have a movable flap elastic zone 70 that longitudinally overlaps the distal portion of the elastic waist member 54 when the absorbent article 10 is in the stretched flat configuration, such as Figure 1 Additionally or alternatively, the leak-proof pocket of the elastic waist member 54 can be opened by configuring the leak-proof flaps 50, 52 to have a pinning area 71 that does not extend to the distal edge of the distal portion of the elastic waist member 54, such as Figure 1 However, such a configuration of the pinning area 71 is not required, and in some exemplary embodiments, the pinning area 71 may extend from the rear waist edge 24 through the distal edge of the distal portion of the elastic waist member 54.

[0082] The example embodiment in which the proximal portion of the elastic waist member 54 is disposed below the base portion 64 of the containment flaps 50, 52 can provide the following advantages: the leak-proof pocket is formed by the elastic waist member 54 that is not constrained by the protruding portion 66 of the leak-proof flaps 50, 52. The base portion 64 and the protruding portion 66 of each leak-proof flap 50, 52 can be connected to the body-facing surface 55 of the elastic waist member 54. Therefore, body exudates can be more freely diffused through the entire width of the leak-proof pocket created by the elastic waist member 54. In addition, connecting the base portion 64 of the leak-proof flaps 50, 52 to the outer cover 26 (or to the body-side liner 28 in some example embodiments) can create a longitudinal barrier that prevents body exudates from lateral diffusion beyond the position of the barrier adhesive from flowing out of the leak-proof pocket, and the barrier adhesive connects the protruding portion 66 of the flaps 50, 52 to the body-facing surface 19 of the backsheet 11. In some exemplary embodiments, the pinned area 71 of the protruding portion 66 of each of the containment flaps 50, 52 may longitudinally overlap the distal portion of the elastic waist member 54. In some exemplary embodiments, the pinned area 71 of the protruding portion 66 of each of the containment flaps 50, 52 may extend to the distal edge of the elastic waist member 54 to further help contain exudates within the containment pocket created by the elastic waist member 54. For example, the containment pocket and other features of the absorbent article 10 may be formed in the same or similar manner as described in U.S. Patent No. 10,159,610, which is incorporated herein by reference in its entirety for all purposes.

[0083] In an exemplary embodiment, the absorbent article 10 can include a fastening system. The fastening system can include one or more rear fasteners 91 and one or more front fasteners 92. Figure 1 The exemplary embodiment shown in illustrative figures depicts an exemplary embodiment having one front fastener 92. Multiple portions of the fastening system may be included in the front waist region 12, the rear waist region 14, or both.

[0084] The fastening system can be configured to secure the absorbent article 10 around the waist of the wearer in a fastened state and help keep the absorbent article 10 in place during use. In an exemplary embodiment, the back fastener 91 can include one or more materials bonded together to form a composite ear panel, as is known in the art. For example, the composite fastener can be made of, for example, Figure 1 , a nonwoven carrier or hook seat 96, and a fastening member 98. In some exemplary embodiments, the elastic waist member 54 can extend laterally to each of the rear fastener 91 and / or the longitudinal side edges 18, 20 of the absorbent article 10. In some exemplary embodiments, the elastic waist member 54 can be directly or indirectly coupled to the stretch member 94 of the rear fastener 91.

[0085] According to some exemplary embodiments of the present disclosure, the bodyside liner 28 of the article 10 may also include regions having different morphological features. In various exemplary embodiments, the morphological features may include one or more of the following: discrete perforated regions; discrete recessed and / or raised regions, for example, having recesses and / or hollow protrusions (such as those formed by embossing or other such web modification processes); discrete holes (whether integrally formed during web formation or formed by a post-web formation process); and / or discrete filled protrusions extending above or below the generally planar surface of the web, depending on orientation.

[0086] As a specific example, the bodyside liner 28 may include a first feature area 21 having one or more first features 23 and a second feature area 25 having one or more second features 27. Figure 1 In the example embodiment shown in , the features 23, 27 can be holes extending through the body side liner 28. The holes 23, 27 can help transfer body exudates through the body side liner 28 to the interior portion of the article 10, where the exudates are stored and set away from the wearer's skin. However, although described in more detail below in the context of holes, it should be understood that in other example embodiments, each of the first feature area 21 and the second feature area 25 may include one or more alternative structural features. For example, each of the first feature area 21 and the second feature area 25 may include one or more of embossing, protrusions, depressions, perforations, protrusions, depressions, holes, etc. Therefore, each of the first feature area 21 and the second feature area 25 may include discrete structural features 23, 27 on the body side liner 28, and the structural features 23 in the first feature area 21 may be spaced apart from the structural features 27 in the second feature area 25 on the body side liner 28. In certain example embodiments, the size and / or formation of the structural features 23 in the first feature region 21 may be different than the structural features 27 in the second feature region 25. Thus, for example, the structural features 23 in the first feature region 21 may provide different performance characteristics than the structural features 27 in the second feature region 25. Furthermore, each of the first feature region 21 and the second feature region 25 may be individually arranged, sized, shaped, and / or configured to provide respective performance characteristics therein.

[0087] Portions of the body-side liner 28 that include orifices 27 may be particularly suitable for transferring and collecting low-viscosity feces away from the wearer's skin. This effect can help maintain the comfort and skin health of the wearer by preventing prolonged contact between feces and the skin of the wearer of the article 10. Portions of the body-side liner 28 that include orifices 27 or other relatively large orifices may be less than ideal for managing urine discharge. For example, where the orifices 27 are large enough or numerous enough to provide a relatively large open area of ​​the liner 28, such orifices 27 provide a path for urine to seep back into the body-facing surface 19 of the article 10 and, therefore, come into contact with the wearer's skin - potentially causing discomfort and / or skin health issues.

[0088] In at least some example embodiments, the second feature area 25 may be disposed in a localized area of ​​the article 10, such as Figure 1 . For example, the longitudinal range of the second feature area 25 may be less than the longitudinal range LAA of the article 10. More specifically, the longitudinal range of the second feature area 25 may be less than seventy percent (70%) of the longitudinal range LAA of the article 10, such as less than sixty percent (60%), such as less than fifty percent (50%), such as approximately less than one forty-seven percent (47%). In addition, the lateral range of the second feature area 25 may be less than the lateral range WAA of the article 10. In some of these exemplary embodiments, the second feature area 25 may be completely disposed between the proximal ends 64a of the base portion 64 of the anti-leakage flaps 50, 52. In some exemplary embodiments, the second feature area 25 may be completely located in the crotch area 16. In other exemplary embodiments, the second feature area 25 may be completely located in the back waist area 14. In yet another exemplary embodiment, the second feature area 25 may span both a portion of the crotch area 16 and the back waist area 14. In yet other exemplary embodiments, the second characteristic zone 25 may be located between no less than forty percent (40%) and no more than eighty percent (80%) of the longitudinal length LAA of the article 10 from the front waist edge 22. In certain exemplary embodiments, the second characteristic zone 25 may also extend across the transverse axis 31, for example, such that the second characteristic zone 25 at least partially overlaps the transverse axis 31 in the crotch region 16. The crotch region 16 and the back waist region 14 are locations within the article 10 where feces are typically received.

[0089] The portion of the body-side liner 28 that forms the first feature area 21 may be particularly suitable for handling fluids, such as urine, for example, by transferring and collecting liquid away from the skin of the wearer of the article 10. This effect can help maintain the comfort and skin health of the wearer by preventing prolonged contact between urine and the skin of the wearer of the article 10. As described above, the first feature area 21 can achieve this function by using a single structural feature or any combination of structural features. In at least some example embodiments, the structural feature 23 of the first area 21 includes an aperture. In the case where the feature 23 includes an aperture, such an aperture can be a relatively small aperture for managing urine exudate.

[0090] Thus, in at least some example embodiments, the first perforated area 21 may be disposed in a localized area of ​​the article 10, such as Figure 1 . For example, the longitudinal extent of the first perforated area 21 may be less than the longitudinal length LAA of the article 10. More specifically, the longitudinal extent of the first perforated area 21 may be less than half, one-third, or one-quarter of the longitudinal extent LAA of the article 10. In addition, the lateral extent of the first perforated area 21 may be less than the lateral extent WAA of the article 10. In some of these exemplary embodiments, the first perforated area 21 may be completely disposed between the proximal ends 64a of the base portion 64 of the anti-leakage flaps 50, 52. In some exemplary embodiments, the first perforated area 21 may be completely located in the crotch area 16. The crotch area 16 is the location in the article 10 where urine is typically received.

[0091] To ensure that the first feature area 21 and the second feature area 25 are located within the desired area of ​​the article 10, a registration system may be used to determine the alignment of the first feature area 21 and the second feature area 25, and the manufacturing process may be adjusted to modify the alignment of the first feature area 21 and the second feature area 25 relative to the article 10. Such a registration system is useful when the bodyside liner material 28 is a full-length material—i.e., a material that extends the full length of the absorbent article—or when the bodyside liner material 28 is a cut-and-place material having a longitudinal extent that is less than the longitudinal extent of the article 10, as will be described in more detail below.

[0092] Figure 2 is a schematic diagram of a manufacturing process 100 in which a first web, such as an open mesh material 112, is combined in a registered manner with a second web, such as a backsheet web 150, and further details portions of the registration system 110 that may be used as part of the manufacturing process 100. Such a manufacturing process 100 may be used as part of a larger manufacturing process to produce an absorbent article including zoned or partial open meshes, wherein the open areas are located at discrete portions of the open mesh, such as those described for article 10.

[0093] Process 100 may include supplying or feeding a continuous first web, such as an open mesh material 112, in a machine direction PD from a supply roll 114. The continuous web of open mesh material 112 may include a series of open areas spaced apart from each other in PD, such as similar to Figure 1 21 and the second characteristic zone 25 depicted in . According to some example embodiments, the continuous web of open-cell material 112 may form a topsheet or a partial surge layer of an absorbent article, such as article 10. Thus, in at least these example embodiments, the continuous web of open-cell material 112 may be formed of any of the materials described for body-side liner 28. However, it should be understood that example aspects of the present disclosure, particularly those related to the registration of the continuous web of open-cell material 112, may be applied to any open-cell material that may be used as any layer within an article, such as article 10.

[0094] The process 100 may also include a feed or drive roller 116. The feed roller 116 may at least assist in feeding the continuous web of open-cell material 112 in the PD. The rotational speed of the feed roller 116 may be adjusted to speed up or slow down the rate at which the continuous web of open-cell material 112 is fed in the machine direction PD. In this way, the process 100 may affect a change in the position of the open area of ​​the continuous web of open-cell material 112 relative to the blade of the knife roller 164 to adjust the position on the continuous web of open-cell material 112 where the knife roller 164 cuts the continuous web of open-cell material 112, as will be described in more detail below. As can be appreciated, changing the position at which the continuous web of open-cell material 112 is cut changes the position of the cut relative to the open area of ​​the continuous web of open-cell material 112, thereby affecting the registration of the open area of ​​the continuous web of open-cell material 112 relative to the backsheet web 150.

[0095] In some example embodiments, the system for feeding the continuous web of open-cell material 112 in the machine direction PD may include additional components, such as an unwinder, a hopper, and / or a dancer roller, etc. (none of which is shown). It should be understood, therefore, that the present disclosure contemplates apparatus and methods for feeding the continuous web of open-cell material 112 in the machine direction PD, which are alternatives to or in addition to the feed roller 116. Regardless of the form taken by the apparatus and method for feeding the continuous web of open-cell material 112 in the machine direction PD, such apparatus(es) and process(es) generally include a mechanism for adjusting the feed speed of the continuous web of open-cell material 112 - that is, slowing down or speeding up the speed at which the continuous web of open-cell material 112 is fed in the machine direction PD. In yet other example embodiments, rather than adjusting the rotational speed of the feed roller 116 to affect a change in the open area of ​​the continuous web of open-cell material 112 relative to the location at which the continuous web of open-cell material 112 is cut, the rotational speed of the knife roller 164 may be adjusted. Still other example embodiments contemplate different ways of affecting the change in the position at which the continuous web of open-cell material 112 is severed relative to the open-cell areas, thereby affecting the registration of the open-cell areas relative to the backsheet web 150. In general, it should be understood that the particular method of varying the position at which the continuous web of open-cell material 112 is severed relative to the open-cell areas is not important, so long as such functionality is included.

[0096] According to process 100, a continuous web of open-cell material 112 may be fed to a cutting mechanism including a knife roll 164 and an anvil roll 162. Knife roll 164 and anvil roll 162 may be configured to cut the continuous web of open-cell material 112 into discrete sheets 113 of individual open-cell material. The discrete sheets 113 of open-cell material are then coupled to a second web, such as backsheet web 150. In some exemplary embodiments, backsheet web 150 may include a continuous backsheet web that includes components of absorbent article 10. For example, backsheet web 150 may include a liner material, such as a web of open-cell material 112 that becomes a local surge material of article 10. In other exemplary embodiments, backsheet web 150 may include a continuous outer cover material. In yet another exemplary embodiment, backsheet web 150 may include a continuous outer cover material, wherein one or more absorbent bodies are disposed on the continuous outer cover material. One or more absorbent bodies may be in the form of a continuous absorbent web, or may be in the form of a series of discrete absorbent webs or absorbent bodies separated in the process direction PD. The backsheet web 150 may be supplied from a supply roll 152, or alternatively may be fed from a different portion of a larger manufacturing process. In at least some example embodiments, the process may include the ability to vary the speed at which the backsheet web 150 moves in the machine direction PD.

[0097] The process 100 may also include a web combiner module 155. In some example embodiments, the web combiner module 155 may be a cutting-and-placing module, for example, where the discrete sheets 113 of the open-cell material are shorter than the finished product length. Such a web combiner module 155 may be combined with a knife roll 164 to cut, separate and combine the discrete sheets 113 of the open-cell material with the backsheet web 150 in a spaced manner. However, in other example embodiments, the cutting and separation steps may be unconnected, such as the cutting performed by the knife roll 164 and the anvil roll 162 and the separation and combination steps performed by the web combiner module 155. In other example embodiments, the web combiner module 155 may be a nip roll, for example, in the case where it is desired that the continuous web of the open-cell material 112 is a full-length material that spans the entire length of the finished product. In such example embodiments, the knife roll 164 and the anvil roll 162 may be located after the web combiner module 155 and may be configured to cut the combined continuous material of the open-cell material 112 and the backsheet web 150. Nevertheless, other modules known in the art and capable of implementing the combination of the apertured material 112 and the backsheet web 150 are contemplated.

[0098] According to example aspects of the present disclosure, the method 100 may also include a registration system 110 that may be used to implement a registration process for registering the open mesh material 112 and the backing web 150. The registration system 110 may include a registration processing device 120, which itself may include one or more processors 122, one or more data storage devices 124, and at least one communication device 126. The registration system 110 may also include external connection devices, such as image capture devices 130, 132, and the system 110 may also be connected to at least the feed roller 116. The one or more processors 122 may be configured to implement functionality and / or process instructions for execution within the device 120. The one or more processors 122 may be capable of processing instructions stored in the data storage device 124. Examples of the processor 122 may include any one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or equivalent discrete or integrated logic circuits.

[0099] The communication device 126 can enable communication between the components and modules of the device 120, as well as communication with any externally connected devices such as the image capture devices 130, 132 and / or the feed roller 116. Each of the components 122, 124, and 126 can be interconnected (physically, communicatively, and / or operatively) for inter-component communication. In some examples, a communication channel (not shown) can extend between the components 122, 124, and 126, which can include a system bus, a network connection, an inter-process communication data structure, or any other method for transferring data.

[0100] Where communication device 126 is included, device 120 may utilize communication device 126 to communicate with external devices via one or more networks (such as one or more wired and / or wireless networks). Communication device 126 may be a network interface card, such as an Ethernet card, an optical transceiver, a radio frequency transceiver, or any other type of device capable of sending and receiving information. Other examples of such network interfaces may include 3G and WiFi radios for computing devices and Universal Serial Bus (USB).

[0101] One or more storage devices 124 may be configured to store information within device 120 during operation. In some examples, storage devices 124 are described as computer-readable storage media. Storage devices 124 may be temporary storage, meaning that the primary purpose of storage devices 124 is not long-term storage. In some examples, storage devices 124 may be volatile memory, such as random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), and other forms of volatile memory known in the art. In some examples, storage devices 124 may be used to store program instructions for execution by processor 122. In one example, software or applications (e.g., modules 121, 123, and 125) running on device 120 may use storage devices 124 to temporarily store information during program execution.

[0102] In some examples, storage device 124 also includes one or more computer-readable storage media. Storage device 124 can be configured to store larger amounts of information than volatile memory. Storage device 124 can also be configured for long-term storage of information. In some examples, storage device 124 includes a non-volatile storage element, such as a magnetic hard disk, an optical disk, a floppy disk, a flash memory, or various forms of electrically programmable memory (EPROM) or electrically erasable programmable (EEPROM) memory.

[0103] One or more data storage devices 124 may include one or more modules stored therein that may help perform the registration functions of system 110, such as image capture module 121 and image modification module 123 and registration module 125. Although modules 121, 123, and 125 are described as implementing multiple functions of system 110, the functions attributed to such modules may be implemented in more, fewer, and / or different modules. In addition, in some examples, the functions may not be distributed between physical or logical modules, but may be performed by, for example, processor 122 based on instructions and data stored on storage device 124. In addition, although ... in some examples, Figure 2124, but in other examples, modules 121, 123, and 125 may be implemented separately from storage device 124, including, for example, in discrete hardware components configured to implement the functionality attributed to the modules in the examples disclosed herein.

[0104] The image capture devices 130, 132 may be configured to capture digital images and transmit such captured images to the device 120 for storage in the storage device 124. The image capture devices 130, 132 may be digital devices that include at least an optical system that includes a lens arrangement and an image sensor, such as a charge coupled device (CCD) sensor or a complementary metal oxide semiconductor (CMOS) sensor, among others. The image capture devices 130, 132 may also include a shutter and other typical components of an image capture device. Although not shown, the image capture devices 130, 132 may additionally include an illumination device for illuminating a location or object at which the image capture devices 130, 132 are configured to capture images. In at least some example embodiments of these embodiments, such illumination devices may be positioned opposite the image capture devices 130, 132 such that the illumination provides backlighting. For example, such illumination devices may be disposed relative to the mesh 112, 170. Figure 2 on opposite sides of the image capture devices 130 , 132 .

[0105] The image capture module 121 may be configured to trigger the image capture devices 130, 132 and obtain discrete images of the continuous web of open mesh material 112 (obtained from the image capture device 130) and discrete images of the combined web 170 (obtained from the image capture device 132), the combined web including at least a portion of the open mesh material 112 and the backing web 150. The images captured from the devices 130, 132 may be stored in the storage device 124. The image capture module 121 may generally be configured to capture images of the open mesh material 112 and the combined web 170 on a once-per-product basis, according to methods known in the art. For example, the image capture module 121 may be connected to the feed roller 116, and the rate at which the image capture module 121 triggers the image capture devices 130, 132 may be adjusted as the speed of the open mesh material 112 increases or decreases. Additionally, initial setting of the trigger may be performed according to methods known in the art to ensure that the captured images correspond to the portion of the open mesh 112 that is ultimately disposed on a single product. For example, such captured images may be displayed on an output device, and manual adjustments to the trigger may be made to ensure proper timing of the image capture trigger. Alternatively, one or more preset parameters may be loaded into the image capture module 121, and one or more image processing techniques may be used to determine features of the captured image. A comparison of the one or more preset parameters to the determined features of the captured image may be performed, and automatic adjustments to the trigger may be performed by the image capture module 121 based on the comparison to ensure proper timing of the image capture trigger.

[0106] In the case where the captured image is stored in the storage device 124, the image modification module 123 can perform one or more image processing modifications on the stored image. For example, the image modification module 123 can be configured to filter the captured image according to one or more filter parameters. This filtering process can help minimize non-interesting features and highlight the features of interest - such as one or more open areas. The image modification module 123 can be further configured to emphasize the features of interest by performing one or more morphological processing techniques on the captured image and / or the filtered captured image.

[0107] Finally, the registration module 125 may be configured to identify features of the modified captured image and adjust the process 100 to ensure that proper registration of the open areas of the mesh material 112 relative to the backsheet web 150 is achieved. For example, the registration module 125 may be configured to identify or determine one or more open areas associated with the open mesh material 112 and the combined web 170. According to some example embodiments, the registration module 125 may be configured to identify one or more features of interest associated with the determined open areas within the modified captured image—e.g., the leading edge of the determined open areas. In some example embodiments, the registration module 125 may be further configured to identify reference features on each of the modified captured images of the open mesh material 112 and the combined web 170. Next, the registration module 125 may be configured to determine one or more metrics associated with the determined features—such as positional differences—and adjust the system 100 based on the one or more determined metrics to ensure that proper registration of the open areas of the mesh material 112 relative to the backsheet web 150 is achieved.

[0108] Figure 3 is a top plan view of a nonwoven material 200 according to an exemplary embodiment of the present disclosure. Figure 3 , the nonwoven material 200 is shown in a flat or planar configuration. Figure 4 It is a top plan view of the first perforated area 220 of the nonwoven material 200. The nonwoven material 200 can be used in the absorbent article 10, for example as a body side liner 28, and therefore, the nonwoven material 200 is described in more detail below in the context of the absorbent article 10. However, it should be understood that in alternative exemplary embodiments, the nonwoven material 200 can be used in any other article or clothing. For example, the nonwoven material 200 can be used for diapers, diapers, training pants, older children's pants, swimming trunks, feminine hygiene products (including but not limited to menstrual pads or menstrual pants), incontinence products, medical clothing, surgical pads and bandages, other personal care or health care clothing, for example, as the inner liner for the wearer of such products. As discussed in more detail below, the nonwoven material 200 can advantageously include features for allowing body exudates such as low viscosity feces to pass through the nonwoven material 200. In addition, the shape and / or size of the first perforated area 220 can be designed to facilitate the registration of the nonwoven material 200, for example, during the manufacturing process 100.

[0109] like Figure 3As shown in , the nonwoven material 200 includes a nonwoven fiber web 210, for example, formed by a plurality of fibers. The fiber web 210 may define a transverse direction LA and a longitudinal direction LO. The transverse direction LA and the longitudinal direction LO may be perpendicular to each other. In certain exemplary embodiments, the transverse direction LA may correspond to the longitudinal direction 30, and the longitudinal direction LO may correspond to the transverse direction 32. The fiber web 210 may extend, for example, along the longitudinal direction LO between the front end or first end portion 212 and the rear end or second end portion 214. Therefore, the first end portion 212 and the second end portion 214 may be spaced apart along the longitudinal direction LO. The first end portion 212 of the fiber web 210 may be positioned at or near the front waist region 12 of the absorbent article 10, and the second end portion 214 of the fiber web 210 may be positioned at or near the rear waist region 14 of the absorbent article 10. The fiber web 210 may also extend, for example, along the transverse direction LA between the first side portion 216 and the second side portion 218. Thus, the first side portion 216 and the second side portion 218 may be spaced apart along the lateral direction LA.

[0110] The length L1 of the web 210 may be defined between the first end portion 212 and the second end portion 214 of the web 210, and the width W1 of the web 210 may be defined between the first side portion 216 and the second side portion 218 of the web 210. In certain example embodiments, the length L1 of the web 210 may be greater than the width W1 of the web 210. For example, the length L1 of the web 210 may be not less than two times (2X) the width W1 of the web 210, such as not less than three times (3X) the width W1 of the web 210. Thus, the web 210 may be elongated along the longitudinal direction LO between the first end portion 212 and the second end portion 214.

[0111] The nonwoven web 210 may include at least one perforated area. Figure 3 As shown in , the nonwoven web 210 may include a first perforated area 220 and a second perforated area 230. The first perforated area 220 may be spaced apart from the second perforated area 230, for example, along the longitudinal direction LO. For example, the first perforated area 220 and the second perforated area 230 may be spaced apart by a gap G along the longitudinal direction LO. In certain example embodiments, the gap G may be not less than six millimeters (6mm) and not more than one hundred and thirty millimeters (130mm), such as not less than twelve millimeters (12mm) and not more than one hundred millimeters (100mm), such as not less than twenty-five millimeters (25mm) and not more than seventy-five millimeters (75mm). As Figure 3, the nonwoven web 210 may be non-perforated, for example, along the longitudinal direction LO, between the first perforated area 220 and the second perforated area 230. Thus, for example, the nonwoven web 210 may not be processed to include holes between the first perforated area 220 and the second perforated area 230 along the longitudinal direction LO. In certain example embodiments, the centroid of the first perforated area 220 may also be arranged colinearly with the centroid of the second perforated area 230, for example, on the longitudinal axis 29.

[0112] The first perforated area 220 may include a plurality of holes 221, and the second perforated area 230 may also include a plurality of holes 231. Figure 3 In the exemplary embodiment shown in FIG. 1 , the holes 221 are oval, and the embossing (not shown) on the first perforated area 220 is indicated by a cross. The holes 221 of the first perforated area 220 may be larger than the holes 231 of the second perforated area 230. For example, the area of ​​each of the holes 221 of the first perforated area 220 may be not less than about five square millimeters (5 mm 2 ) and not larger than approximately 28 square millimeters (28mm 2 ), such as not less than about eight square millimeters (8mm 2 ) and not larger than about 20 square millimeters (20mm 2 ), such as not less than about nine square millimeters (9mm 2 ) and not larger than about twelve square millimeters (12mm 2 In contrast, the area of ​​each of the holes 231 of the second perforated area 230 may be no less than about one quarter square millimeter (0.25 mm 2 ) and not larger than about five square millimeters (5mm 2 ), such as not less than about one square millimeter (1mm 2 ) and not larger than about four square millimeters (4mm 2 ), such as about two and a half square millimeters (2.5 mm 2 ). This size difference between the holes 221 of the first perforated area 220 and the holes 231 of the second perforated area 230 can advantageously facilitate the movement of body exudates through the nonwoven fiber web 210. In addition, the size of the larger holes 221 of the first perforated area 220 can be designed to transfer and collect low-viscosity feces. Conversely, the size of the smaller holes 231 of the second perforated area 230 can be designed to transfer and collect urine exudates. In certain example embodiments, the holes 221 can be evenly distributed throughout the first perforated area 220, and the holes 231 can be evenly distributed throughout the second perforated area 230.

[0113] Although the first and second regions 220, 230 are described in more detail below in the context of holes 221, 231, it should be understood that in other exemplary embodiments, the first and second regions 220, 230 may include one or more alternative structural features. For example, each of the first and second regions 220, 230 may include one or more structural features, including embossing, protrusions, depressions, perforations, protrusions, depressions, holes, etc. Thus, each of the first and second regions 220, 230 may include discrete structural features on the nonwoven web 210. In different exemplary embodiments, the first and second regions 220, 230 may include any combination of such structural features. In at least one exemplary embodiment, the first and / or second regions 220, 230 may include a combination of holes and protrusions or embossings.

[0114] The portion of the nonwoven web 210 that forms the first zone 220 may be particularly suitable for handling fluids, such as urine, e.g., transferring and collecting liquid away from adjacent skin. As described above, the first zone 220 can achieve this function by using a single structural feature or any combination of structural features. In at least some example embodiments, the structural features of the first zone 220 include apertures 221. Where the features include apertures 221, such apertures 221 may be relatively small apertures for managing urine exudate—e.g., having a size similar to the apertures described above with respect to the second zone 230.

[0115] like Figure 4 As shown in , the first perforated area 220 of the fiber mesh 210 may extend between the front end or first end portion 222 and the rear end or second end portion 223, for example, along the longitudinal direction LO. Therefore, the first end portion 222 and the second end portion 223 of the first perforated area 220 may be spaced apart along the longitudinal direction LO. The first perforated area 220 of the nonwoven material 200 may also extend between the first side portion 224 and the second side portion 225, for example, along the transverse direction LA. Therefore, the first side portion 224 and the second side portion 225 of the first perforated area 220 may be spaced apart along the transverse direction LA. The central portion 226 of the first perforated area 220 may be disposed between the first side portion 224 and the second side portion 225 of the first perforated area 220, for example, along the transverse direction LA. In addition, the central portion 226 of the first perforated area 220 may be disposed between the first end portion 222 and the second end portion 223 of the first perforated area 220, for example, along the longitudinal direction LO. In certain example embodiments, the central portion 226 of the first perforated area 220 may include the centroid of the first perforated area 220 .

[0116] The width of the first perforated area 220 may be defined, for example, along the transverse direction LA. The width of the first perforated area 220 may taper at a first end portion 222 of the first perforated area 220, for example, such that a width W2 of the first perforated area 220 at the first end portion 222 of the first perforated area 220 may be smaller than a width W3 of the first perforated area 220 at a central portion 226 of the first perforated area 220, which may extend between a first side portion 224 and a second side portion 225 of the first perforated area 220 along the transverse direction LA. For example, the width W2 of the first perforated area 220 at the first end portion 222 of the first perforated area 220 may be no less than twenty percent (20%) and no more than ninety percent (90%) of the width W3 of the first perforated area 220 at the center portion 226 of the first perforated area 220, such as no less than thirty percent (30%) and no more than seventy percent (70%) of the width W3 of the first perforated area 220 at the center portion 226 of the first perforated area 220, such as no less than forty percent (40%) and no more than sixty percent (60%) of the width W3 of the first perforated area 220 at the center portion 226 of the first perforated area 220. As described in more detail below, the tapering of the width of the first perforated area 220 can advantageously aid in the registration of the nonwoven material 200. In certain example embodiments, the width of the first perforated area 220 at the second end portion 223 of the first perforated area 220 can be tapered in a manner similar to that described above for the width of the first perforated area 220 at the first end portion 222 of the first perforated area 220. However, in certain example embodiments, the width of the first perforated area 220 at the second end portion 223 of the first perforated area 220 can be selected and / or shaped to be different from the width of the first perforated area 220 at the first end portion 222 of the first perforated area 220. For example, one of the widths of the first perforated area 220 at the first end portion 222 and the second end portion 223 of the first perforated area 220 can be tapered in the manner described above to facilitate registration during manufacturing of the nonwoven material 200, while the other of the widths of the first perforated area 220 at the first end portion 222 and the second end portion 223 of the first perforated area 220 can be shaped in any suitable manner.

[0117] The length of the first perforated area 220 may be defined, for example, along the longitudinal direction LO. The length of the first perforated area 220 may taper at the first side portion 224 of the first perforated area 220, for example, such that the length L3 of the first perforated area 220 at the first side portion 224 of the first perforated area 220 may be less than the length L2 of the first perforated area 220 at a central portion 226 of the first perforated area 220, which central portion may extend between the first end portion 222 and the second end portion 223 of the first perforated area 220 along the longitudinal direction LO. For example, the length L3 of the first perforated area 220 at the first side portion 224 of the first perforated area 220 may be not less than fifty percent (50%) and not more than ninety-seven (97%) of the length L2 of the first perforated area 220 at the central portion 226 of the first perforated area 220, such as not less than seventy percent (70%) and not more than ninety-five percent (95%) of the length L2 of the first perforated area 220 at the central portion 226 of the first perforated area 220. In certain example embodiments, the length of the first perforated area 220 may similarly taper at the second side portion 225 of the first perforated area 220 .

[0118] The length L2 of the first perforated area 220 at the central portion 226 of the first perforated area 220 may be greater than the width W3 of the first perforated area 220 at the central portion 226 of the first perforated area 220. For example, the length L2 of the first perforated area 220 at the central portion 226 of the first perforated area 220 may be not less than twice (2X) the width W3 of the first perforated area 220 at the central portion 226 of the first perforated area 220, such as not less than three times (3X) the width W3 of the first perforated area 220 at the central portion 226 of the first perforated area 220. Therefore, the first perforated area 220 may be elongated in the longitudinal direction LO between the first end portion 222 and the second end portion 223. Furthermore, in certain example embodiments, the first perforated area 220 may have an elongated octagonal shape. Figure 1 In the example embodiment shown in , the length L2 of the first perforated area 220 at the central portion 226 of the first perforated area 220 corresponds to the maximum length of the first perforated area 220 , and the width W3 of the first perforated area 220 at the central portion 226 of the first perforated area 220 corresponds to the maximum width of the first perforated area 220 .

[0119] refer to Figure 4, the holes 221 of the first perforated area 220 may be distributed in a plurality of rows spaced apart in the first perforated area 220, for example, along the longitudinal direction LO. In certain example embodiments, the plurality of rows may be no less than ten (10) rows. The leading row 240 may be positioned at the first end portion 222 of the first perforated area 220. The leading row 240 may be the first row of holes 221 in the first perforated area 220. Thus, for example, during the manufacturing process 100, the leading row 240 may be positioned upstream of other rows of holes 221 in the first perforated area 220 along the machine direction PD. In such example embodiments, the holes 221 of the leading row 240 may be the first holes 221 in the first perforated area 220 in the digital image captured by the image capture device 130, 132 during the manufacturing process 100. In certain example embodiments, the leading row 240 may include no less than four (4) holes 221. Such a number of holes in the front row 240 can advantageously allow a fixed camera (such as one of the image capture devices 130, 132) to detect the front row 240 regardless of changes in the lateral position of the first perforated area 220. The second row 242 can be positioned adjacent to and continuous with the front row 240, for example, along the longitudinal direction LO. In certain example embodiments, the number of holes 221 in the second row 242 can be greater than the number of holes 221 in the first row 240. Thus, for example, the total area of ​​the holes 221 in the front row 240 can be less than the total area of ​​the holes 221 in the second row 242.

[0120] The holes 221 of the first perforated area 220 may also be distributed in a plurality of columns spaced apart in the first perforated area 220, for example, along the transverse direction LA. In certain example embodiments, the plurality of columns may be no less than six (6) columns. The first edge column 250 may be located at the first side portion 224 of the first perforated area 220. The first edge column 250 may be the first column of holes 221 in the first perforated area 220 at the first side portion 224. In certain example embodiments, the first edge column 250 may include no less than seven (7) holes 221. The second column 252 may be located adjacent to and continuous with the first edge column 250, for example, along the transverse direction LA. In certain example embodiments, the number of holes 221 in the second column 252 may be greater than the number of holes 221 in the first edge column 250.

[0121] The size and shape of the first perforated area 220 can have a pleasing decorative appearance. For example, the width of the first perforated area 220 is gradually tapered at the first end portion 222 and / or the second end portion 223 of the first perforated area 220 to provide a pleasing decorative appearance for the portion of the nonwoven material 200 having relatively large holes, for example, these holes can be visible at the interior of the absorbent article 10. In addition, the size and shape of the first perforated area 220 can, for example, help with the registration of the first perforated area 220 during the manufacturing process 100, while also providing a pleasing decorative appearance. As described above, during the manufacturing process 100, the front row 240 can be positioned upstream of other rows of holes 221 in the first perforated area 220 along the machine direction PD, and the holes 221 of the front row 240 can be the first holes 221 in the first perforated area 220 in the digital image captured by the image capture device 130, 132 during the manufacturing process 100. The size and shape of the first perforated area 220 can facilitate registration of the first perforated area 220 using digital images captured by the image capture devices 130, 132 during the manufacturing process 100. The tapering of the width of the first perforated area 220 at the first end portion 222 and / or the second end portion 223 of the first perforated area 220 can provide a pleasing decorative appearance to that portion of the nonwoven material 200, but excessive tapering can limit light transmission through the front row 240, thereby reducing the accuracy of registering the first perforated area 220 using digital images captured by the image capture devices 130, 132 during the manufacturing process 100. Therefore, the above-described size and / or shape of the first perforated area 220 can advantageously provide both a pleasing decorative appearance and facilitate registration of the first perforated area 220.

[0122] Figure 5 is a graph of the registration signal 500 of the first perforated area 220. Figure 5 , the light transmittance through the web 210 is limited upstream of the front row 240. However, at the front row 240, the signal 500 increases significantly. In addition, the signal 500 also increases significantly from the front row 240 to the second row 242, such as from the second row 242 to the subsequent third row 244 that is continuous with the second row 242. The size and shape of the first perforated area 220 can advantageously ensure that the size of the signal 500 is sufficient to register the leading edge of the first perforated area 220 in the manufacturing process 100. Therefore, for example, the cutting of the web 210 can be accurately and / or precisely controlled.

[0123] The size and / or shape of the first perforated area 220 along the leading edge of the first perforated area 220 can facilitate accurate registration of the web 210. In addition, the shape, size, and number of holes 221 in the first perforated area 220 can advantageously provide a hole density for light transmittance through the holes 221 in the first perforated area 220, which facilitates accurate registration of the first perforated area 220. The shape, size, and number of holes 221 in the first perforated area 220 can be selected, for example, in the manner described above, so that the density of the total area of ​​the holes 221 in the leading row 240 (e.g., along the longitudinal direction LO) can be greater than about four and nine-tenths square millimeters per millimeter (4.9 mm 2 / mm). Thus, due to the density of the total area of ​​holes 221 in the preceding row 240, the light transmittance through the web 210 can be significantly increased at the preceding row 240 relative to the non-perforated areas adjacent to the preceding row 240 (e.g., immediately upstream of the preceding row 240 in the machine direction PD). This initial magnitude of the hole density can advantageously allow the magnitude of light passing through the web 210 to be similarly increased, thereby allowing accurate registration of the web 210 by distinguishing the relatively lower light transmittance of the non-perforated areas adjacent to the preceding row 240 from the relatively higher light transmittance of the holes 221 in the preceding row 240. Thus, due to this high initial rate of change of the total area of ​​holes 221 in the preceding row 240 relative to the non-perforated areas adjacent to the preceding row 240, the preceding row 240 of the first perforated area 220 can be advantageously detected. Furthermore, the above-described density of the total area of ​​holes 221 in the preceding row 240 can advantageously facilitate accurate registration of the first perforated area 220 during high speeds in the machine direction PD. In contrast, the density of the total area of ​​the holes 221 in the front row 240 is less than 4 and 9 tenths square millimeters per millimeter (4.9 mm 2 / mm) may provide insufficient contrast for registration.

[0124] In certain example embodiments, the density of the total area of ​​the holes 221 in the front row 240 may be no greater than thirty square millimeters (30 mm 2 / mm), such as no more than twenty square millimeters (20mm 2 / mm), such as no larger than fifteen square millimeters (15mm 2 / mm), so that the first perforated area 220 tapers at the first end portion 222 of the first perforated area 220. For example, although the greater density of the total area of ​​the holes 221 in the first row 240 allows for easier registration, the greater density value results in a flatter and less tapered shape of the first perforated area 220. In addition, for example, due to the tapering of the first perforated area 220 at the first end portion 222 of the first perforated area 220, the density of the total area of ​​the holes 221 in the second row 242 (e.g., along the longitudinal direction LO) may be greater than the density of the total area of ​​the holes 221 in the first row 240. In certain example embodiments, the density of the total area of ​​the holes 221 in the second row 242 (e.g., along the longitudinal direction LO) may be no less than five square millimeters per millimeter (5mm 2 In addition, in certain example embodiments, the density of the total area of ​​the holes 221 in the second row 242 may be no greater than fifty square millimeters per millimeter (50 mm 2 / mm), such as not more than 40 square millimeters per millimeter (40mm 2 / mm), such as no more than thirty square millimeters per millimeter (30mm 2 / mm), such as not more than twenty square millimeters per millimeter (20mm 2 / mm), such as not more than fifteen square millimeters per millimeter (15mm 2 / mm). This density of the total area of ​​the holes 221 in the second row 242 can advantageously provide a desired taper while also facilitating registration by increasing the size of light passing through the fiber web 210, thereby allowing accurate registration of the fiber web 210 by distinguishing the relatively lower light transmittance of the holes in the preceding row 240 from the relatively higher light transmittance of the holes 221 in the second row 242. Therefore, due to this change in the density of the total area of ​​the holes 221 between the preceding row 240 and the second row 242, the second row 242 of the first perforated area 220 can be advantageously detected. In certain example embodiments, for example, due to the tapering of the first perforated area 220 at the first end portion 222 of the first perforated area 220, the density of the total area of ​​the holes 221 in the third row 244 (e.g., in the longitudinal direction LO) can be greater than the density of the total area of ​​the holes 221 in the second row 242. Subsequently, the rows of holes 221 can also have increasing hole densities, for example, until the maximum width of the first perforated area 220 is reached.

[0125] In the case where the registration of the web 210 is based on the leading row 240 of the first perforated area 220, the trailing row of the second end portion 223 (e.g., the row of the first perforated area 220 that is farthest from the leading row 240 in the longitudinal direction LO) may have a density of less than four and nine-tenths square millimeters per millimeter (4.9 mm2 / mm) of the total area of ​​the holes 221. In certain example embodiments, the density of the total area of ​​the holes 221 in the trailing row may be no greater than four and one-half square millimeters per millimeter (4.5 mm2 / mm), such as no greater than four square millimeters per millimeter (4 mm2 / mm), such as no greater than three and one-half square millimeters per millimeter (3.5 mm2 / mm), such as no greater than three square millimeters per millimeter (3.0 mm2 / mm), so that the taper of the first perforated area 220 at the second end portion 223 is even greater than the taper at the first end portion 222. In at least some of these example embodiments, a row adjacent to a rear row in the longitudinal direction LO (e.g., a row of first perforated regions 220 that is second away from a front row 240 in the longitudinal direction LO) may have a density of the total area of ​​the holes 221 that is less than the density of the total area of ​​the holes 221 in the second row 242.

[0126] It has been found that the above-described hole densities advantageously provide a pleasing shape (e.g., a tapered shape) to the first perforated area 220 while also facilitating accurate registration of the first perforated area 220 during the manufacturing process 100. Each density of the total area of ​​a row of holes can be calculated by dividing the total area of ​​the holes in a row by the length of the row in the machine direction, as shown below:

[0127]

[0128] Where A is the total area of ​​a row of holes, and L is the length of the row of holes along the machine direction (such as the machine direction PD and / or the longitudinal direction LO of the fiber web 210).

[0129] It should be understood that the orientation of the holes within each row can affect the length of each row of holes along the machine direction. For example, orienting a row of elliptical holes so that the major axis of the elliptical holes is parallel to the machine direction will increase the length of the row of holes along the machine direction relative to orienting a row of elliptical holes so that the major axis of the elliptical holes is perpendicular to the machine direction. Angling the major axis of the elliptical holes relative to the machine direction will also affect the length of the row of holes along the machine direction. Therefore, the holes of the row can be oriented or angled relative to the machine direction to adjust the density of the total area of ​​the holes.

[0130] Example

[0131] The initial hole density of the preceding row of tapered perforated areas in five sample webs was tested. The holes in the test webs were counted and measured to determine the density of the total area of ​​the holes in the preceding row and to evaluate the light transmittance through the test web to the camera. The effect of the number and size of the holes on the registration was recorded to determine if registration was recorded.

[0132] surface

[0133]

[0134] As shown in the table above, the tapered perforation area is less than 4.9 mm 2 / mm density failed to match. In contrast, in the tapered perforation area greater than 4.9mm 2 In addition, the size and number of holes can be varied to provide the density required for forward registration.

[0135] As can be seen from the above, the exemplary aspects of the disclosed subject matter advantageously provide a personal care absorbent article with a body-facing material, the body-facing material including a zone of holes to prevent leakage of body exudates (such as semi-solid fecal material or menstruation). The shape of the zone of holes can advantageously provide functional benefits and visual benefits. For example, the length of the central portion of the zone of holes in the processing direction can be longer than the length of the side portions of the zone of holes. In addition, the number of holes in the central portion can be greater than the number of holes in the side portions. This size and shape is visually pleasing. The front edge and / or rear edge of the zone of holes can also provide visual benefits and functional benefits. For example, the width of the zone of holes at or near the front edge and / or rear edge can be less than the width of the zone of holes between the front edge and the rear edge. In addition, the number of discrete holes located at or near the front edge and / or rear edge in the transverse direction can be less than the number of discrete holes located between the front edge and the rear edge in the transverse direction. The size and / or number of holes located at or near the leading and / or trailing edges may also improve the ability to accurately register a continuous mesh having a repeating region of holes relative to a mesh having small or few discrete holes located at or near the leading and / or trailing edges, which may have poor hole definition. Providing relatively wide and / or a large number of discrete apertures may advantageously increase the likelihood that a transmittance registration system will detect the region of holes. For example, the hole density at the leading edge may be greater than about 4.9 mm 2 / mm, preferably not less than 9.81mm 2 / mm to accurately align the holes.

[0136] These and other modifications and variations of the present invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the present invention described more specifically in the appended claims. In addition, it should be understood that the aspects of the various embodiments may be interchangeable in whole or in part. In addition, it will be appreciated by those of ordinary skill in the art that the above description is by way of example only and is not intended to limit the present invention further described in such appended claims.

[0137] Reference Numbers

[0138] 10 Absorbent products

[0139] 11 Negatives

[0140] 12 Frontal area

[0141] 14. Back waist area

[0142] 16 Crotch area

[0143] 18 longitudinal side edges

[0144] 19 Body-facing surface

[0145] 20 longitudinal side edges

[0146] 21 Perforation Area

[0147] 22 Front edge

[0148] 23 holes

[0149] 24 Back edge

[0150] 25 Perforation Area

[0151] 26 Outer layer

[0152] 27 holes

[0153] 28 Body side lining

[0154] 29 Longitudinal axis

[0155] 30 Vertical direction

[0156] 31 Horizontal axis

[0157] 32 Horizontal direction

[0158] 34 Absorption body

[0159] 36 Vertical Edge

[0160] 38 longitudinal edge

[0161] 40 First end edge

[0162] 42 Second end edge

[0163] 44 Absorption components

[0164] 45 Body-facing surface

[0165] 50 Leak-proof flaps

[0166] 52 Leak-proof flap

[0167] 54 Elastic waist member

[0168] 56 Body-facing surface

[0169] 60 Leg elastic member

[0170] 62 Leg elastic member

[0171] 64 base part

[0172] 64a Proximal end

[0173] 64b Distal end

[0174] 66 protrusion

[0175] 68 flap elastic member

[0176] 70 Active flap elastic area

[0177] 71 Pinning Area

[0178] 72 first longitudinal side edge

[0179] 74 second longitudinal side edge

[0180] 84 Pinning Area

[0181] 86 Elastic member

[0182] 91 Rear fastener

[0183] 92 Front fastener

[0184] 94 Stretch parts

[0185] 96 Nonwoven carrier or hook holder

[0186] 98 Fastening parts

[0187] 100 Manufacturing Process

[0188] 110 Registration System

[0189] 112 Open mesh material

[0190] 113 Open-cell material

[0191] 114 Supply Roller

[0192] 116 Feed roller

[0193] 120 Registration processing equipment

[0194] 121 Image Capture Module

[0195] 122 Processor

[0196] 123 Image Modification Module

[0197] 124 Data storage devices

[0198] 125 Registration Module

[0199] 126 Communication equipment

[0200] 130 Image Capture Device

[0201] 132 Image Capture Devices

[0202] 150 Film Network

[0203] 152 Supply Roller

[0204] 155 Net combiner module

[0205] 162 Anvil Roller

[0206] 164 Knife Roller

[0207] 170 Combination Network

[0208] 200 Nonwoven Materials

[0209] 210 Fiber Net

[0210] 212 first end portion

[0211] 214 second end portion

[0212] 216 first side portion

[0213] 218 Second side portion

[0214] 220 First perforation area

[0215] 221 hole

[0216] 222 first end portion

[0217] 223 Second end portion

[0218] 224 first side portion

[0219] 225 Second side portion

[0220] 226 center part

[0221] 230 Second perforation area

[0222] 231 holes

[0223] 240 Moving Forward

[0224] 242 Second row

[0225] 244 Third line

[0226] 250 First edge column

[0227] 252 Second column

[0228] LAA Length of absorbent article

[0229] Length of L1 network

[0230] L2 Length of the perforated area at the first end portion

[0231] L3 Length of the perforated area at the center

[0232] WAA Width of absorbent article

[0233] W1 Width of the mesh

[0234] W2 Width of the perforated area at the first end portion

[0235] W3 Width of the perforated area at the center

[0236] PD Processing Direction

[0237] Example Implementation

[0238] First exemplary embodiment: A nonwoven material comprises a plurality of fibers, the plurality of fibers forming a nonwoven web, the nonwoven web defining a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The nonwoven web comprises a perforated area having a plurality of holes. The perforated area of ​​the nonwoven web has a first side portion and a second side portion spaced apart along the transverse direction, and also has a first end portion and a second end portion spaced apart along the longitudinal direction. The center portion of the perforated area is disposed between the first side portion and the second side portion of the perforated area along the transverse direction. The width of the perforated area is defined along the transverse direction, and the length of the perforated area is defined along the longitudinal direction. The width of the perforated area at the first end portion of the perforated area is less than the width of the perforated area at the center portion. The length of the perforated area at the first side portion and the second side portion of the perforated area is less than the length of the perforated area at the center portion of the perforated area. The width of the perforated area at the first end portion of the perforated area is greater than twenty percent and less than ninety percent of the width of the perforated area at the central portion of the perforated area.

[0239] Second example embodiment: The nonwoven material of the first example embodiment, wherein the width of the perforated area at the second end portion of the perforated area is smaller than the width of the perforated area at the center portion of the perforated area.

[0240] A third exemplary embodiment: A nonwoven material as described in the first exemplary embodiment or the second exemplary embodiment, wherein the plurality of holes are distributed in a plurality of rows spaced apart along the longitudinal direction in the perforated area, a front row of the plurality of rows is positioned at the first end portion of the perforated area, and the front row includes no less than four holes of the plurality of holes.

[0241] Fourth exemplary embodiment: The nonwoven material of the third exemplary embodiment, wherein a second row of the plurality of rows is positioned adjacent to and continuous with the preceding row of the plurality of rows, and the number of the plurality of holes in the second row is greater than the number of the plurality of holes in the preceding row.

[0242] Fifth exemplary embodiment: The nonwoven material of the third exemplary embodiment, wherein the plurality of rows comprises no less than ten rows.

[0243] Sixth exemplary embodiment: A nonwoven material as described in any one of the first exemplary embodiment to the fifth exemplary embodiment, wherein the plurality of holes are distributed in a plurality of columns spaced apart along the transverse direction in the perforated area, a first edge column of the plurality of columns is positioned at the first side portion of the perforated area, and the first edge column includes no less than seven holes of the plurality of holes.

[0244] Seventh exemplary embodiment: The nonwoven material of the sixth exemplary embodiment, wherein a second column of the plurality of columns is positioned adjacent to and continuous with the first edge column of the plurality of columns, and the number of the plurality of holes in the second column is greater than the number of the plurality of holes in the first edge column.

[0245] Eighth exemplary embodiment: The nonwoven material of the sixth exemplary embodiment, wherein the plurality of columns comprises no less than six columns.

[0246] Ninth exemplary embodiment: The nonwoven material of any one of the first to eighth exemplary embodiments, wherein the maximum length of the perforated area is not less than twice the maximum width of the perforated area.

[0247] Tenth example embodiment: The nonwoven material of any one of the first to ninth example embodiments, wherein the area of ​​each hole in the plurality of holes is not less than about eight square millimeters and not more than about eighteen square millimeters.

[0248] Eleventh exemplary embodiment: The nonwoven material of any one of the first to tenth exemplary embodiments, wherein the plurality of holes are evenly distributed throughout the perforated area.

[0249] Twelfth exemplary embodiment: A nonwoven material as described in any one of the first exemplary embodiment to the eleventh exemplary embodiment, wherein: the perforated area is a first perforated area, and the plurality of holes are a first plurality of holes; the nonwoven fiber web includes a second perforated area having a second plurality of holes; and the average area of ​​each hole in the first plurality of holes is not less than twice the average area of ​​each hole in the second plurality of holes.

[0250] Thirteenth exemplary embodiment: The nonwoven material as described in any one of the first to twelfth exemplary embodiments, wherein the nonwoven fiber web is a fluid-entangled nonwoven fiber web, a meltblown nonwoven fiber web, a spunbond nonwoven fiber web, or a carded nonwoven fiber web.

[0251] Fourteenth exemplary embodiment: The nonwoven material of any one of the first to thirteenth exemplary embodiments, wherein the plurality of pores are formed by fluid entanglement, needle aperturing, water jet punching, overbonding, or ring rolling.

[0252] Fifteenth exemplary embodiment: A garment comprising a layer formed of the nonwoven material as described in any one of the first to fourteenth exemplary embodiments.

[0253] Sixteenth exemplary embodiment: A nonwoven material comprising a plurality of fibers forming a nonwoven web defining a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The nonwoven web comprises a perforated area having a plurality of holes. The perforated area of ​​the nonwoven web has a first side portion and a second side portion spaced apart along the transverse direction, and also has a first end portion and a second end portion spaced apart along the longitudinal direction. The central portion of the perforated area is disposed between the first side portion and the second side portion of the perforated area along the transverse direction. The width of the perforated area defined along the transverse direction tapers gradually at the first end portion of the perforated area, so that the width of the perforated area at the first end portion of the perforated area is not less than twenty percent and not more than eighty percent of the width of the perforated area at the central portion of the perforated area.

[0254] Seventeenth exemplary embodiment: A nonwoven material as described in the sixteenth exemplary embodiment, wherein the width of the perforated area at the second end portion of the perforated area gradually tapers at the second end portion of the perforated area, so that the width of the perforated area at the second end portion of the perforated area is not less than twenty percent and not more than eighty percent of the width of the perforated area at the center portion of the perforated area.

[0255] Eighteenth exemplary embodiment: The nonwoven material as described in the sixteenth exemplary embodiment or the seventeenth exemplary embodiment, wherein the plurality of holes are distributed in a plurality of rows spaced apart along the longitudinal direction in the perforated area, a front row of the plurality of rows is positioned at the first end portion of the perforated area, and the front row includes no less than four holes of the plurality of holes.

[0256] Nineteenth exemplary embodiment: The nonwoven material of the eighteenth exemplary embodiment, wherein a second row of the plurality of rows is positioned adjacent to and continuous with the preceding row of the plurality of rows, and the number of the plurality of holes in the second row is greater than the number of the plurality of holes in the preceding row.

[0257] Twentieth exemplary embodiment: A nonwoven material as described in any one of the sixteenth exemplary embodiment to the nineteenth exemplary embodiment, wherein the plurality of holes are distributed in a plurality of columns spaced apart along the transverse direction in the perforated area, a first edge column of the plurality of columns is positioned at the first side portion of the perforated area, and the first edge column includes no less than seven holes of the plurality of holes.

[0258] Twenty-first exemplary embodiment: The nonwoven material as described in the twentieth exemplary embodiment, wherein a second column of the plurality of columns is positioned adjacent to and continuous with the first edge column of the plurality of columns, and the number of the plurality of holes in the second column is greater than the number of the plurality of holes in the first edge column.

[0259] Twenty-second exemplary embodiment: The nonwoven material of any one of the sixteenth to twenty-first exemplary embodiments, wherein the maximum length of the perforated area is not less than twice the maximum width of the perforated area.

[0260] Twenty-third exemplary embodiment: The nonwoven material of any one of the sixteenth to twenty-second exemplary embodiments, wherein the area of ​​each hole in the plurality of holes is not less than about eight square millimeters and not more than about eighteen square millimeters.

[0261] Twenty-fourth exemplary embodiment: A garment comprising a layer formed of the nonwoven material as described in any one of the sixteenth to twenty-third exemplary embodiments.

[0262] Twenty-fifth exemplary embodiment: A nonwoven material, comprising a plurality of fibers, the plurality of fibers forming a nonwoven web, the nonwoven web defining a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The nonwoven web comprises a perforated area having a plurality of holes. The perforated area of ​​the nonwoven web has a first side portion and a second side portion spaced apart along the transverse direction, and also has a first end portion and a second end portion spaced apart along the longitudinal direction. The central portion of the perforated area is disposed between the first side portion and the second side portion of the perforated area along the transverse direction. The plurality of holes are distributed in a plurality of rows spaced apart along the longitudinal direction in the perforated area. A front row of the plurality of rows is positioned at the first end portion of the perforated area. A second row of the plurality of rows is positioned adjacent to and continuous with the front row of the plurality of rows. The total area of ​​the plurality of holes in the front row is less than the total area of ​​the plurality of holes in the second row. The total area of ​​the front row has a density along the longitudinal direction of greater than about four and nine-tenths square millimeters per millimeter.

[0263] Twenty-sixth exemplary embodiment: A nonwoven material as described in the twenty-fifth exemplary embodiment, wherein the third row of the plurality of rows is positioned adjacent to and continuous with the second row of the plurality of rows, and the total area of ​​the plurality of holes in the second row is smaller than the total area of ​​the plurality of holes in the third row.

Claims

1. A nonwoven material comprising: a plurality of fibers, the plurality of fibers forming a nonwoven web, the nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, wherein the nonwoven web comprises a perforated area having a plurality of holes, the perforated area of ​​the nonwoven web having a first side portion and a second side portion spaced apart along the transverse direction, and also having a first end portion and a second end portion spaced apart along the longitudinal direction, a central portion of the perforated area being disposed between the first side portion and the second side portion of the perforated area along the transverse direction, wherein the width of the perforated area is defined along the transverse direction, and the length of the perforated area is defined along the longitudinal direction, the width of the perforated area at the first end portion of the perforated area is smaller than the width of the perforated area at the central portion of the perforated area, and the length of the perforated area at the first side portion and the second side portion of the perforated area is smaller than the length of the perforated area at the central portion of the perforated area, and Wherein the width of the perforated area at the first end portion of the perforated area is greater than twenty percent and less than ninety percent of the width of the perforated area at the central portion of the perforated area.

2. The nonwoven material of claim 1, wherein the width of the perforated area at the second end portion of the perforated area is smaller than the width of the perforated area at the center portion of the perforated area.

3. The nonwoven material of claim 1 or claim 2, wherein the plurality of holes are distributed in a plurality of rows spaced apart in the longitudinal direction in the perforated area, a front row of the plurality of rows being positioned at the first end portion of the perforated area, and the front row comprising no less than four holes of the plurality of holes.

4. The nonwoven material of claim 3, wherein a second row of the plurality of rows is positioned adjacent to and continuous with the preceding row of the plurality of rows, and the number of the plurality of holes in the second row is greater than the number of the plurality of holes in the preceding row.

5. The nonwoven material of claim 3, wherein the plurality of rows comprises no less than ten rows.

6. A nonwoven material as claimed in any one of the above claims, wherein the plurality of holes are distributed in a plurality of columns spaced apart along the transverse direction in the perforated area, a first edge column of the plurality of columns is positioned at the first side portion of the perforated area, and the first edge column includes no less than seven holes of the plurality of holes.

7. The nonwoven material of claim 6, wherein a second column of the plurality of columns is positioned adjacent to and continuous with the first edge column of the plurality of columns, and the number of the plurality of holes in the second column is greater than the number of the plurality of holes in the first edge column.

8. The nonwoven material of claim 6, wherein the plurality of columns comprises no less than six columns.

9. The nonwoven material of any of the preceding claims, wherein the maximum length of the perforated area is not less than twice the maximum width of the perforated area.

10. The nonwoven material of any of the above claims, wherein each aperture of the plurality of apertures has an area of ​​not less than about eight square millimeters and not more than about eighteen square millimeters.

11. The nonwoven material of any of the above claims, wherein the plurality of holes are evenly distributed throughout the perforated area.

12. The nonwoven material of any one of the preceding claims, wherein: The perforated region is a first perforated region and the plurality of holes is a first plurality of holes; The nonwoven web includes a second perforated region having a second plurality of apertures; and The average area of ​​each hole in the first plurality of holes is not less than twice the average area of ​​each hole in the second plurality of holes.

13. The nonwoven material of any of the above claims, wherein the nonwoven web is a fluid entangled nonwoven web, a meltblown nonwoven web, a spunbond nonwoven web, or a carded nonwoven web.

14. The nonwoven material of any of the above claims, wherein the plurality of apertures are formed by fluid entanglement, needle aperturing, water jet punching, overbonding, or ring rolling.

15. A garment comprising a layer formed from a nonwoven material as claimed in any one of the preceding claims.

16. A nonwoven material comprising: a plurality of fibers, the plurality of fibers forming a nonwoven web, the nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, wherein the nonwoven web comprises a perforated area having a plurality of holes, the perforated area of ​​the nonwoven web having a first side portion and a second side portion spaced apart along the transverse direction, and also having a first end portion and a second end portion spaced apart along the longitudinal direction, a central portion of the perforated area being disposed between the first side portion and the second side portion of the perforated area along the transverse direction, The width of the perforated zone defined along the transverse direction gradually tapers at the first end portion of the perforated zone, so that the width of the perforated zone at the first end portion of the perforated zone is not less than twenty percent and not more than eighty percent of the width of the perforated zone at the central portion of the perforated zone.

17. The nonwoven material of claim 16, wherein the width of the perforated area at the second end portion of the perforated area tapers gradually at the second end portion of the perforated area so that the width of the perforated area at the second end portion of the perforated area is not less than twenty percent and not more than eighty percent of the width of the perforated area at the center portion of the perforated area.

18. A nonwoven material as described in claim 16 or claim 17, wherein the plurality of holes are distributed in a plurality of rows spaced apart along the longitudinal direction in the perforated area, a front row of the plurality of rows is positioned at the first end portion of the perforated area, and the front row includes no less than four holes of the plurality of holes.

19. The nonwoven material of claim 18, wherein a second row of the plurality of rows is positioned adjacent to and continuous with the preceding row of the plurality of rows, and the number of the plurality of apertures in the second row is greater than the number of the plurality of apertures in the preceding row.

20. A nonwoven material as described in any one of claims 16 to 19, wherein the plurality of holes are distributed in a plurality of columns spaced apart along the transverse direction in the perforated area, a first edge column of the plurality of columns is positioned at the first side portion of the perforated area, and the first edge column includes no less than seven holes of the plurality of holes.

21. The nonwoven material of claim 20, wherein a second column of the plurality of columns is positioned adjacent to and continuous with the first edge column of the plurality of columns, and the number of the plurality of apertures in the second column is greater than the number of the plurality of apertures in the first edge column.

22. The nonwoven material of any one of claims 16 to 21, wherein the maximum length of the perforated area is not less than twice the maximum width of the perforated area.

23. The nonwoven material of any one of claims 16 to 22, wherein each hole in the plurality of holes has an area of ​​not less than about eight square millimeters and not more than about eighteen square millimeters.

24. A garment comprising a layer formed from the nonwoven material of any one of claims 16 to 23.

25. A nonwoven material comprising: a plurality of fibers, the plurality of fibers forming a nonwoven web, the nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, wherein the nonwoven web comprises a perforated region having a plurality of holes, the perforated region of the nonwoven web having a first side portion and a second side portion spaced apart along the transverse direction, and also having a first end portion and a second end portion spaced apart along the longitudinal direction, wherein the plurality of holes are distributed in a plurality of rows spaced apart along the longitudinal direction in the perforated area, a front row of the plurality of rows is positioned at the first end portion of the perforated area, and a second row of the plurality of rows is positioned adjacent to and continuous with the front row of the plurality of rows, a total area of ​​the plurality of holes in the front row is smaller than a total area of ​​the plurality of holes in the second row, and a density of the total area of ​​the front row along the longitudinal direction is greater than approximately four and nine-tenths square millimeters per millimeter.

26. The nonwoven material of claim 25, wherein a third row of the plurality of rows is positioned adjacent to and continuous with the second row of the plurality of rows, and the total area of ​​the plurality of holes in the second row is less than the total area of ​​the plurality of holes in the third row.

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