Reinforced nonwoven material

Abstract

The nonwoven material includes a plurality of fibers forming a nonwoven web. The nonwoven web includes a perforated region having a plurality of apertures. The nonwoven web further includes a plurality of support regions configured to limit elongation of the nonwoven web when the nonwoven web is under tension.

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 the body exudates (such as semi-solid fecal materials) captured in the article and the wearer's skin can cause discomfort. Allowing the body exudates to move through the liner and away from the wearer's skin can reduce or limit this discomfort. Therefore, a nonwoven material with features that promote the movement of body exudates through the nonwoven material would be useful.

[0002] Nonwoven materials with orifices can facilitate the movement of body exudates through the nonwoven materials; however, known methods and mechanisms for forming nonwoven materials with orifices are defective. For example, nonwoven webs can curl under tension, and multilayer webs with orifices tend to curl more severely during high-speed conversion. In addition, orifices can reduce the size and mechanical stability of the web, and the porous web can therefore exhibit an elongation greater than that observed in a non-porous web. Edge curling can lead to web folding (fold-over) and flipping, adhesive overspray and other product problems during high-speed conversion. Therefore, a nonwoven material with features for limiting curling would be useful. Summary of the invention

[0003] Generally speaking, the present disclosure relates to a nonwoven material having (for example, when the nonwoven material is under tension) the feature of reducing curling. The nonwoven material may include a nonwoven web with a plurality of support areas. When the nonwoven web is under tension, the support area can limit the curling of the nonwoven web, and therefore improve the high-speed web conversion. The support area can provide the entanglement strengthened between the adjacent layers of the nonwoven material and therefore provide bonding to strengthen the nonwoven material. Therefore, when the nonwoven web is under tension, the support area can advantageously help limit the elongation of the nonwoven web, which can then also limit the curling of the nonwoven web. The nonwoven material with support area can be incorporated into absorbent articles such as urine pads, diapers, disposable underwear, etc.

[0004] In an exemplary embodiment, the multilayer nonwoven material includes a laminated nonwoven web defining a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The laminated nonwoven web includes a first web and a second web. The laminated nonwoven web includes a perforated area with a plurality of orifices, the plurality of orifices being distributed across the width of the perforated area in the transverse direction, and across the length of the perforated area in the longitudinal direction. The laminated nonwoven web includes one or more support areas. The fibers of the first web are entangled in discrete areas of the first web, and are consolidated to a greater extent with the fibers of the second web at the one or more support areas than at the area adjacent to the one or more support areas of the laminated nonwoven web. The overall area of ​​the one or more support areas on the laminated nonwoven web is not less than 0.5 percent and not more than 30 percent of the total area of ​​the laminated nonwoven web.

[0005] In another exemplary embodiment, the multilayer nonwoven material includes a laminated nonwoven web defining a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The laminated nonwoven web includes a first web and a second web. The laminated nonwoven web includes a perforated area with a plurality of orifices, the plurality of orifices being distributed across the width of the perforated area in the transverse direction, and being distributed across the length of the perforated area in the longitudinal direction. The laminated nonwoven web includes a first surface and a second surface. The first surface on the laminated nonwoven web is opposite to the second surface. The laminated nonwoven web includes a plurality of nodes extending away from the base plane on the first surface. The laminated nonwoven web includes one or more support areas. The fibers of the first web are entangled in discrete areas of the first web, and are consolidated to a greater extent with the fibers of the second web at the one or more support areas than at the area adjacent to the one or more support areas of the laminated nonwoven web.

[0006] In another exemplary embodiment, the multilayer nonwoven material includes a laminated nonwoven web defining a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The laminated nonwoven web includes a first web and a second web. The laminated nonwoven web includes a perforated area with a plurality of orifices, the plurality of orifices being distributed across the width of the perforated area in the transverse direction and across the length of the perforated area in the longitudinal direction. The laminated nonwoven web includes a first surface and a second surface. The first surface on the laminated nonwoven web is opposite to the second surface. The laminated nonwoven web includes a plurality of hollow nodes extending away from the base plane on the first surface. The laminated nonwoven web includes one or more support areas. The fibers of the first web are entangled in discrete areas of the first web, and are consolidated to a greater extent with the fibers of the second web at the one or more support areas than at the area adjacent to the one or more support areas of the laminated nonwoven web. The plurality of support areas are filled between the first surface and the second surface of the laminated nonwoven web by the fibers of the first web and the second web.

[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, to one 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 top plan view of a nonwoven material according to an example embodiment of the present disclosure.

[0011] Figure 3 yes Figure 2 A partial side view of a support area of ​​an example nonwoven material.

[0012] Figure 4 is a schematic side view of an apparatus and process for making a nonwoven material according to an example embodiment of the present disclosure.

[0013] Figure 4A yes Figure 4 A partial exploded view of the forming surface of an example device.

[0014] Figure 4B yes Figure 4 A partial cross-sectional view of a forming surface of an example apparatus.

[0015] Figure 5 is a top plan view of a nonwoven material according to another example embodiment of the present disclosure.

[0016] Figure 6 is a top plan view of a nonwoven material according to another example embodiment of the present disclosure.

[0017] Figure 7 is a top plan view of a nonwoven material according to another example embodiment of the present disclosure.

[0018] 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

[0019] In one embodiment, the present disclosure generally relates to nonwoven materials having support areas, for example, when the nonwoven material is under tension, the support areas can advantageously help limit the curling of the nonwoven material. It should be understood by those of ordinary skill in the art that this discussion is only a description of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0020] 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%).

[0021] definition :

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] The terms "fluid entanglement" and "fluid entangled" generally refer to a formation method for further increasing the degree of fiber entanglement in a given fiber nonwoven web or between a fiber nonwoven web and other materials in this article so that individual fibers and / or these layers are more difficult to separate due to entanglement. Typically, this is achieved by supporting the fiber nonwoven web on some types of formation or carrier surfaces, which have some permeability to the pressurized fluid that impacts. The pressurized fluid stream (usually multiple streams) is then directed to the surface of the nonwoven web opposite to the web support surface. The pressurized fluid contacts the fiber and compresses the fiber portion in the direction of fluid flow, thereby displacing all or part of a variety of fibers toward the web support surface. The result is that the fiber is further entangled, and the direction of entanglement can be referred to as the Z direction (thickness) of the web relative to its flatter dimension, i.e., the XY plane. When two or more separate webs or other layers are placed adjacent to one another on a forming / carrier surface and subjected to a pressurized fluid, the generally desired result is that some fibers of at least one web are pressed into an adjacent web or layer, thereby causing fiber entanglement between the two surface interfaces so as to bond or join the webs / layers together due to increased fiber entanglement. The degree of bonding or entanglement will depend on a variety of factors, including but not limited to the type of fibers used, the fiber length, the degree of pre-bonding or entanglement of one or more webs prior to being subjected to the fluid entanglement process, the type of fluid used (liquid, such as water, stream, or gas, such as air), the fluid pressure, the number of fluid streams, the process speed, the fluid residence time, and the porosity of one or more webs / other layers and the forming / carrier surface. One of the most common fluid entanglement processes is known as hydraulic entanglement, which is a process well known to those of ordinary skill in the nonwoven web art. Examples of fluid entangling processes can be found in US Pat. No. 4,939,016 to Radwanski et al., US Pat. No. 3,485,706 to Evans, and US Pat. Nos. 4,970,104 and 4,959,531 to Radwanski, each of which is incorporated herein by reference in its entirety for all purposes.

[0028] The term "gsm" herein means grams per square meter.

[0029] 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.

[0030] 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.

[0031] The term "liquid permeable" is used herein to refer to any material that is not liquid impermeable.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] Absorbent products :

[0040] 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 1The 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.

[0041] Figure 1 The 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.

[0042] 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.

[0043] 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.

[0044] 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 .

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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 and / or sides of the body side liner 28.

[0063] 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 staple 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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 1 The 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.

[0069] 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.

[0070] 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 flap 50, 52. The elastic member 68 can be located within the containment flap 50, 52 when in an elastically contractible state so that contraction of the strands gathers and shortens the protruding portion 66 of the containment flap 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 flap 50, 52, the elastic member 68 can bias the protruding portion 66 of the containment flap 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.

[0071] 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 portions of the elastic members 68 that are not coated with adhesive 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).

[0072] 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.

[0073] 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.

[0074] 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 114, 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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 assist 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 assisting 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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 apertures (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.

[0091] 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 orifices extending through the body side liner 28. The orifices 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 orifices, 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, orifices, 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 area 21 may be different from the structural features 27 in the second feature area 25. Thus, for example, the structural features 23 in the first feature area 21 may provide different performance characteristics than the structural features 27 in the second feature area 25. In addition, each of the first feature area 21 and the second feature area 25 may be individually arranged, sized, shaped and / or configured to provide corresponding performance characteristics therein. As another example, the features 27 of the second feature area 25 may provide a different visual appearance than the features 23 in the first feature area 21, such as printed dots or a wavy pattern, to help the user distinguish between the first area 21 and the second area 25.

[0092] The portion of the body-side liner 28 that includes the 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. The portion of the body-side liner 28 that includes the 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.

[0093] 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.

[0094] 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, to transfer and collect 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 feature area 21 includes an orifice. Where the feature 23 includes an orifice, such an orifice may be a relatively small hole for managing urine exudate.

[0095] Therefore, in at least some example embodiments, the first feature area 21 may be disposed in a local area of ​​the article 10, such as Figure 1 As shown in . For example, the longitudinal extent of the first feature area 21 may be smaller than the longitudinal extent LAA of the article 10. More specifically, the longitudinal extent of the first feature area 21 may be smaller than half, one-third, or one-quarter of the longitudinal extent LAA of the article 10. In addition, the lateral extent of the first feature area 21 may be smaller than the lateral extent WAA of the article 10. In some of these example embodiments, the first feature area 21 may be completely disposed between the proximal ends 64a of the base portions 64 of the anti-leakage flaps 50, 52. In some example embodiments, the first feature 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.

[0096] Three-dimensional web with support areas:

[0097] Figure 2 is a top plan view of a nonwoven material 200 according to an exemplary embodiment of the present disclosure. Figure 2 In the embodiment of the present invention, nonwoven material 200 is shown as flat configuration or flat configuration.Nonwoven material 200 can be used in absorbent article 10, for example, as body side liner 28, therefore, nonwoven material 200 is described in more detail below in the context of absorbent article 10.However, it should be understood that in alternative exemplary embodiments, nonwoven material 200 can be used in any other article or clothing.For example, nonwoven material 200 can be used for diapers, diapers, training pants, larger 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 liner and wipes for the wearer of such products.As discussed in more detail below, nonwoven material 200 can advantageously include the feature that is used to limit or reduce the nonwoven material 200 curling under tension, for example, although there are other features on nonwoven material 200, such as orifice, node etc.

[0098] like Figure 2As shown, 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 longitudinal direction LO may correspond to the longitudinal direction 30, and the transverse direction LA may correspond to the transverse direction 32. The fiber web 210 may extend, for example, between a front end or first end portion 212 and a rear end or second end portion 214 along the longitudinal direction LO. 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 rear waist region 14 of the absorbent article 10, and the second end portion 214 of the fiber web 210 may be positioned at or near the front waist region 12 of the absorbent article 10. The fiber web 210 may also extend, for example, between a first side portion 216 and a second side portion 218 along the transverse direction LA. Thus, the first side portion 216 and the second side portion 218 may be spaced apart along the lateral direction LA.

[0099] 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.

[0100] The nonwoven web 210 may include at least one characteristic region. Figure 3 As shown, the nonwoven web 210 may include a first feature area 220 and a second feature area 230. The first feature area 220 may be spaced apart from the second feature area 230, for example, along the longitudinal direction LO. For example, the first feature area 220 and the second feature 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). Figure 2As shown, the nonwoven web 210 may be non-perforated, for example, along the longitudinal direction LO between the first feature area 220 and the second feature area 230. Thus, for example, the nonwoven web 210 may not be processed to include pores between the first feature area 220 and the second feature area 230 along the longitudinal direction LO. In certain example embodiments, the centroid of the first feature area 220 may also be co-linear with the centroid of the second feature area 230, for example, arranged on the longitudinal axis 29. In addition, the first feature area 220 and the second feature area 230 may be positioned at the middle portion of the nonwoven web 210, for example, along the transverse direction LA between the first side portion 216 and the second side portion 218 of the web 210.

[0101] The first feature area 220 may include a plurality of orifices 221 and a plurality of nodes 222, and the second feature area 230 may also include a plurality of orifices 231. The orifices 221 of the first feature area 220 may be larger than the orifices 231 of the second feature area 230. For example, the area of ​​each orifice 221 of the first feature area 220 may be not less than about five square millimeters (5mm 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 twenty 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 orifices 231 of the second feature region 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 orifices 221 of the first feature area 220 and the orifices 231 of the second feature area 230 can advantageously promote the movement of body exudates through the nonwoven fiber web 210. In addition, the size of the larger orifices 221 of the first feature area 220 can be set to transfer and collect low-viscosity feces. Conversely, the size of the smaller orifices 231 of the second feature area 230 can be set to transfer and collect urine exudates. In certain example embodiments, the orifices 221 can be distributed throughout the first feature area 220, and the orifices 231 can be distributed throughout the second feature area 230. For example, the orifices 221 can be evenly distributed throughout the first feature area 220, and the orifices 231 can be evenly distributed throughout the second feature area 230.

[0102] As described above, the nonwoven material 200 may include nodes 222 at the first feature area 220. It should be understood that in alternative example embodiments, the nonwoven material 200 may include nodes located at other locations on the nonwoven material 200. In addition, it should be understood that in certain example embodiments, the first feature area 220 may include nodes 222 without apertures 221, and vice versa. Figure 2 As shown, the nonwoven web 210 may also include a plurality of connecting ties 223 at the first feature area 220. The nodes 222 may face away from the first surface 211 ( Figure 3 ) extends from the base plane 215 on the first surface 211 of the nonwoven material 200. The base plane 215 can be defined as a substantially flat area of ​​the first surface 211 of the nonwoven material 200, rather than a portion of the nonwoven material 200 that forms the node 222. In other words, for Figure 2 and Figure 3 In the exemplary embodiment shown, the base plane 215 can be formed by the first surface 211 of the nonwoven material 200 that provides the connecting ties 223. The nonwoven material 200 can also include a second surface 213. Figure 3 As shown, a first surface 211 on the nonwoven web 210 may be opposite to a second surface 213 .

[0103] Nodes 222 may be configured in a variety of shapes and sizes. In some example embodiments, nodes 222 may be substantially cylindrical in shape. In certain example embodiments, nodes 222 may be configured to not include any openings or orifices. In certain example embodiments, nodes 222 may have a height between about half a millimeter (0.5 mm) and about ten millimeters (10 mm) (as measured in a direction perpendicular to base plane 215, e.g., from base plane 215 to the distal end portion of node 222), such as from about one millimeter (1 mm) to about three millimeters (3 mm), such as from about one and one-tenth millimeters (1.1 mm) to about one and five-tenths millimeters (1.5 mm), such as about one and three-tenths millimeters (1.3 mm). In certain example embodiments, most nodes 222 may each have a height from about five square millimeters (5 mm) to about 10 mm. 2 ) to about 35 square millimeters (35mm 2 ) (measured by the area of ​​the node 222 at the base plane 215), such as from about ten square millimeters (10mm 2 ) to about 20 square millimeters (20mm 2 The nodes 222 may be configured in the first feature region 220 such that the nodes 222 provide approximately one node per square centimeter (1.0 node / cm 2 ) to approximately three nodes per square centimeter (3.0 nodes / cm 2 )’s node density.

[0104] like Figure 2 As shown, the connecting ties 223 can interconnect the nodes 222. In addition, each connecting tether 223 can be said to extend only between two (2) adjacent nodes 222. In other words, a single discrete connecting tether 223 may not interconnect three (3) or more nodes 222. In this way, this node and tether structure is different from the "island" configuration, in which the nodes are dispersed between continuously extending and interconnected "base areas". In an example embodiment, a majority of the nodes 222 may include at least three (3) connecting ties 223 connected to adjacent nodes 222. In certain example embodiments, a majority of the nodes 222 may include ten (10) or fewer connecting ties 223 connected to adjacent nodes 222. In some example embodiments, the nonwoven material 200 may be configured such that a majority of the nodes 222 may include three (3) to eight (8) connecting ties 223 connected to adjacent nodes 222. For example, in Figure 2 In the exemplary embodiment, most nodes 222 include four connecting ties 223 connected to adjacent nodes 222.

[0105] The orifice 221 can be a region of the nonwoven web 210 having a lower fiber density of the nonwoven web 210 than the nodes 222 and the connecting ties 223. In some exemplary embodiments, the orifice 221 can be substantially free of fibers. As used herein, the orifice 221 will be distinguished from the spacing between normal interstitial fibers that are typically present in a fiber nonwoven material. For example, the orifice 221 may include fibers with a lower density than adjacent nodes 222 and connecting ties 223. The orifice 221 can be formed between the connecting ties 223 and the nodes 222. A separate orifice 221 can be disposed between adjacent nodes 222. In certain exemplary embodiments, each orifice 221 can be defined between at least three (3) connecting ties 223 and at least three (3) nodes 222. In some exemplary embodiments, a separate discrete orifice 221 can be defined between at least four (4) connecting ties 223 and at least four (4) nodes 222.

[0106] like Figure 2 and Figure 3Shown, nonwoven material 200 can include a plurality of support areas 240.Support areas 240 can advantageously help, for example, to reduce curling when nonwoven material 200 is under tension.For example, nonwoven material 200 can be a multilayer nonwoven material 200 with two materials, for example, laminated together and having two webs with different elongation characteristics.When under tension, two materials of multilayer nonwoven material 200 may act differently due to different mechanical properties, thereby causing the edge curling (for example, at the first side portion 216 and the second side portion 218) of multilayer nonwoven material 200, which may cause web folding and overturning, adhesive overspray and other product problems during high-speed conversion.The orifice 221 in the first perforated zone 220 can also reduce the size and mechanical stability of nonwoven material 200 relative to other parts of nonwoven material 200 that do not have orifice and / or have less orifice. Such reduced dimensional and mechanical stability of a nonwoven material having an aperture similar to the aperture 221 in the first perforated area 220 may also cause the nonwoven material to curl under tension (e.g., due to elongation), which may result in web folding and flipping, adhesive overspray, and other product problems during high-speed conversion. When the nonwoven material 200 is a multi-layer nonwoven material 200, edge curling may be particularly evident due to the combination of the different mechanical properties of the two materials in the multi-layer nonwoven material 200 and the reduced dimensional and mechanical stability associated with the aperture 221 in the first perforated area 220. The support area 240 on the nonwoven material 200 may advantageously reduce or limit the curling of the nonwoven material 200, which may be caused, for example, by the different mechanical properties at the discrete areas in the multi-layer nonwoven material 200, which may therefore reduce the dimensional stability and mechanical stability associated with the aperture 221 in the first perforated area 220.

[0107] The support regions 240 may correspond to regions of the multi-layer nonwoven material 200 that have more or greater bonding within the first web / layer and between the two materials in the multi-layer nonwoven material 200 relative to other regions of the multi-layer nonwoven material 200, such as non-perforated regions of the multi-layer nonwoven material 200 that are (e.g., directly) adjacent to the support regions 240. For example, the two materials in the multi-layer nonwoven material 200 may have more or greater entanglement between fibers within the discrete support regions 240 at the support regions 240 than other regions of the multi-layer nonwoven material 200, such as non-perforated regions of the multi-layer nonwoven material 200 that are (e.g., directly) adjacent to the support regions 240. Thus, for example, a greater portion of the fibers of the first web of the multilayer nonwoven material 200 at the support region 240 may be entangled together, and a greater portion of the fibers of the first web and the second web may be consolidated together at the interface of the first web and the second web at the support region 240 than at the nodes 222 and / or at the non-perforated portions of the multilayer nonwoven material 200. By increasing the bonding of the fibers of the first web of the multilayer nonwoven material 200 at the support region 240 and the fibers between the two webs, the different elongation characteristics of the two materials due to the different mechanical properties may be advantageously reduced, so that the curling of the multilayer nonwoven material 200 under tension is also reduced. In addition, the greater the degree of bonding of the multilayer nonwoven material 200 at discrete areas at the support region 240, the more the multilayer nonwoven material 200 can behave like a nonwoven material 200 having one material or web in terms of edge curling by reducing the difference between the elongation characteristics of the two materials.

[0108] The support area 240 on the nonwoven material 200 may correspond to an area of ​​the nonwoven material 200 having a different basis weight, a different density, a different caliper (e.g., material height), and / or a different level of inter-fiber bonding compared to adjacent areas of the nonwoven material 200. Thus, for example, the basis weight of the nonwoven material 200 at the support area 240 may be greater than the basis weight of the nonwoven material 200 at an area of ​​the nonwoven material 200 (e.g., directly) adjacent to the support area 240 (e.g., greater than not less than ten percent (10%) and / or not greater than ninety percent (90%) thereof). As another example, the thickness of the nonwoven material 200 at the support area 240 may be greater than the thickness of the nonwoven material 200 at an area of ​​the nonwoven material 200 (e.g., directly) adjacent to the support area 240 (e.g., greater than not less than ten percent (10%) and / or not greater than ninety percent (90%) thereof). As yet another example, the density of the nonwoven material 200 at the support region 240 can be greater (e.g., not less than ten percent (10%) and / or not more than ninety percent (90%) greater) than the density of the nonwoven material 200 at an area of ​​the nonwoven material 200 (e.g., directly) adjacent to the support region 240. Thus, the support region 240 can have different material or mechanical properties than adjacent areas of the nonwoven material 200, e.g., to provide increased local strength and / or stiffness relative to adjacent areas of the nonwoven material 200.

[0109] As can be seen from the above, due to the increased bonding between the discrete regions and the two materials, the support region 240 can advantageously reduce the curling of the multilayer nonwoven material 200. The support region 240 can also provide increased strength for the nonwoven material 200. For example, the support region 240 can strengthen the material 200 in a manner similar to an I-beam, so as to increase the rigidity of the material 200. This increased elongation resistance under tension helps to reduce necking (necking), which in turn can cause edge folding. It is also believed that the exemplary embodiments of the present disclosure of the support region 240 disposed in the side regions of the adjacent material 200 provide increased strength particularly concentrated in those edge regions. Therefore, in addition to contributing to the overall strength under tension, it is believed that such support regions 240 can provide increased resistance to the bending of the material 200 in the side regions, and therefore also contribute to reducing folding under tension and during conversion.

[0110] It should be understood that the support areas 240 can have a variety of sizes, locations, and orientations on the nonwoven material 200, each of which can reduce curling of the multi-layer nonwoven material 200 due to increased bonding between the two materials. Example positioning, sizes, and orientations of support areas 240 for promoting reduced curling, such as when the nonwoven material 200 is under tension are described below, but it should be understood that such locations, sizes, and orientations of support areas 240 are provided by way of example, and other locations, sizes, and orientations of support areas 240 are also within the scope of the present disclosure.

[0111] In certain example embodiments, at least some of the support regions 240 may be positioned adjacent to the first side portion 225 of the first perforated area 220. The size, location, and / or orientation of the support regions 240 adjacent to the first perforated area 220 on the nonwoven material 200 may advantageously limit curling of the nonwoven material 200 when the nonwoven material 200 is under tension. For example, the support regions 240 may limit elongation of the nonwoven material 200 due to the presence of the apertures 221 within the first perforated area 220, and thus may reduce the risk of web folding and flipping, adhesive overspray, and other product issues during high-speed conversions when the nonwoven material 200 is under tension.

[0112] In some example embodiments, such support regions 240 may be formed directly in the material 200 itself during the hydroentanglement process, as described in more detail below. As some examples, the support regions 240 may be formed as elongated protrusions, for example, via a patterned sleeve having a series of grooves that allow fibers from the protruding layer to consolidate and form the support regions. However, other methods of forming such support regions 240 are also contemplated.

[0113] Generally speaking, support area 240 can be located on the side edge of nonwoven material such as nonwoven material 200, and this side edge can be the non-porous passage for attaching (for example, gluing, bonding etc.) nonwoven material 200, or can extend across the whole width of nonwoven material 200 in other exemplary embodiments.Support area 240 can be parallel to longitudinal orientation, or can be parallel to longitudinal orientation.Support area 240 also can be with respect to longitudinal orientation with other angles.The length, width and depth of support area 240 can change, and the distance between adjacent support area 240 also can be adjusted, to provide different levels of fiber web strengthening.Describe below and will describe further details.

[0114] The support region 240 may be formed on a selected portion of the nonwoven material 200. For example, the overall area of ​​the support region 240 on the nonwoven material 200 (e.g., at the first surface 211) may be no less than 0.5 percent (0.5%) and no more than thirty percent (30%), such as no less than five percent (5%) and no more than twenty percent (20%) of the total area of ​​the nonwoven material 200, for example, at the first surface 211. Thus, the support region 240 may occupy only a portion of the nonwoven material 200 while advantageously limiting the curling of the nonwoven material 200 under tension.

[0115] The size and / or shape of the support area 240 can be set in a selected manner. For example, the support area 240 can be extended on the nonwoven material 200. Thus, for example, in certain example embodiments, the support area 240 can be strip-shaped or beam-shaped. In addition, the support area 240 can be extended along the length LB of the support area 240, and the width WB of the support area 240 can be defined as perpendicular to the length LB of the support area 240, for example, in the base plane 215 of the first surface 211 of the nonwoven material 200. In an example embodiment, the length LB of each support area 240 can be not less than three times (3X) the width WB of each support area 240, such as not less than five times (5X) the width WB of each support area 240, such as not less than seven times (7X) the width WB of each support area 240. Figure 2 and Figure 3 In the illustrated exemplary embodiment, the support region 240 is elongated along the transverse direction LA. Thus, for example, the length LB of the support region 240 can be oriented generally parallel to the transverse direction LA, and the width WB of the support region 240 can be oriented generally parallel to the longitudinal direction LO. However, it should be understood that in alternative exemplary embodiments, the support region 240 can have other orientations on the nonwoven material 200. For example, the support region 240 can be oriented at an angle relative to one or both of the transverse direction LA and the longitudinal direction LO.

[0116] Similarly, support area 240 can be configured to various shapes and sizes. In some example embodiments, such as when support area 240 is formed by hydroentangling, support area 240 can be a roughly semi-cylindrical shape. In other example embodiments, support area 240 can have a triangular prism shape, a rectangular prism shape, etc. In some example embodiments, support area 240 can be configured to not include any opening or orifice. However, support area 240 can be flush with base plane 215 at the proximal end portion 244 of support area 240. In addition, support area 240 can usually fill fibers between distal end portion 246 and proximal end portion 244 of support area 240, particularly when support area 240 is formed by fluid entanglement. In addition, support area 240 can be filled between first surface 211 and second surface 213 of nonwoven material 200 by the fiber of nonwoven material 200. Even more specifically, where the material 200 is a laminate, the support region 240 may preferably be filled with fibers from one of the layers of the nonwoven material 200 .

[0117] In certain exemplary embodiments, such as where support region 240 is disposed on a porous material such as nonwoven material 200, the length LB of support region 240 (as measured between opposite ends of support region 240) may extend between an edge of material 200 and a first characteristic region of material 200 for a length between about 25% to about 100%, or between about 33% and 100%, or between about 50% and 100%, or between about 66% and 100% of the total length between the edge of the material and the first characteristic region. In more specific embodiments, length LB may advantageously be between about five millimeters (5 mm) and about four hundred millimeters (400 mm). In addition, in example embodiments, and depending on the arrangement of the support region 240 on the nonwoven material 200, the length LB of the support region 240 can be between about two hundred and fifty millimeters (250 mm) and about four hundred millimeters (400 mm), between about one hundred and fifty millimeters (150 mm) and about three hundred millimeters (300 mm), between about fifty millimeters (50 mm) and about one hundred millimeters (100 mm), or between about twelve millimeters (12 mm) and about fifty millimeters (50 mm). In certain example embodiments, the width WB of the support region 240 (as measured between opposite ends of the support region 240) can be between about half a millimeter (0.5 mm) and about six millimeters (6 mm), such as between about one millimeter (1 mm) and about three millimeters (3 mm), such as about two millimeters (2 mm). In certain example embodiments, the support region 240 may have a height HB between about half a millimeter (0.5 mm) and about twelve millimeters (12 mm) (as measured in a direction perpendicular to the base plane 215, e.g., from the base plane 215 to the distal end portion 246 of the support region 240), such as from about one millimeter (1 mm) to about five millimeters (5 mm), such as from about one and one-tenth millimeters (1.1 mm) to about three millimeters (3 mm), such as about two millimeters (2 mm). In certain example embodiments, the average height of the support region 240 may be less than the average height of the nodes 222. For example, the average height of the support region 240 may be not less than two percent (2%) and not more than seventy percent (70%) of the average height of the nodes 222, such as not less than five percent (5%) and not more than fifty percent (50%), such as not less than ten percent (10%) and not more than forty percent (40%). Where nonwoven material 200 includes both nodes 222 and support regions 240, support regions 240 may extend away from base plane 215 in the same direction as nodes 222. In alternative exemplary embodiments, support regions 240 may extend away from base plane 215 in the opposite direction as nodes 222.

[0118] like Figure 2As shown, the support area 240 can be positioned at the first side portion 216 of the nonwoven material 200. In addition, the support area 240 can be positioned between the first side portion 225 of the first perforated area 220 and the first side portion 216 of the nonwoven material 200, for example, along the transverse direction LA. In addition, the support area 240 can be located in a non-porous channel between the first side portion 225 of the first perforated area 220 and the first side portion 216 of the nonwoven material 200, for example, the non-porous channel is used to attach (e.g., glue, bond, etc.) the nonwoven material 200. Therefore, for example, the support area 240 can extend along the transverse direction LA between the first side portion 225 of the first perforated area 220 and the first side portion 216 of the nonwoven material 200. The support area 240 can also be distributed along the longitudinal direction LO. For example, in certain exemplary embodiments, the support area 240 can be spaced apart along the longitudinal direction LO at the first side portion 216 of the nonwoven material 200. In other example embodiments, the support areas 240 may be spaced apart in the longitudinal direction LO at the first side portion 225 of the first perforated area 220, for example, so that the support areas 240 are not positioned adjacent to the second perforated area 230 or other portions of the nonwoven material 200. In certain example embodiments, adjacent support areas 240 may be spaced apart by not less than about ten millimeters (10 mm) and not more than about two hundred millimeters (200 mm), such as not less than about fifteen millimeters (15 mm) and not more than about one hundred millimeters (100 mm), such as about twenty millimeters (20 mm). In certain example embodiments, the support areas 240 may be arranged parallel to each other. The support areas 240 may additionally be spaced apart evenly in the longitudinal direction LO, but this is not required in all example embodiments.

[0119] The nonwoven material 200 may also include, for example, a plurality of additional support areas 242 formed in the same or similar manner as the support areas 240 described above. The additional support areas 242 on the nonwoven material 200 may be positioned relative to the support areas 240. Thus, for example, the additional support areas 242 may be positioned at the second side portion 218 of the nonwoven material 200. Furthermore, the additional support areas 242 may be positioned, for example, along the transverse direction LA, between the second side portion 226 of the first perforated area 220 and the second side portion 218 of the nonwoven material 200. For example, the additional support areas 242 may be located in a non-porous channel between the second side portion 226 of the first perforated area 220 and the second side portion 218 of the nonwoven material 200, for example, the non-porous channel being used to attach (e.g., glue, bond, etc.) the nonwoven material 200. The additional support area 242 may extend along the transverse direction LA between the second side portion 226 of the first perforated area 220 and the second side portion 218 of the nonwoven material 200. The additional support area 242 may also be distributed along the longitudinal direction LO. For example, in certain example embodiments, the additional support area 242 may be spaced apart along the longitudinal direction LO at the second side portion 218 of the nonwoven material 200. In other example embodiments, the additional support area 242 may be spaced apart along the longitudinal direction LO at the second side portion 226 of the first perforated area 220, for example, so that the support area 240 is not positioned adjacent to the second perforated area 230 or other portions of the nonwoven material 200. In at least some example embodiments, the support area 240 and the support area 242 may be aligned along the transverse direction LA.

[0120] The positioning of the support area 240 and the additional support area 242 on the nonwoven material 200 can complement each other. Thus, for example, the support area 240 can limit the curling of the nonwoven material 200 at the first side portion 216 of the nonwoven material 200, and the additional support area 242 can limit the curling of the nonwoven material 200 at the second side portion 218 of the nonwoven material 200.

[0121] Figure 2 and Figure 3 The size, location and / or orientation of the support area 240 on the nonwoven material 200 shown in FIG. 2 is provided by way of example. It should be understood that other sizes, locations and / or orientations of the support area 240 on the nonwoven material 200 are also within the scope of the present disclosure.

[0122] Although discussed in the context by being formed as a part of the above-mentioned hydroentanglement process, the support area 240 envisioned within the scope of the present disclosure can be formed according to different processes. In other exemplary embodiments, the support area 240 can be formed as a bonding portion formed by heat, ultrasound and / or pressure or other bonding methods known in the art. Alternatively, the support area 240 can be an embossing of a discrete densified area formed in the nonwoven material 200. Such alternative formation process can also cause the nonwoven material 200 to have an increased elongation resistance under tension, thereby helping to solve the disclosed conversion challenge. It is understood that the specific characteristics of such support areas 240 will be different according to different formation methods. For example, specific density, thickness and / or inter-fiber bonding can be different between the support areas 240 formed by different methods. In addition, different methods can lead to different shapes of the support area 240, for example, forming the support area 240 by a bonding process can lead to a flat structure, which is opposite to the protruding structure formed according to the hydroentanglement process. However, the preferred general longitudinal directions and transverse dimensions of support regions 240 described above with respect to support regions 240 formed according to a hydroentanglement process are equally applicable to support regions 240 formed according to other methods.

[0123] Although the support area 240 may be most advantageously useful in the example embodiment of the nonwoven material 200 including the characteristic area with the orifice and the node, it should be understood that such support areas 240 according to the example aspects of the present disclosure are also useful in other cases. For example, the nonwoven material including the laminate of the material with different mechanical properties can cause undesirable curling or folding or other effects when placed under tension. Therefore, according to the example embodiments of the present disclosure, the nonwoven material 200 may be included, and the nonwoven material includes a laminate of two different fiber webs with different mechanical properties, and the laminate does not include any node 222, orifice 221 or lace 223, but includes such support areas 240. Further example embodiments according to various aspects of the present disclosure include nonwoven material 200, and the nonwoven material includes a laminate of two different fiber webs with different mechanical properties, and the laminate does not include any node 222 or lace 223, but includes an orifice 221 and such support areas 240. Such contemplated example embodiments include material 200 in which nodes 222 or apertures 221 are arranged in a configuration as described throughout this disclosure with respect to patterns of features 21 , 25 and / or nodes 222 or apertures 221 .

[0124] Go to Figure 5, depicting a nonwoven material 501 according to another exemplary embodiment of the present subject matter, the support region 240 may be elongated along the transverse direction LA. In addition, the support region 240 may extend between the first side portion 216 and the second side portion 218 of the nonwoven material 501 along the transverse direction LA. Thus, the support region 240 may extend from the first side portion 216 of the nonwoven material 501 along the transverse direction LA, across the first perforated area 220 to the second side portion 218 of the nonwoven material 501. Similarly, the support region 240 may extend from the first side portion 216 of the nonwoven material 501 along the transverse direction LA, across the second perforated area 230 to the second side portion 218 of the nonwoven material 501. Conversely, in certain exemplary embodiments, the support region 240 may not be positioned at the gap G between the first perforated area 220 and the second perforated area 230 and / or at other non-perforated areas of the nonwoven material 501.

[0125] like Figure 6 As shown, on a nonwoven material 600 according to another exemplary embodiment of the present subject matter, a support region 240 can be elongated along a longitudinal direction LO. Furthermore, the support region 240 can extend along the longitudinal direction LO between a first end portion 212 and a second end portion 214 of the nonwoven material 501. Thus, the support region 240 can extend along the longitudinal direction LO from the first end portion 212 of the nonwoven material 501, across the first perforated area 220 and the second perforated area 230 to the second end portion 214 of the nonwoven material 501. The support region 240 can also extend across a gap G between the first perforated area 220 and the second perforated area 230 at the first end portion 212 and the second end portion 214 of the nonwoven material 501, and across an unperforated area of ​​the nonwoven material 501; however, the support region 240 may not be positioned adjacent to the first side portion 216 and the second side portion 218 of the nonwoven material 501. Figure 6 In the example embodiment shown, the support regions 240 may also be distributed along the lateral direction LA. For example, in certain example embodiments, the support regions 240 may be spaced apart along the lateral direction LA at the first perforated area 220 and the second perforated area 230 .

[0126] Go to Figure 7, on a nonwoven material 700 according to another exemplary embodiment of the present subject matter, a support region 240 may be elongated along the longitudinal direction LO. Furthermore, the support region 240 may extend along the longitudinal direction LO between a first end portion 227 and a second end portion 228 of the first perforated area 220. Thus, the support region 240 may extend along the longitudinal direction LO from the first end portion 227 of the first perforated area 220 across the first perforated area 220 to the second end portion 228 of the first perforated area 220. Conversely, in certain exemplary embodiments, the support region 240 may not be positioned at the second perforated area 230, at the gap G between the first perforated area 220 and the second perforated area 230, and / or at other non-perforated areas of the nonwoven material 501. Figure 7 In the example embodiments shown, the support regions 240 may also be distributed along the lateral direction LA. For example, in certain example embodiments, the support regions 240 may be spaced apart along the lateral direction LA at the first perforated area 220 .

[0127] refer to Figure 4 , a first exemplary embodiment of a method and apparatus 500 for forming, for example, a fluid-entangled laminate web 502 (such as a nonwoven material 200) having apertures 221, nodes 222, and / or support areas 240 according to exemplary aspects of the present disclosure is shown. In some exemplary embodiments, the process and apparatus 500 may be the same or similar to the process and apparatus described in U.S. Pat. No. 11,365,495 to Mark J. Beitz et al., entitled “Process for making fluid-entangled laminate webs with hollow projections and apertures,” the entire contents of which are incorporated herein by reference.

[0128] The method and apparatus 500 may include entanglement and thereby bonding of a support layer or web 514 and a projection layer or web 516. In some exemplary embodiments, the fibers of the support web 514 may be similar to those described in U.S. Pat. No. 9,327,473 to Niall Finn et al., entitled “Fluid-entangled laminate webs having hollow projections and a process and apparatus for making the same” with respect to the support web 14, the entire contents of which are incorporated herein by reference. Similarly, the fibers of the projection web 516 may be similar to those described in U.S. Pat. No. 9,327,473 with respect to the projection web 16, the entire contents of which are incorporated herein by reference.

[0129] Suitable materials for the support layer 514 may include a fibrous nonwoven web composed of a plurality of randomly placed fibers, which may be short length fibers, such as used in, for example, a carded web, an air-laid web, etc., or these materials may be continuous fibers, such as found in, for example, a meltblown or spunbond web. Due to the functions that the support layer 514 must perform, the support layer 514 may have a higher degree of integrity than the protruding web 516. In this regard, when the support layer 514 is subjected to the fluid entanglement process discussed in more detail below, the support layer 514 may be able to remain substantially intact. The degree of integrity of the support layer 514 may be such that the material forming the support layer 514 resists being driven downwardly into and filling the protruding web 516 and the hollow nodes 222 of the support area 240 during the formation of the web 502, for example, by resisting being driven into and filling the forming holes 534 and forming indentations 537 of the forming surface 530. Thus, when the support layer 514 is a fibrous nonwoven web, it may be desirable for the support layer 514 to have a higher degree of inter-fiber bonding and / or fiber entanglement than the fibers in the raised web 516. While it is desirable to have the fibers of the support layer 514 entangled with the fibers of the raised web 516 near the interface between the two layers, it is generally advantageous that the fibers of the support layer 514 not be so joined or entangled into the raised web 516 to the extent that a significant portion of such fibers penetrate into the interior of the hollow nodes 222.

[0130] The type, basis weight, strength and other characteristics of the support layer 514 can be selected and varied according to the specific end use of the laminate 502 obtained. When the laminate 502 is to be used as a part of an absorbent article such as a personal care absorbent article, a wipe, etc., it can be generally advantageous that the support layer 514 is a fluid-permeable layer, has good wet strength and dry strength, can absorb fluids such as body exudates, can store fluids for a specific period of time and then release the fluids to one or more layers below. In this regard, fiber nonwovens such as spunbond fiber webs, meltblown fiber webs, carded fiber webs such as air-laid fiber webs, bonded carded fiber webs, and co-formed materials are particularly suitable as support layer 514. Foam materials and scrim materials are also very suitable. In addition, the support layer 514 can be a multilayer material, which is due to the use of several layers or the use of multiple groups of forming processes, such as it is commonly used in the manufacture of spunbond fiber webs and meltblown fiber webs and spunbond fiber webs and meltblown fiber webs. In the formation of such a support layer 514, both natural materials and synthetic materials can be used alone or in combination to manufacture the material. Typically, for the end-use applications outlined herein, the basis weight of support layer 514 can range between about five grams per square meter (5 gsm) to about forty grams per square meter (40 gsm), although basis weights outside of this range can be used depending on the particular end-use application.

[0131] The type, basis weight, and porosity of the support web 514 may affect the process conditions required to form the nodes 222 in the protruding web 516 and the support areas 240 between the support web 514 and the protruding web 516. Heavier basis weight materials may increase the entanglement forces of the entangling fluid streams required to form the nodes 222 in the protruding web 516 and the support areas 240 between the support web 514 and the protruding web 516. However, a heavier basis weight support layer 514 may also provide increased support for the protruding web 516, because the main problem with the protruding web 516 itself is that the protruding web 516 is too stretchy to maintain the shape of the nodes 222 after the forming process. The protruding web 516 itself is overstretched longitudinally due to the mechanical forces applied to the protruding web 516 by the subsequent winding and converting processes, which shrinks and deforms the nodes 222. Additionally, without the support layer 514, the nodes 222 in the raised web 516 collapse due to the winding pressure and compressive weight experienced by the raised web 516 during the winding process and subsequent conversion, and do not recover to the same extent as they do with the support layer 514. As described above, this material property difference can also be mitigated by the support areas 240. For example, the support areas 240 between the support web 514 and the raised web 516 (e.g., and the resulting increase in bonding or entanglement of fibers of the raised web 516 at the discrete support areas 240, and the resulting increase in bonding or entanglement between fibers of the support web 514 and fibers of the raised web 516 at the support areas 240) can advantageously limit the difference in elongation between the support web 514 and the raised web 516 under tension, and thus reduce curling of the laminate web 502 under tension, particularly when the laminate web 502 includes the apertures 221.

[0132] The raised web 516 can be composed of a plurality of randomly disposed fibers, which can be short length fibers such as those used in, for example, carded webs, air-laid webs, coform webs, etc., or these fibers can be more continuous fibers such as those found in, for example, meltblown webs or spunbond webs. The fibers in the raised web 516 can advantageously have less inter-fiber bonding and / or fiber entanglement, and therefore have less integrity than the integrity of the support layer 514, especially when the support layer 514 is a fibrous nonwoven web. To allow for the formation of the hollow nodes 222 (which formation will be further described below in conjunction with the description of the process and apparatus for forming the fluid-entangled laminated web 502), the fibers in the raised web 516 can have no initial inter-fiber bonding. Alternatively, when both the support layer 514 and the raised web 516 are fibrous nonwoven webs, the raised web 516 will have less integrity than the support web 514 because the raised web 516 has less inter-fiber bonding, less adhesive, or less pre-entanglement of the fibers forming the web 516, for example, in areas such as nodes 222 and having openings 221.

[0133] The raised web 516 may have a sufficient amount of fiber movement capability to allow the fluid entanglement process described below to move the fibers of the raised web 516 out of the XY plane of the raised web 516 and into the vertical or Z direction of the web 516 (the thickness direction of the web 516) so as to form the hollow nodes 222 and / or support areas 240. If a more continuous fiber structure such as a meltblown or spunbond web is used, it may be advantageous to perform little or no pre-bonding of the raised web 516 prior to the fluid entanglement process. Longer fibers, such as those produced in meltblown and spunbond processes (which are often referred to as continuous fibers to distinguish such fibers from staple length fibers), may generally require more force to displace the fibers in the Z direction than shorter staple length fibers, which typically have a fiber length of less than one hundred millimeters (100 mm), and more typically have a fiber length in the range of ten millimeters (10 mm) to sixty millimeters (60 mm). In contrast, staple fiber webs such as carded webs and airlaid webs may have a certain degree of fiber pre-bonding or entanglement due to the shorter length of such staple fibers. Such shorter fibers may require less fluid force from the fluid entangling stream to move them in the Z direction to form hollow nodes 222 and / or support areas 240. Thus, a balance may be selected between fiber denier, fiber length, degree of pre-fiber bonding, fluid force, web speed, and residence time so that hollow nodes 222 and / or support areas 240 can be produced without (unless desired) forming orifices in the base area or forcing too much material into the interior of the node 222, thereby making the node 222 too rigid for some end-use applications.

[0134] Typically, for the purposes outlined herein, the raised web 516 may have a basis weight ranging from about ten grams per square meter (10 gsm) to about eighty-five grams per square meter (85 gsm), however basis weights outside this range may be used depending on the specific end-use application. When used as a raised web 516, a spunbond web may typically have a basis weight ranging from about fifteen grams per square meter (15 gsm) to about fifty grams per square meter (50 gsm). The fiber diameter may be in the range of about five microns (5 μm) to about twenty microns (20 μm). The fibers may be monocomponent fibers formed from a single polymer component or the fibers may be bicomponent or multicomponent fibers, wherein a portion of the fibers has a lower melting point than the other components, so as to allow inter-fiber bonding by using heat and / or pressure. Hollow fibers may also be used. The fibers may be formed from any polymer formulation commonly used to form spunbond webs. Examples of such polymers include, but are not limited to, polypropylene (PP), polyester (PET), polyamide (PA), polyethylene (PE), and polylactic acid (PLA). If necessary, the spunbond web may be subjected to post-forming bonding and entanglement techniques before it is subjected to the projection forming process to improve the processing properties of the web.

[0135] When used as the protruding web 516, the meltblown web may typically have a basis weight between about twenty grams per square meter (20 gsm) and about fifty grams per square meter (50 gsm). The fiber diameter may range between about half a micron (0.5 μm) and about five microns (5 μm). The fibers may be monocomponent fibers formed from a single polymer component or they may be bicomponent or multicomponent fibers, wherein a portion of the fiber has a lower melting point than the other components so as to allow inter-fiber bonding by using heat and / or pressure. The fibers may be formed from any polymer formulation commonly used to form the above-described spunbond webs. Examples of such polymers include, but are not limited to, PP, PET, PA, PE, and PLA.

[0136] Carded webs and air-laid webs use staple fibers, the length of which can be generally in the range of about ten millimeters (10mm) to about one hundred millimeters (100mm). The range of fiber denier is between about 0.5 denier and about 6 denier according to the special end use. The basis weight can be in the range of about 20 grams per square meter (20gsm) to about eighty-five grams per square meter (85gsm). Staple fibers can be made of a variety of polymers, including but not limited to PP, PET, PA, PLA, cotton, rayon, flax, wool, hemp and regenerated cellulose such as viscose. Blends of fibers can also be used, such as blends of bicomponent fibers and monocomponent fibers and blends of solid fibers and hollow fibers. If bonding is required, it can be achieved in a variety of ways, including, for example, by hot air bonding, calendering bonding, point bonding, chemical bonding and adhesive bonding such as powder bonding. If desired, to further enhance the integrity and processability of such webs prior to the projection forming process, the fibers may be subjected to a pre-entanglement process to increase fiber entanglement within the projection web 516 prior to forming the nodes 222 and / or support areas 240. Hydraulic entanglement is particularly advantageous in this regard.

[0137] While the nonwoven web types and forming processes described above are suitable for use in conjunction with the raised web 516, it is contemplated that other webs and forming processes may be used as long as the web is capable of forming hollow nodes 222 and / or support areas 240.

[0138] like Figure 4 As shown, the apparatus 500 includes a first conveyor belt 510, a conveyor belt drive roller 520, a protrusion forming surface 530, a fluid entangling device 540, an optional overfeed roller 550, and a fluid removal system 560, such as a vacuum or other conventional suction device. Such vacuum devices and other mechanisms are well known to those of ordinary skill in the art. The conveyor belt 510 is used to carry the protrusion web 516 to the apparatus 500. If it is to be Figure 4 The conveyor belt 510 may be porous upstream of any pre-entanglement on the raised web 516 in the process 500 shown in FIG. The conveyor belt 510 runs at a first speed or velocity V1 in a first direction (i.e., longitudinal direction) as indicated by arrow 512. The conveyor belt 510 may be driven by a conveyor belt drive roller 520 or other suitable mechanism such as those well known to those of ordinary skill in the art.

[0139] like Figure 4 The protrusion forming surface 530 shown is in the form of a textured roller 530, a partial exploded view of which is shown in FIG. Figure 4A and its partial cross-sectional view is shown in Figure 4B The protrusion forming surface 530 is as shown in FIG. Figure 4The protrusion forming surface 530 moves in the longitudinal direction indicated by the middle arrow 531 at a speed or velocity V3. The protrusion forming surface 530 is driven and speed controlled by any suitable drive mechanism (not shown), such as a motor and gear device known to those of ordinary skill in the art. Figure 4A and Figure 4B The texturing drum 530 depicted in FIG. 5 includes a forming surface 532 containing a pattern of forming holes 534 that correspond to the shape and pattern of the nodes 222 desired in the raised web 516. The forming holes 534 are separated by base areas 536. The forming holes 534 can be any shape and any pattern. Figure 2 , Figure 3 and Figures 5 to 7 As can be seen, the shape of the hole is round, but it is understood that many shapes and combinations of shapes can be used according to the end-use application. Examples of possible hole shapes include but are not limited to ellipse, cross, square, rectangle, rhombus, hexagon and other polygons. This shape can be formed in the protrusion forming surface 530 by casting, punching, stamping, laser cutting and water jet cutting. The spacing degree of the forming hole 534 and thus the base area 536 can also be changed according to the specific final application of the fluid entangled laminated fiber web 502. In addition, the pattern of the forming hole 534 in the textured roller 530 can be changed according to the specific final application of the fluid entangled laminated fiber web 502. The material forming the textured roller 530 can be many suitable materials commonly used for such forming rollers, including but not limited to metal plates, plastics and other polymer materials, rubber, etc. The forming hole 534 can be formed in a material sheet 532, and then the material sheet forms the textured roller 530, or the textured roller 530 can be molded or cast by a suitable material or printed with 3D printing technology.

[0140] The forming surface 532 also includes a pattern of protrusions 535 that corresponds to the shape and pattern of the desired apertures 221 in the laminate web 502. The protrusions 535 are adjacent to the base area 536. The protrusions 535 can be any shape and any pattern. Figure 2 , Figure 3 and Figures 5 and 6As can be seen, the protrusions are "spiky" / pointed to create circular apertures, but it should be understood that any number of shapes and combinations of shapes may be used depending on the end-use application of the laminated web 502. Examples of possible protrusion shapes include, but are not limited to, pointed, domed, and flat; the protrusions 535 may be further configured to create apertures 221 having any of the following shapes: elliptical, cross, square, rectangular, slit, knife edge, diamond, hexagonal, and other polygonal shapes. The shape of the protrusions 535 may vary, so long as the selected shape results in the protrusions 535 being able to utilize the energy of the entangling fluid 542 flowing from the protruding fluid jet to move the fibers of the support layer 514 and the protruding web 516 to form apertures 221 in the laminated web 502. The apertures 221 are formed at the contact points of the laminated web 502 with the protrusions 535. When the projections 535 move the fibers of the laminated web 502 as the laminated web 502 passes over the protrusion forming surface 530, the fibers of the laminated web 502 (fibers from the support layer 514 and the protrusion web 516) gather at the base periphery of the projections 535. The fibers from the support layer 514 are entangled with the fibers from the protrusion web 516 around the circumference / periphery of the orifice 221. Therefore, the placement of the projections 535 on the protrusion forming surface 530 does not cause the solid surface area 536 to disappear. The projections 535 can be formed in the drum surface by casting, threaded attachment, press fit, weld attachment, machining, grinding, punching or stamping. The projections 535 can also be fixed to the protrusion forming surface 530 with screws, bolts, rivets, compression fittings, weld attachments, adhesive attachments or other mechanical mechanisms. The spacing degree of the projections 535 and thus the base area 536 can also be changed according to the specific final application of the fluid-entangled laminated web 502. Furthermore, the pattern of the protrusions 535 in the protrusion forming surface 530 can be varied depending on the particular end application of the fluid entangled laminate web 502. The protrusions 535 can be formed in a sheet of material 532 which then forms the protrusion forming surface 530, or the protrusion forming surface 530 can be molded or cast from a suitable material, or printed using 3D printing techniques.

[0141] The forming surface 532 also includes a pattern of forming dimples or forming recesses 537 that correspond to the shape and pattern of the desired support area 240 between the support layer 514 and the raised web 516. The forming recesses 537 can be of any shape and in any pattern. Figure 2 , Figure 3 and Figures 5 to 7It can be seen that the forming recess 537 is grooved or elongated, but it is understood that many shapes and combinations of shapes can be used depending on the end-use application. Examples of possible forming recess shapes include, but are not limited to, circular, oval, cross, square, rectangular, diamond, hexagonal and other polygonal shapes. Such shapes can be formed in the protruding forming surface 530 by casting, punching, stamping, laser cutting, machining and water jet cutting. The spacing of the forming recess 537 can also be changed according to the specific end application of the fluid-entangled laminated fiber web 502. In addition, the pattern of the forming recess 537 in the texturing cylinder 530 can be changed according to the specific end application of the fluid-entangled laminated fiber web 502.

[0142] Typically, the perforated drum 530 is removably mounted to an optional perforated inner drum shell 538 so that different forming surfaces 532 can be used for different final product designs. The perforated inner drum shell 538 is connected to a fluid removal system 560 that facilitates drawing the entanglement fluid and fibers downward into the forming holes 534 in the outer textured drum surface 532 to form hollow nodes 222 in the raised web 516, and also facilitates drawing the entanglement fluid and fibers downward into the forming recesses 537 in the outer textured drum surface 532 to form support areas 240 by increasing the entanglement of the fibers of the raised web 516 at these discrete locations and increasing the entanglement between the fibers of the raised web 516 and the fibers of the support layer 514. The perforated inner drum shell 538 can also be used as a blocking mechanism to prevent the fibers from moving further downward into the fluid removal system 560 and other parts of the equipment, thereby reducing contamination of the equipment. The perforated inner drum shell 538 rotates in the same direction and at the same speed as the textured drum 530. In addition, to further control the height of the nodes 222, the distance between the inner drum shell 538 and the texturing drum 530 can be varied. Typically, the spacing between the inner surface of the raised forming surface 530 and the outer surface of the inner drum shell 538 can be in a range of between about zero millimeters (0 mm) and about five millimeters (5 mm). Other ranges can be used depending on the specific end-use application and the desired characteristics of the fluid-entangled laminate web 502.

[0143] The depth of the forming holes 534 in the textured roller 530 or other raised forming surface 530 can be between one millimeter (1mm) and ten millimeters (10mm), such as between about three millimeters (3mm) and five millimeters (5mm), to produce nodes 222 with a shape that is most suitable for use in the expected common applications. As measured along the major axis, the cross-sectional size of the hole can be between about two millimeters (2mm) and ten millimeters (10mm), such as between three millimeters (3mm) and six millimeters (6mm), and the spacing of the forming holes 534 from center to center can be between three millimeters (3mm) and ten millimeters (10mm), such as between four millimeters (4mm) and seven millimeters (7mm). The spacing pattern between the forming holes 534 can be changed and selected according to the specific end use. Some examples of patterns include, but are not limited to, patterns of aligned rows and / or columns, skewed patterns, hexagonal patterns, wavy patterns, and patterns depicting pictures, graphics, and objects.

[0144] The cross-sectional dimensions of the forming holes 534 and the depth of the forming holes 534 affect the cross-sectional dimensions and height of the nodes 222 produced in the raised web 516. Generally, hole shapes with sharp or narrow angles at the leading edges of the forming holes 534 when viewed in the machine direction 531 should be avoided because such sharp or narrow angles can sometimes impair the ability to safely remove the fluid-entangled laminated web 502 from the forming surface 532 without damaging the nodes 222. Additionally, the thickness / hole depth in the texturing drum 530 can often correspond to the depth or height of the hollow nodes 222. It should be noted, however, that each hole depth, spacing, size, shape, and other parameters can be varied independently of one another and can be varied based on the specific end use of the fluid-entangled laminated web 502 to be formed.

[0145] The depth of the forming surface recess 537 (e.g., the depth into the forming surface 532) can be less than the depth of the forming hole 534. Figure 4BAs shown, in certain example embodiments, the forming holes 534 may be blind holes extending into the forming surface 532 such that the depth of the forming holes 534 is less than the thickness of the forming surface 532, and the forming recesses 537 may also extend into only a portion of the forming surface 532 such that the depth of the recesses 537 is less than the thickness of the forming surface 532. In other example embodiments, the forming holes 534 may extend through the forming surface 532 such that the depth of the forming holes 534 is equal to the thickness of the forming surface 532; conversely, the forming recesses 537 may extend into only a portion of the forming surface 532 such that the depth of the recesses 537 is less than the thickness of the forming surface 532. The reduced depth of the forming recesses 537 relative to the forming holes 534 may advantageously increase entanglement between the fibers of the raised web 516 to form the support areas 240. For example, a fluid that impacts the bottom surface of the forming recesses 537 and bounces off thereof may displace or entangle the fibers of the raised web 516. Generally, the depth of the forming holes 534 in the texturing drum 530 or other raised forming surface 530 can be between one quarter millimeter (0.25 mm) and five millimeters (5 mm), such as between about half a millimeter (0.5 mm) and two millimeters (2 mm) to produce a support area 240 with the desired entanglement of the fibers within the raised web 516 and consolidation of the fibers of the raised web 516 and the fibers of the support layer 514 to produce a support area 240 best suited for use in the common applications contemplated. The spacing pattern between the forming recesses 537 can be varied and selected depending on the particular end use. Some examples of patterns include, but are not limited to, patterns of aligned rows and / or columns, skewed patterns, hexagonal patterns, wavy patterns, and patterns depicting pictures, graphics, and objects.

[0146] The base region 536 in the forming surface 532 of the texturing drum 530 is generally solid to prevent the passage of the entangling fluid 542 ejected from the pressurized fluid jets contained in the fluid entangling device 540, but in some cases it is desirable to make the base region 536 fluid permeable to further texture the exposed surface of the raised web 516 and to facilitate fluid (e.g., via Figure 4B Alternatively, selected areas of the forming surface 532 of the texturing drum 530 can be fluid permeable while other areas are impermeable. For example, a central area (not shown) of the texturing drum 530 can be fluid permeable while lateral areas (not shown) on either side of the central area can be fluid impermeable.

[0147] The height of the protrusions 535 in the textured roller 530 or other raised forming surface 530 can be between one millimeter (1mm) and ten millimeters (10mm), such as between about three millimeters (3mm) and five millimeters (5mm), to produce a fully formed orifice 221 through the laminated web 502. As measured along the major axis, the cross-sectional size of the protrusion can be between about two millimeters (2mm) and ten millimeters (10mm), such as between three millimeters (3mm) and six millimeters (6mm). The spacing between the protrusions 535 on the forming surface 532 can be selected based on the location and / or pattern of the orifice 221 required in the laminated web 502. The spacing between the protrusions 535 can be selected based on the desired alignment with the forming hole 534. In one example aspect, the protrusions 535 can be spaced between three millimeters (3mm) and one hundred millimeters (100mm) from center to center. In another example aspect, the protrusions 535 can be spaced between five millimeters (5mm) and thirty millimeters (30mm) from center to center. In another example aspect, the pattern of spacing between the protrusions 535 can be non-uniform, such that the density of protrusions 535 in one area / location of the forming surface 532 is higher than the density in an adjacent area / location. The adjacent areas / locations on the forming surface 532 can be around the circumference of the forming surface 532 or across the width of the forming surface 532. In a representative example aspect, the protrusions 535 are arranged in "array channels"; an "array channel" is a pattern of protrusions 535 that can extend across the width of the forming surface 532. A group of array channels can be positioned close to each other to form a larger pattern of protrusions 535; the array channels can be separated from each other by a distance in the circumferential direction of the forming surface 532. The advantage of the non-uniform distribution of the protrusions 535 on the forming surface 532 can be to provide areas without orifices 221 in the laminated fiber web 502 to promote adhesive bonding of the non-porous areas of the laminated fiber web 502 in the absorbent article, thereby minimizing the risk of exposed adhesive.

[0148] exist Figure 4In the exemplary embodiment of the device 500 shown in FIG. 5 , the protruding forming surface 530 is shown in the form of a textured roller. However, it should be understood that other mechanisms can be used to form the protruding forming surface 530. For example, a continuous belt or wire (not shown) with small holes can be used, which includes a forming hole 534 formed at a suitable position in the belt or wire. Alternatively, a flexible rubberized belt (not shown) can be used, which is impermeable to the pressurized fluid entanglement stream, and the forming hole 534 is eliminated. Such belts and wires are well known to those of ordinary skill in the art, as are the mechanisms for driving and controlling the speed of such belts and wires. The textured roller 530 can be more advantageous for the formation of the fluid entangled laminated fiber web 502 according to the exemplary aspects of the present invention, because the textured roller 530 can be made with a base area 536, which is smooth and impermeable to the entanglement fluid 542, and unlike the wire belt, the base area does not leave a wire weaving pattern on the outer surface of the protruding fiber web 516.

[0149] An alternative to a forming surface 532 having a pore depth that defines the protrusion height is a forming surface 532 that is thinner than the desired protrusion height but that is spaced apart from the porous inner drum shell 538 surface that the forming surface 532 surrounds. The spacing between the texturing drum 530 and the porous inner drum shell 538 can be achieved by any mechanism that preferably does not interfere with the process of forming the hollow nodes 222 and withdrawing the entangling fluid 542 from the apparatus 540. For example, one mechanism is a hard wire or filament that can be inserted between the outer texturing drum 530 and the porous inner drum shell 538 as a spacer or the inner porous drum shell 538 is wrapped under the texturing drum 530 to provide the appropriate spacing. A shell depth of the forming surface 532 of less than two millimeters (2 mm) can make it more difficult to remove the raised web 516 and laminate 502 from the texturing drum 530 because the fibrous material of the raised web 516 can expand or be moved by the flow of the entangling fluid 542 to the overhanging area below the texturing drum 530, which can deform the resulting fluid-entangled laminate web 502. However, it has been discovered that by incorporating a support layer 514 with the raised web 516 as part of the forming process, deformation of the resulting two-layer fluid-entangled laminate web 502 can be greatly reduced. The use of a support layer 514 generally promotes more complete removal of the fluid-entangled laminate web 502 because the less stretchable, more dimensionally stable support layer 514 bears the load as the fluid-entangled laminate 502 is removed from the texturing drum 530. The higher tension that can be applied to the support layer 514, as compared to the single raised web 516, means that as the fluid-entangled laminate 502 is removed from the texturing drum 530, the nodes 222 can smoothly exit the forming holes 534 in a direction that is generally perpendicular to the forming surface 532 and coaxial with the forming holes 534 in the texturing drum 530. Additionally, by using the support layer 514, processing speeds can be increased.

[0150] In order to form nodes 222 in the protruding web 516, to laminate the support layer 514 and the protruding web 516 together, to form orifices 221 in the laminated web 502, and to form support areas 240 between the support layer 514 and the protruding web 516, one or more fluid entanglement devices 540 are spaced above the protruding forming surface 530. The most common process in this regard is called a hydroentanglement or hydroentanglement process, which uses pressurized water as a fluid for entanglement. As one or more webs that are unbonded or relatively unbonded are fed to the fluid entanglement device 540, multiple high-pressure fluid jets (not shown) from the one or more fluid entanglement devices 540 move the fibers of the web and the fluid turbulence causes the fibers to entangle. These fluid streams (in this case water) can further entangle the fibers in each web. These streams can also cause the fibers to move and entangle at the interface of two or more webs / layers, thereby joining the webs / layers together. In addition, if the fibers in a web such as raised web 516 are loosely held together, the fibers can be driven out of the XY plane of the fibers and thus form nodes 222 in the Z direction, which are preferably hollow. Depending on the desired degree of entanglement, one or more such fluid entangling devices 540 may be used.

[0151] exist Figure 4 , a single fluid entangling device 540 is shown. When multiple fluid entangling devices are used, the entangling fluid pressure in each subsequent fluid entangling device 540 is typically higher than the previous entangling fluid pressure, resulting in increased energy imparted to the web / layer and, therefore, increased fiber entanglement within or between the webs / layers. This reduces disruption to the overall uniformity of the areal density of the web / layer by the pressurized fluid jets while achieving the desired degree of entanglement and, therefore, bonding of the web / layer and formation of nodes 222 and support areas 240. The entangling fluid 542 of the fluid entangling device 540 is ejected from an ejector via an ejection group or ejection belt (not shown) comprising one or more rows of pressurized fluid jets having small orifices typically having a diameter of between eight hundredths of a millimeter (0.08 mm) and fifteen hundredths of a millimeter (0.15 mm) and a spacing of about half a millimeter (0.5 mm) in the longitudinal direction. The pressure in the jets can be between about five (5) bar and about four hundred (400) bar, but is typically less than two hundred (200) bar, except for heavy fluid entangled laminate webs 502 and when fibrillation is desired. Other jet sizes, spacing, number of jets, and jet pressures may be used, depending on the particular end application. Such fluid entangling devices 540 are well known to those of ordinary skill in the art and are commercially available from manufacturers such as Fleissner of Germany and Andritz-Perfojet of France.

[0152] The fluid entangling device 540 typically has jet orifices located at or spaced from the protrusion forming surface 530 by between about twenty (20) millimeters and about forty (40) millimeters, and more typically between about twenty (20) millimeters and about thirty (30) millimeters, although the actual spacing may vary depending upon the basis weight of the material being acted upon, the fluid pressure, the number of individual jets used, the amount of vacuum applied via the fluid removal system 560, and the speed at which the apparatus is operated.

[0153] exist Figure 4 In the illustrated exemplary embodiment, the fluid entangling device 540 is a conventional hydraulic entanglement device, the construction and operation of which are well known to those of ordinary skill in the art. See, for example, U.S. Pat. No. 3,485,706 to Evans, the contents of which are incorporated herein by reference for all purposes. See also Honeycomb Systems, Inc., Biddeford, Me., for a description of hydraulic entanglement equipment in an article entitled "Rotary Hydraulic Entanglement of Nonwovens," which is reproduced from INSIGHT'86 INTERNATIONAL ADVANCED FORMING / BONDING Conference, the contents of which are incorporated herein by reference for all purposes.

[0154] Back again Figure 4 , the raised web 516 is fed into the apparatus and process 500 at a speed V1, the support layer 514 is fed into the apparatus and process 500 at a speed V2 and the fluid entangled laminated web 502 exits the apparatus and process 500 at a speed V3 (which is the speed of the raised forming surface 530 and may also be referred to as the raised forming surface speed). As will be explained in more detail below, these speeds V1, V2 and V3 may be the same or different from one another to change the forming process and the characteristics of the resulting fluid entangled laminated web 502. Feeding both the raised web 516 and the support layer 514 into the process 500 at the same speeds (V1 and V2) may produce a fluid entangled laminated web 502 having desired hollow nodes 222 according to exemplary aspects of the present invention. Feeding both the raised web 516 and the support layer 514 into the process at the same speed that is faster than the longitudinal speed (V3) of the raised forming surface 530 may also form the desired hollow nodes 222.

[0155] Also in Figure 4 Shown is an optional overfeed roller 550 which can be set at a speed or velocity V f The overfeed roller 550 may be driven at the same speed as the speed V1 of the protruding web 516, in which case V f Can be equal to V1, or when overfeeding is required, V fIt is possible to run at a faster rate to tension the projection web 516 upstream of the overfeed roller 550. Overfeeding occurs when one or both of the incoming webs / layers (516, 514) are fed onto the projection forming surface 530 at a speed that is higher than the projection forming surface speed of the projection forming surface 530. It has been found that feeding the projection web 516 onto the projection forming surface 530 at a speed higher than the introduction speed V2 of the support layer 514 can achieve improved projection formation in the projection web 516. However, in addition, it has been found that improved properties and projection formation can be achieved by changing the feed rate of the webs / layers (516, 514) and by using an overfeed roller 550 just upstream of the texturing drum 530 to supply a greater amount of fibers through the projection web 516 for subsequent movement down into the forming holes 534 in the texturing drum 530 through the entangling fluid 542. In particular, by overfeeding the projection web 516 onto the texturizing drum 530, improved projection formation, including increased projection height, can be achieved.

[0156] To provide excess fiber so that the height of the nodes 222 can be increased or maximized and the fibers at the support areas 240 can be entangled, the raised web 516 can be fed onto the texturing drum 530 at a surface speed (V1) greater than the travel speed (V3) of the texturing drum 530. Figure 4 , when overfeed is desired, the raised web 516 is fed to the texturing drum 530 at a speed V1 and the support layer 514 is fed at a speed V2 and the texturing drum 530 is operated at a speed V3 which is slower than V1 but may be equal to V2. The overfeed percentage or overfeed ratio (the ratio at which the raised web 516 is fed to the texturing drum 530) may be defined as OF = [(V1 / V3)-1] x 100, where V1 is the input speed of the raised web 516 and V3 is the output speed of the resulting fluid-entangled laminated web 502 and the speed of the texturing drum 530. (When an overfeed roller 550 is used to increase the speed at which the incoming material is introduced onto the texturing drum 530, it should be noted that the speed V1 of the material after the overfeed roller 550 may be faster than the speed V1 upstream of the overfeed roller 550. This faster speed V1 should be used when calculating the overfeed ratio. f .) It has been found that good formation of nodes 222 and support areas 240 occurs when the overfeed ratio is between about five percent (5%) and about fifty percent (50%). It is also noted that this overfeed technique and ratio can be used not only with the raised web 516, but also with the combination of the raised web 516 and the support layer 514, because the webs 514, 516 are fed together to the raised forming surface 530.

[0157] In order to minimize the length of the raised web 516 that supports its own weight before it is subjected to the entanglement fluid 542 and to avoid wrinkling and folding of the raised web 516, an overfeed roller 550 may be used to carry the raised web 516 at a speed V1 to a position close to the texturing zone 544 on the texturing drum 530. Figure 4 In the example shown in FIG. 5 , the overfeed roller 550 is driven away from the conveyor belt 510 but the overfeed roller 550 may be driven separately so as not to place excessive stress on the introduced raised web material 516. The support layer 514 may be fed to the texturing zone 544 separately from the raised web 516 at a speed V2, which may be greater than, equal to, or less than the textured drum speed V3 and greater than, equal to, or less than the raised web 516 speed V1. Preferably, the support layer 514 is pulled into the texturing zone 544 by its frictional engagement with the raised web 516 positioned on the textured drum 530 and once on the textured drum 530, the support layer 514 has a surface speed close to the textured drum 530 speed V3 or the support layer 514 may be actively fed into the texturing zone 544 at a speed close to the textured drum speed V3. The texturing process causes some shrinkage of the support layer 514 in the machine direction 531. The overfeed of the support layer 514 or the raised web 516 can be adjusted depending on the specific materials and the equipment and conditions used so that the excess material fed into the texturing zone 544 is exhausted, thereby avoiding any unsightly wrinkling in the resulting fluid-entangled laminated web 502. Therefore, the two webs / layers (516, 514) are always under some tension despite the overfeed process. The take-off speed of the fluid-entangled laminated web 502 must be arranged to be close to the texturing drum speed V3 so that excess tension is not applied to the fluid-entangled laminated web 502 when the laminate 502 is removed from the texturing drum 530, because such excess tension will be detrimental to the definition and size of the nodes 222.

[0158] After the fluid entanglement device 540 is fluidly entangled from the fluid entanglement stream 542, the precursor web 510 becomes a nonwoven web forming the nonwoven material 200 described above, and the nonwoven web includes a support area 240, for example, with a node 222 as described above, a tie 223 and / or an orifice 221 of the interconnected node 222. This nonwoven material 200 can be free of any binder such as an adhesive, etc., and can be kept together only by fiber entanglement. The process and equipment 500 may also include removing the web of the nonwoven material 200 from the forming surface 530 and drying the hydroentangled web to provide a three-dimensional nonwoven material 200. The drying of the nonwoven material 200 can be carried out by techniques known to those of ordinary skill in the art. In the exemplary embodiment in which the precursor web includes a bonding fiber, the drying of the nonwoven material 200 can activate the bonding fiber. The activated binder fibers can help maintain the three-dimensionality of the nonwoven material 200 by helping to maintain the geometry and height of the support regions 240 that extend away from the base plane 215 on the first surface 211 of the nonwoven material 200 (e.g., Figure 2 and Figure 3 shown).

[0159] In the case where the support areas 240 are formed by a method or mechanism other than hydroentanglement, the dry nonwoven material 200 may initially not have such support areas 240. Further processes (not shown) such as a bonding process or an embossing process may impart bonds and / or embossing to the dry nonwoven material 200 to form the support areas 240 in the nonwoven material 200.

[0160] 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 as more particularly described 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 as further described in such appended claims.

[0161] Reference Numbers

[0162] 10 Absorbent products

[0163] 11 Negatives

[0164] 12 Frontal area

[0165] 14. Back waist area

[0166] 16 Crotch area

[0167] 18 longitudinal side edges

[0168] 19 Body-facing surface 20 longitudinal side edges

[0169] 21 Perforation Area

[0170] 22 Front edge

[0171] 23 Orifice

[0172] 24 Back edge

[0173] 25 Perforation Area

[0174] 26 Outer layer

[0175] 27 Orifice

[0176] 28 Body side lining

[0177] 29 Longitudinal axis

[0178] 30 Vertical direction

[0179] 31 Horizontal axis

[0180] 32 Horizontal direction

[0181] 34 Absorption body

[0182] 36 Vertical Edge

[0183] 38 longitudinal edge

[0184] 40 First end edge 42 Second end edge 44 Absorption components

[0185] 45 Body-facing surface 50 Leak-proof flaps

[0186] 52 Leak-proof flap

[0187] 54 Elastic waist member 56 Body-facing surface 60 Leg elastic member 62 Leg elastic member 64 base part

[0188] 64a Proximal end

[0189] 64b Distal end

[0190] 66 protrusion

[0191] 68 flap elastic member

[0192] 70 Active flap elastic area

[0193] 71 Pinning Area

[0194] 72 first longitudinal side edge

[0195] 74 second longitudinal side edge

[0196] 84 Pinning Area

[0197] 86 Elastic member

[0198] 91 Rear fastener

[0199] 92 Front fastener

[0200] 94 Stretch parts

[0201] 96 Nonwoven carrier or hook seat

[0202] 98 Fastening parts

[0203] 200 Nonwoven Materials

[0204] 210 Fiber Net

[0205] 211 First Surface

[0206] 212 first end portion (fiber web)

[0207] 213 Second Surface

[0208] 214 second end portion (fiber web)

[0209] 215 base plane

[0210] 216 first side portion

[0211] 218 second side portion (fiber web)

[0212] 220 first perforated area (fiber web)

[0213] 221 Orifice

[0214] 222 nodes

[0215] 223 Lace-up

[0216] 225 first side portion (first area)

[0217] 226 second side portion (first area)

[0218] 227 first end portion (first zone)

[0219] 228 second end portion (first zone)

[0220] 230 Second perforation area

[0221] 231 Orifice

[0222] 240 Support Area

[0223] 242 Additional support area

[0224] 244 Open end portion

[0225] 246 distal end portion

[0226] 252 caps (nodes)

[0227] 254 walls (nodes)

[0228] LAA Length of absorbent article

[0229] Length of L1 network

[0230] WAA Width of absorbent article

[0231] W1 Width of the mesh

[0232] HB height (support area)

[0233] LB length (support area)

[0234] WB width (support area)

[0235] Example Implementation

[0236] A first exemplary embodiment: A multi-layer nonwoven material, comprising: a laminated nonwoven web, the laminated nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, the laminated nonwoven web comprising a first web and a second web, the laminated nonwoven web comprising a perforated area having a plurality of apertures, the plurality of apertures being distributed across the width of the perforated area along the transverse direction and across the length of the perforated area along the longitudinal direction, wherein the laminated nonwoven web comprises one or more support areas, the fibers of the first web being entangled in discrete areas of the first web and being consolidated to a greater extent with the fibers of the second web at the one or more support areas than at areas of the laminated nonwoven web adjacent to the one or more support areas, the overall area of ​​the one or more support areas on the laminated nonwoven web being not less than 0.5 percent and not more than 30 percent of the total area of ​​the laminated nonwoven web.

[0237] Second exemplary embodiment: A multilayer nonwoven material as described in the first exemplary embodiment, wherein the one or more support regions differ from the regions of the laminated nonwoven web adjacent to the one or more support regions in one or more of basis weight, density, thickness, and inter-fiber bonding.

[0238] A third exemplary embodiment: A multilayer nonwoven material as described in the first exemplary embodiment or the second exemplary embodiment, wherein the overall area of ​​the one or more support regions on the laminated nonwoven web is not less than five percent and not more than twenty percent of the total area of ​​the laminated nonwoven web.

[0239] Fourth exemplary embodiment: A multilayer nonwoven material as described in any of the first exemplary embodiment to the third exemplary embodiment, wherein the basis weight of the laminated nonwoven fiber web at the one or more support areas is greater than the basis weight of the laminated nonwoven fiber web at the area of ​​the laminated nonwoven fiber web adjacent to the one or more support areas.

[0240] Fifth exemplary embodiment: A multilayer nonwoven material as described in any one of the first exemplary embodiment to the fourth exemplary embodiment, wherein the thickness of the laminated nonwoven fiber web at the multiple support areas is greater than the thickness of the laminated nonwoven fiber web at the areas of the laminated nonwoven fiber web adjacent to the one or more support areas.

[0241] Sixth exemplary embodiment: A multilayer nonwoven material as described in any one of the first exemplary embodiment to the fifth exemplary embodiment, wherein the laminated nonwoven fiber web includes a first surface and a second surface, the first surface on the laminated nonwoven fiber web is opposite to the second surface, the plurality of openings extend between the first surface and the second surface of the laminated nonwoven fiber web, the plurality of support areas are filled with the fibers of the first fiber web at the first surface, and are consolidated with the fibers of the second fiber web between the first surface and the second surface of the laminated nonwoven fiber web.

[0242] Seventh exemplary embodiment: A multilayer nonwoven material as described in any one of the first exemplary embodiment to the sixth exemplary embodiment, wherein the laminated nonwoven fiber web includes a first surface and a second surface, the first surface on the laminated nonwoven fiber web is opposite to the second surface, and the laminated nonwoven fiber web includes a plurality of nodes extending away from a base plane on the first surface.

[0243] Eighth exemplary embodiment: The multilayer nonwoven material according to the seventh exemplary embodiment, wherein the plurality of nodes are hollow.

[0244] Ninth exemplary embodiment: A multilayer nonwoven material as described in the seventh exemplary embodiment or the eighth exemplary embodiment, wherein the plurality of nodes extend the height of the plurality of nodes from the first surface, the one or more support regions extend the height of the one or more support regions from the first surface, and the average height of the plurality of nodes is greater than the average height of the one or more support regions.

[0245] Tenth example embodiment: A multilayer nonwoven material as described in any one of the seventh to ninth example embodiments, wherein the fibers of the first fiber web are entangled in discrete areas of the first fiber web and are consolidated to a greater extent with the fibers of the second fiber web at the one or more support areas than at the multiple nodes.

[0246] Eleventh exemplary embodiment: The multilayer nonwoven material as described in any one of the first to tenth exemplary embodiments, wherein at least one support member comprises a plurality of support regions, and the plurality of support regions are discrete from each other on the laminated nonwoven fiber web.

[0247] The twelfth exemplary embodiment: The multilayer nonwoven material as described in the eleventh exemplary embodiment, wherein: the width of the perforated area along the transverse direction is smaller than the width of the nonwoven fiber web along the transverse direction; the multiple support areas extend along the transverse direction; the multiple support areas include a first plurality of support areas and a second plurality of support areas; the first plurality of support areas are positioned along the transverse direction between the first side portion of the perforated area and the first side portion of the nonwoven fiber web, and the first plurality of support areas are distributed along the longitudinal direction; and the second plurality of support areas are positioned along the transverse direction between the second side portion of the perforated area and the second side portion of the nonwoven fiber web, and the second plurality of support areas are distributed along the longitudinal direction.

[0248] Thirteenth exemplary embodiment: A multilayer nonwoven material as described in the twelfth exemplary embodiment, wherein: a first side channel extends along the transverse direction between the first side portion of the perforated area and the first side portion of the nonwoven fiber web; a second side channel extends along the transverse direction between the second side portion of the perforated area and the second side portion of the nonwoven fiber web; a length of each of the first plurality of support areas along the transverse direction is not less than twenty-five percent and not more than one hundred percent of a length of the first side channel along the transverse direction; and a length of each of the second plurality of support areas along the transverse direction is not less than twenty-five percent and not more than one hundred percent of a length of the second side channel along the transverse direction.

[0249] Fourteenth exemplary embodiment: The multilayer nonwoven material of any one of the eleventh to thirteenth exemplary embodiments, wherein the plurality of support regions are arranged in parallel, with adjacent support regions spaced apart by not less than about ten millimeters and not more than about two hundred millimeters.

[0250] Fifteenth exemplary embodiment: A multilayer nonwoven material as described in any one of the eleventh exemplary embodiment to the fourteenth exemplary embodiment, wherein: the nonwoven fiber web includes a first surface and a second surface, the first surface on the nonwoven fiber web is opposite to the second surface; the distal end portion of each of the multiple support areas is spaced apart from the first surface of the nonwoven fiber web by the height of each of the multiple support areas; and the average height of the multiple support areas is not less than half a millimeter and not more than five millimeters.

[0251] Sixteenth exemplary embodiment: The multi-layer nonwoven material as described in any one of the eleventh to fifteenth exemplary embodiments, wherein the one or more support regions are formed on the nonwoven fiber web by a hydraulic entanglement process.

[0252] Seventeenth exemplary embodiment: The multilayer nonwoven material as described in any one of the eleventh exemplary embodiment to the fifteenth exemplary embodiment, wherein the one or more support areas are formed on the nonwoven fiber web by one or both of a bonding process and an embossing process.

[0253] Eighteenth exemplary embodiment: A garment comprising a layer formed of the nonwoven material as described in any one of the eleventh to seventeenth exemplary embodiments.

[0254] Nineteenth exemplary embodiment: A multi-layer nonwoven material, comprising: a laminated nonwoven web, the laminated nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, the laminated nonwoven web comprising a first web and a second web, the laminated nonwoven web comprising a perforated area having a plurality of apertures, the plurality of apertures being distributed across the width of the perforated area along the transverse direction and across the length of the perforated area along the longitudinal direction, wherein the laminated nonwoven web comprises a first surface and a second surface, the first surface on the laminated nonwoven web being opposite to the second surface, the laminated nonwoven web comprising a plurality of nodes extending away from a base plane on the first surface, wherein the laminated nonwoven web comprises one or more support regions, the fibers of the first web being entangled in discrete regions of the first web and being bonded to a greater degree with the fibers of the second web at the one or more support regions than at the regions of the laminated nonwoven web adjacent to the one or more support regions.

[0255] Twentieth exemplary embodiment: A multilayer nonwoven material as described in the nineteenth exemplary embodiment, wherein the one or more support regions differ from the regions of the laminated nonwoven web adjacent to the one or more support regions in one or more of basis weight, density, thickness, and inter-fiber bonding.

[0256] Twenty-first exemplary embodiment: A multilayer nonwoven material as described in any of the nineteenth exemplary embodiment or the twentieth exemplary embodiment, wherein the overall area of ​​the one or more support regions on the laminated nonwoven fiber web is not less than 0.5 percent and not more than thirty percent of the total area of ​​the laminated nonwoven fiber web at the first surface.

[0257] Twenty-second exemplary embodiment: The multilayer nonwoven material as described in the twenty-first exemplary embodiment, wherein the overall area of ​​the one or more support regions on the laminated nonwoven fiber web is not less than five percent and not more than twenty percent of the total area of ​​the laminated nonwoven fiber web.

[0258] Twenty-third exemplary embodiment: The multilayer nonwoven material of any one of the nineteenth to twenty-second exemplary embodiments, wherein the plurality of nodes are hollow.

[0259] Twenty-fourth exemplary embodiment: A multilayer nonwoven material as described in any one of the first exemplary embodiment to the twenty-third exemplary embodiment, wherein the plurality of nodes extend from the first surface to the height of the plurality of nodes, the one or more support regions extend from the first surface to the height of the one or more support regions, and the average height of the plurality of nodes is greater than the average height of the one or more support regions.

[0260] Twenty-fifth exemplary embodiment: A multilayer nonwoven material as described in any one of the nineteenth exemplary embodiment to the twenty-fourth exemplary embodiment, wherein the fibers of the first fiber web are entangled within discrete areas of the first fiber web and are consolidated to a greater extent with the fibers of the second fiber web at the one or more support areas than at the multiple nodes.

[0261] Twenty-sixth exemplary embodiment: The multilayer nonwoven material as described in any one of the nineteenth to twenty-fifth exemplary embodiments, wherein the at least one support member includes a plurality of support regions, and the plurality of support regions are discrete from each other on the laminated nonwoven fiber web.

[0262] Twenty-seventh exemplary embodiment: The multilayer nonwoven material of the twenty-sixth exemplary embodiment, wherein the plurality of support regions are arranged in parallel, with adjacent support regions spaced apart by no less than about ten millimeters and no more than about fifty millimeters.

[0263] Twenty-eighth exemplary embodiment: A multilayer nonwoven material as described in any of the twenty-sixth exemplary embodiment or the twenty-seventh exemplary embodiment, wherein: a distal end portion of each of the plurality of support areas is spaced apart from the first surface of the nonwoven fiber web by the height of each of the plurality of support areas; and an average height of the plurality of support areas is not less than half a millimeter and not more than five millimeters.

[0264] Twenty-ninth exemplary embodiment: The multilayer nonwoven material of any one of the twenty-sixth to twenty-eighth exemplary embodiments, wherein the plurality of apertures provide the perforated region with an open area percentage of not less than about ten percent and not more than about sixty percent.

[0265] Thirty-ninth exemplary embodiment: The multilayer nonwoven material of any one of the twenty-sixth to twenty-ninth exemplary embodiments, wherein the area of ​​each of the plurality of apertures is not less than about eight square millimeters and not more than about eighteen square millimeters.

[0266] Thirty-first exemplary embodiment: A garment comprising a layer formed of the multi-layer nonwoven material of any one of the nineteenth to thirty-first exemplary embodiments.

[0267] Thirty-second exemplary embodiment: A multi-layer nonwoven material, the multi-layer nonwoven material comprising: a laminated nonwoven web, the laminated nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, the laminated nonwoven web comprising a first web and a second web, the laminated nonwoven web comprising a perforated area having a plurality of orifices, the plurality of orifices being distributed across the width of the perforated area in the transverse direction and across the length of the perforated area in the longitudinal direction, wherein the laminated nonwoven web comprises a first surface and a second surface, the first surface on the laminated nonwoven web being opposite to the second surface , the laminated nonwoven web includes a plurality of hollow nodes extending away from a base plane on the first surface, wherein the laminated nonwoven web includes one or more support areas, fibers of the first web are entangled at the one or more support areas and are bonded to a greater extent with fibers of the second web at the one or more support areas than at the areas of the laminated nonwoven web adjacent to the one or more support areas, the plurality of support areas are filled with the fibers of the first web at the first surface and are bonded to the fibers of the second web between the first surface and the second surface of the laminated nonwoven web.

[0268] Thirty-third exemplary embodiment: A multilayer nonwoven material as described in the thirty-second exemplary embodiment, wherein the one or more support regions differ from the regions of the laminated nonwoven fiber web adjacent to the one or more support regions in one or more of basis weight, density, thickness, and fiber-to-fiber bonding.

[0269] The thirty-fourth exemplary embodiment: A multilayer nonwoven material as described in the thirty-second exemplary embodiment or the thirty-third exemplary embodiment, wherein the overall area of ​​the one or more support regions on the laminated nonwoven fiber web is not less than 0.5 percent and not more than thirty percent of the total area of ​​the laminated nonwoven fiber web at the first surface.

[0270] Thirty-fifth exemplary embodiment: The multilayer nonwoven material as described in the thirty-fourth exemplary embodiment, wherein the overall area of ​​the one or more support regions on the laminated nonwoven fiber web is not less than five percent and not more than twenty percent of the total area of ​​the laminated nonwoven fiber web.

[0271] Thirty-sixth exemplary embodiment: The multilayer nonwoven material of any one of the thirty-second to thirty-fifth exemplary embodiments, wherein the plurality of apertures extend between the first surface and the second surface of the laminated nonwoven web.

[0272] Thirty-seventh exemplary embodiment: A multilayer nonwoven material as described in any one of the thirty-second exemplary embodiment to the thirty-sixth exemplary embodiment, wherein the plurality of hollow nodes extend from the first surface to the height of the plurality of hollow nodes, the one or more support regions extend from the first surface to the height of the one or more support regions, and the average height of the plurality of hollow nodes is greater than the average height of the one or more support regions.

[0273] Thirty-eighth exemplary embodiment: A multilayer nonwoven material as described in any one of the thirty-fourth exemplary embodiment to the thirty-seventh exemplary embodiment, wherein the fibers of the first fiber web are entangled to a greater extent at the one or more support areas than at the plurality of hollow nodes.

[0274] Thirty-ninth exemplary embodiment: The multilayer nonwoven material as described in any one of the thirty-fourth exemplary embodiment to the thirty-eighth exemplary embodiment, wherein the at least one support member includes a plurality of support regions, and the plurality of support regions are discrete from each other on the laminated nonwoven fiber web.

[0275] The 40th exemplary embodiment: The multilayer nonwoven material as described in the 39th exemplary embodiment, wherein: the width of the perforated area along the transverse direction is smaller than the width of the nonwoven fiber web along the transverse direction; the multiple support areas are extended along the transverse direction; the multiple support areas include a first plurality of support areas and a second plurality of support areas; the first plurality of support areas are positioned along the transverse direction between the first side portion of the perforated area and the first side portion of the nonwoven fiber web, and the first plurality of support areas are distributed along the longitudinal direction; and the second plurality of support areas are positioned along the transverse direction between the second side portion of the perforated area and the second side portion of the nonwoven fiber web, and the second plurality of support areas are distributed along the longitudinal direction.

[0276] The 41st exemplary embodiment: A multilayer nonwoven material as described in the 39th exemplary embodiment or the 40th exemplary embodiment, wherein: a first side channel extends along the transverse direction between the first side portion of the perforated area and the first side portion of the nonwoven fiber web; a second side channel extends along the transverse direction between the second side portion of the perforated area and the second side portion of the nonwoven fiber web; a length of each of the first plurality of support areas along the transverse direction is not less than twenty-five percent and not more than one hundred percent of a length of the first side channel along the transverse direction; and a length of each of the second plurality of support areas along the transverse direction is not less than twenty-five percent and not more than one hundred percent of a length of the second side channel along the transverse direction.

[0277] Forty-second exemplary embodiment: A multilayer nonwoven material as described in any one of the thirty-ninth exemplary embodiment to the forty-first exemplary embodiment, wherein the width of the perforated area along the transverse direction is smaller than the width of the nonwoven fiber web along the transverse direction, the multiple support areas are elongated along the transverse direction and extend between the first side portion of the nonwoven fiber web and the second side portion of the nonwoven fiber web along the transverse direction, and the multiple support areas are distributed along the longitudinal direction.

[0278] Forty-third exemplary embodiment: A multilayer nonwoven material as described in any one of the thirty-ninth exemplary embodiment to the forty-second exemplary embodiment, wherein: the distal end portion of each of the plurality of support areas is spaced apart from the first surface of the nonwoven fiber web by the height of each of the plurality of support areas; and the average height of the plurality of support areas is not less than half a millimeter and not more than five millimeters.

[0279] Forty-fourth exemplary embodiment: The multilayer nonwoven material as described in any one of the thirty-second to forty-third exemplary embodiments, wherein the one or more support regions are formed on the nonwoven fiber web by a hydraulic entanglement process.

[0280] Forty-fifth exemplary embodiment: The multilayer nonwoven material as described in any one of the thirty-second exemplary embodiment to the forty-third exemplary embodiment, wherein the one or more support areas are formed on the nonwoven fiber web by one or both of a bonding process and an embossing process.

[0281] Forty-sixth exemplary embodiment: A garment comprising a layer formed of the multi-layer nonwoven material as described in any one of the thirty-second to forty-fifth exemplary embodiments.

Claims

1. A multi-layer nonwoven material, comprising: A laminated nonwoven web, the laminated nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, the laminated nonwoven web comprising a first web and a second web, the laminated nonwoven web comprising a perforated area having a plurality of apertures, the plurality of apertures being distributed across a width of the perforated area in the transverse direction and across a length of the perforated area in the longitudinal direction, The laminated nonwoven web comprises one or more support regions, fibers of the first web are entangled in discrete regions of the first web and are bonded to a greater extent with fibers of the second web at the one or more support regions than at regions of the laminated nonwoven web adjacent to the one or more support regions, and the overall area of ​​the one or more support regions on the laminated nonwoven web is not less than 0.5 percent and not more than 30 percent of the total area of ​​the laminated nonwoven web.

2. The multilayer nonwoven material of claim 1, wherein the one or more support regions differ from the regions of the laminated nonwoven web adjacent to the one or more support regions in one or more of basis weight, density, thickness, and inter-fiber bonding.

3. The multilayer nonwoven material of claim 1, wherein the overall area of ​​the one or more support regions on the laminated nonwoven web is not less than five percent and not more than twenty percent of the total area of ​​the laminated nonwoven web.

4. The multilayer nonwoven material of claim 1, wherein the basis weight of the laminated nonwoven web at the one or more support regions is greater than the basis weight of the laminated nonwoven web at the regions of the laminated nonwoven web adjacent to the one or more support regions.

5. The multilayer nonwoven material of claim 1, wherein the thickness of the laminated nonwoven web at the plurality of support regions is greater than the thickness of the laminated nonwoven web at the regions of the laminated nonwoven web adjacent to the one or more support regions.

6. The multilayer nonwoven material of claim 1, wherein the laminated nonwoven web comprises a first surface and a second surface, the first surface on the laminated nonwoven web being opposite to the second surface, the plurality of openings extending between the first surface and the second surface of the laminated nonwoven web, the plurality of support areas being filled with the fibers of the first web at the first surface and being bonded to the fibers of the second web between the first surface and the second surface of the laminated nonwoven web.

7. The multilayer nonwoven material of claim 1, wherein the laminated nonwoven web comprises a first surface and a second surface, the first surface on the laminated nonwoven web being opposite to the second surface, the laminated nonwoven web comprising a plurality of nodes extending away from a base plane on the first surface.

8. The multilayer nonwoven material of claim 7, wherein the plurality of nodes are hollow.

9. The multilayer nonwoven material of claim 7, wherein the plurality of nodes extend a height of the plurality of nodes from the first surface, the one or more support regions extend a height of the one or more support regions from the first surface, and an average height of the plurality of nodes is greater than an average height of the one or more support regions.

10. The multilayer nonwoven material of claim 7, wherein the fibers of the first web are entangled within discrete regions of the first web and are bonded to a greater extent with the fibers of the second web at the one or more support regions than at the plurality of nodes.

11. The multi-layer nonwoven material of claim 1, wherein at least one support element comprises a plurality of support regions, and the plurality of support regions are discrete from one another on the laminated nonwoven web.

12. The multilayer nonwoven material of claim 11, wherein: The width of the perforated area along the transverse direction is less than the width of the nonwoven web along the transverse direction; The plurality of support regions are elongated along the transverse direction; the plurality of support regions comprising a first plurality of support regions and a second plurality of support regions; The first plurality of support regions are positioned along the transverse direction between a first side portion of the perforated area and a first side portion of the nonwoven web, the first plurality of support regions being distributed along the longitudinal direction; and The second plurality of support regions are positioned along the transverse direction between a second side portion of the perforated area and a second side portion of the nonwoven web, the second plurality of support regions being distributed along the longitudinal direction.

13. The multilayer nonwoven material of claim 12, wherein: a first side channel extending along the transverse direction between the first side portion of the perforated area and the first side portion of the nonwoven web; a second side channel extending along the transverse direction between the second side portion of the perforated area and the second side portion of the nonwoven web; A length of each of the first plurality of support areas along the transverse direction is not less than 25 percent and not more than 100 percent of a length of the first side channel along the transverse direction; and The length of each of the second plurality of support areas along the transverse direction is not less than 25 percent and not more than 100 percent of the length of the second side channel along the transverse direction.

14. The multi-layer nonwoven material of claim 11, wherein the plurality of support regions are arranged in parallel, with adjacent support regions spaced apart by no less than about ten millimeters and no more than about two hundred millimeters.

15. The multilayer nonwoven material of claim 11, wherein: The nonwoven web comprises a first surface and a second surface, the first surface on the nonwoven web being opposite to the second surface; a distal end portion of each of the plurality of support regions spaced from the first surface of the nonwoven web by a height of each of the plurality of support regions; and The average height of the plurality of support areas is not less than half a millimeter and not more than five millimeters.

16. The multi-layer nonwoven material of claim 1, wherein the one or more support regions are formed on the nonwoven web by a hydroentanglement process.

17. The multi-layer nonwoven material of claim 1, wherein the one or more support regions are formed on the nonwoven web by one or both of a bonding process and an embossing process.

18. A garment comprising a layer formed from the multi-layer nonwoven material of claim 1.

19. A multi-layer nonwoven material, comprising: A laminated nonwoven web, the laminated nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, the laminated nonwoven web comprising a first web and a second web, the laminated nonwoven web comprising a perforated area having a plurality of apertures, the plurality of apertures being distributed across a width of the perforated area in the transverse direction and across a length of the perforated area in the longitudinal direction, wherein the laminated nonwoven web comprises a first surface and a second surface, the first surface on the laminated nonwoven web being opposite to the second surface, the laminated nonwoven web comprising a plurality of nodes extending away from a base plane on the first surface, wherein the laminated nonwoven web comprises one or more support regions, wherein fibers of the first web are entangled within discrete regions of the first web and are bonded to a greater degree with fibers of the second web at the one or more support regions than at regions of the laminated nonwoven web adjacent to the one or more support regions.

20. The multilayer nonwoven material of claim 19, wherein the one or more support regions differ from the regions of the laminated nonwoven web adjacent to the one or more support regions in one or more of basis weight, density, thickness, and inter-fiber bonding.

21. The multilayer nonwoven material of claim 19, wherein the overall area of ​​the one or more support regions on the laminated nonwoven web is not less than 0.5 percent and not more than 30 percent of the total area of ​​the laminated nonwoven web at the first surface.

22. The multilayer nonwoven material of claim 21, wherein the overall area of ​​the one or more support regions on the laminated nonwoven web is no less than five percent and no more than twenty percent of the total area of ​​the laminated nonwoven web.

23. The multilayer nonwoven material of claim 19, wherein the plurality of nodes are hollow.

24. The multilayer nonwoven material of claim 19, wherein the plurality of nodes extend a height of the plurality of nodes from the first surface, the one or more support regions extend a height of the one or more support regions from the first surface, and an average height of the plurality of nodes is greater than an average height of the one or more support regions.

25. The multilayer nonwoven material of claim 19, wherein the fibers of the first web are entangled within discrete regions of the first web and are bonded to a greater extent with the fibers of the second web at the one or more support regions than at the plurality of nodes.

26. The multi-layer nonwoven material of claim 19, wherein at least one support element comprises a plurality of support regions, and the plurality of support regions are discrete from one another on the laminated nonwoven web.

27. The multilayer nonwoven material of claim 26, wherein the plurality of support regions are arranged in parallel, with adjacent support regions spaced apart by no less than about ten millimeters and no more than about two hundred millimeters.

28. The multilayer nonwoven material of claim 26, wherein: a distal end portion of each of the plurality of support regions spaced from the first surface of the nonwoven web by a height of each of the plurality of support regions; and The average height of the plurality of support areas is not less than half a millimeter and not more than five millimeters.

29. The multilayer nonwoven material of claim 19, wherein the plurality of apertures provide the perforated region with a percent open area of ​​not less than about ten percent and not more than about sixty percent.

30. The multilayer nonwoven material of claim 29, wherein each of the plurality of apertures has an area of ​​not less than about eight square millimeters and not more than about eighteen square millimeters.

31. A garment comprising a layer formed from the multi-layer nonwoven material of claim 26.

32. A multi-layer nonwoven material, comprising: A laminated nonwoven web, the laminated nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, the laminated nonwoven web comprising a first web and a second web, the laminated nonwoven web comprising a perforated area having a plurality of apertures, the plurality of apertures being distributed across a width of the perforated area in the transverse direction and across a length of the perforated area in the longitudinal direction, wherein the laminated nonwoven web comprises a first surface and a second surface, the first surface on the laminated nonwoven web being opposite to the second surface, the laminated nonwoven web comprising a plurality of hollow nodes extending away from a base plane on the first surface, The laminated nonwoven web comprises one or more support regions, fibers of the first web are entangled at the one or more support regions of the first web, and are bonded to a greater extent with fibers of the second web at the one or more support regions than at regions of the laminated nonwoven web adjacent to the one or more support regions, and the multiple support regions are filled with the fibers of the first web at the first surface and are bonded to the fibers of the second web between the first surface and the second surface of the laminated nonwoven web.

33. A multilayer nonwoven material as described in claim 32, wherein the one or more support regions differ from the regions of the laminated nonwoven fiber web adjacent to the one or more support regions in one or more of basis weight, density, thickness and fiber-to-fiber bonding.

34. The multilayer nonwoven material of claim 32, wherein the overall area of ​​the one or more support regions on the laminated nonwoven web is not less than 0.5 percent and not more than 30 percent of the total area of ​​the laminated nonwoven web at the first surface.

35. The multilayer nonwoven material of claim 34, wherein the overall area of ​​the one or more support regions on the laminated nonwoven web is no less than five percent and no more than twenty percent of the total area of ​​the laminated nonwoven web.

36. The multilayer nonwoven material of claim 32, wherein the plurality of apertures extend between the first surface and the second surface of the laminated nonwoven web.

37. A multilayer nonwoven material as described in claim 32, wherein the plurality of hollow nodes extend from the first surface by the height of the plurality of hollow nodes, the one or more support regions extend from the first surface by the height of the one or more support regions, and the average height of the plurality of hollow nodes is greater than the average height of the one or more support regions.

38. The multi-layer nonwoven material of claim 32, wherein the fibers of the first web are entangled with the fibers of the second web to a greater extent at the one or more support areas than at the plurality of hollow nodes.

39. The multi-layer nonwoven material of claim 32, wherein at least one support member comprises a plurality of support regions, and wherein the plurality of support regions are discrete from one another on the laminated nonwoven web.

40. The multilayer nonwoven material of claim 39, wherein: The width of the perforated area along the transverse direction is less than the width of the nonwoven web along the transverse direction; The plurality of support regions are elongated along the transverse direction; the plurality of support regions comprising a first plurality of support regions and a second plurality of support regions; The first plurality of support regions are positioned along the transverse direction between a first side portion of the perforated area and a first side portion of the nonwoven web, the first plurality of support regions being distributed along the longitudinal direction; and The second plurality of support regions are positioned along the transverse direction between a second side portion of the perforated area and a second side portion of the nonwoven web, the second plurality of support regions being distributed along the longitudinal direction.

41. The multilayer nonwoven material of claim 40, wherein: a first side channel extending along the transverse direction between the first side portion of the perforated area and the first side portion of the nonwoven web; a second side channel extending along the transverse direction between the second side portion of the perforated area and the second side portion of the nonwoven web; A length of each of the first plurality of support areas along the transverse direction is not less than 25 percent and not more than 100 percent of a length of the first side channel along the transverse direction; and The length of each of the second plurality of support areas along the transverse direction is not less than 25 percent and not more than 100 percent of the length of the second side channel along the transverse direction.

42. A multilayer nonwoven material as described in claim 39, wherein the width of the perforated area along the transverse direction is smaller than the width of the nonwoven fiber web along the transverse direction, the multiple support areas are extended along the transverse direction and extend between the first side portion of the nonwoven fiber web and the second side portion of the nonwoven fiber web along the transverse direction, and the multiple support areas are distributed along the longitudinal direction.

43. The multilayer nonwoven material of claim 39, wherein: a distal end portion of each of the plurality of support regions spaced from the first surface of the nonwoven web by a height of each of the plurality of support regions; and The average height of the plurality of support areas is not less than half a millimeter and not more than five millimeters.

44. The multi-layer nonwoven material of claim 32, wherein the one or more support regions are formed on the nonwoven web by a hydroentanglement process.

45. The multi-layer nonwoven material of claim 32, wherein the one or more support regions are formed on the nonwoven web by one or both of a bonding process and an embossing process.

46. ​​A garment comprising a layer formed from the multi-layer nonwoven material of claim 32.

Images