Nonwoven material and method of making same

Abstract

A nonwoven material includes a plurality of fibers forming a nonwoven web and a plurality of fibers forming a nonwoven web having a plurality of nodes. The nodes can have a desired distribution of material, such as a ratio of an average thickness of the wall to an average thickness of the cap between 1.1: 1 and 1.5: 1, a ratio of an average height of the nodes to an average thickness of the wall between 3.2: 1 and 2.6: 1, and the material has a compression linearity greater than between 0.9 and 1.1.

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 having features that facilitate the movement of body exudates through the nonwoven material would be useful.

[0002] Nonwoven materials with three-dimensional topography can facilitate the movement of body exudates through the nonwoven materials; however, known methods and mechanisms for forming nonwoven materials with three-dimensional topography have disadvantages, including reduced material thickness, material hardness, and lower elasticity. Therefore, nonwoven materials with improved three-dimensional topography would be useful. Summary of the invention

[0003] In general, the present disclosure relates to a nonwoven material with improved three-dimensional morphology, such as a fluid entangled nonwoven material. The nonwoven material may include a plurality of fibers that form a nonwoven web. The nonwoven web may form a plurality of nodes extending from the surface of the nonwoven web. During fluid entanglement forming, the nodes may advantageously be formed with a desired material distribution. For example, the ratio of the average wall height of the node to the average wall thickness of the node may be selected so that the node is not as slender as a conventional node. As another example, the ratio of the average wall thickness of the node to the average cap thickness of the node may be selected so that the node is more uniform than a conventional node. This material distribution within the node may advantageously increase the compression linearity of the node relative to a conventional node and / or may increase the anisotropy value of the node relative to a conventional node. The nonwoven material with nodes may be incorporated into absorbent articles such as pads, diapers, disposable underwear, etc.

[0004] In an exemplary embodiment, the nonwoven material includes a plurality of fibers forming a nonwoven web having a first surface and a second surface. The first surface is opposite to the second surface on the nonwoven web. The nonwoven web is defined by a plurality of nodes extending away from the base plane on the first surface. Each of the plurality of nodes includes a wall and a cap. The cap is positioned at the distal end portion of each of the plurality of nodes, and the wall is positioned between the first surface and the cap. The ratio of the average thickness of the wall to the average thickness of the cap is between 1.1:1 and 1.5:1.

[0005] In another exemplary embodiment, the nonwoven material includes a plurality of fibers forming a nonwoven web having a first surface and a second surface. The first surface is opposite to the second surface on the nonwoven web. The nonwoven web is defined as a plurality of nodes extending away from the base plane on the first surface. Each of the plurality of nodes includes a wall between the distal end portion of each of the first surface and the plurality of nodes, the wall being spaced apart from the first surface by the height of each of the plurality of nodes. The ratio of the average height of the nodes to the average thickness of the wall is between 3.2:1 and 2.6:1.

[0006] In another exemplary embodiment, the nonwoven material includes a plurality of fibers forming a nonwoven web having a first surface and a second surface. The first surface is opposite to the second surface on the nonwoven web. The nonwoven web is defined by a plurality of nodes extending away from the base plane on the first surface. Each node in the plurality of nodes includes a wall between the distal end portion of each node in the first surface and the plurality of nodes, and the wall is spaced apart from the height of each node in the plurality of nodes from the first surface. The material has a compression linearity greater than about 0.9 as measured by the compression linearity test method.

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

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

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

[0010] Figure 2 is a top plan view of a nonwoven material according to an example embodiment of the present disclosure.

[0011] Figure 3 Yes Figure 1 Image of a detailed view of the nodes of an example nonwoven material.

[0012] Figure 4 It was taken along line 4-4 Figure 2 A partial side cross-sectional view of an example nonwoven material.

[0013] Figure 5 is a schematic side view of an apparatus and process for making a nonwoven material according to an example embodiment of the present disclosure.

[0014] Figure 6 is a schematic side view of an apparatus and process for making a nonwoven material according to another exemplary embodiment of the present disclosure.

[0015] Figure 7 is a schematic side view of an apparatus and process for making a nonwoven material according to yet another exemplary embodiment of the present disclosure.

[0016] Figure 8 is a schematic side view of an apparatus and process for making a nonwoven material according to additional example embodiments of the present disclosure.

[0017] Fig. 9 is a side cross-sectional view of a forming surface according to an example embodiment of the present disclosure.

[0018] Fig.10 yes Fig. 9 A side cross-sectional view of a forming hole of an example forming surface.

[0019] Fig.11 During the fluid entangling operation on the nonwoven web Fig.10 Side cross-sectional view of the formed hole.

[0020] Fig.12 is a side cross-sectional view of a formed hole according to another example embodiment of the present subject matter.

[0021] Fig.13 is a side cross-sectional view of a formed hole according to another example embodiment of the present subject matter.

[0022] Fig.14 is a side cross-sectional view of a formed hole according to another example embodiment of the present subject matter.

[0023] Fig.15 is a side cross-sectional view of a formed hole according to another example embodiment of the present subject matter.

[0024] Fig.16 is a perspective view of an example equipment and facility for performing the "Material Sample Analysis Test Method" as described herein.

[0025] 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

[0026] In embodiments, the present disclosure generally relates to a nonwoven material, such as a fluid-entangled nonwoven material, having improved three-dimensional topography. One of ordinary skill in the art will appreciate that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0027] 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%).

[0028] definition :

[0029] 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.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] The term "gsm" herein means grams per square meter.

[0036] 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.

[0037] 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.

[0038] The term "liquid permeable" is used herein to refer to any material that is not liquid impermeable.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] Absorbent products :

[0047] 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.

[0048] 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 products manufactured in a transverse manufacturing process, such as in a three-piece structure, 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 structure. However, it is conceivable that the absorbent article may be manufactured in the lateral direction without being a three-piece structure garment.

[0049] 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.

[0050] 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.

[0051] 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 .

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] For example, the body side liner 28 can be composed of a meltblown or spunbond web of polyolefin fibers. Alternatively, the body side liner 28 can be a bonded carded web composed of natural fibers and / or synthetic fibers. The body side liner 28 can be composed of a substantially hydrophobic material, and the hydrophobic material can optionally be treated with a surfactant or otherwise treated to impart a desired degree of wettability and hydrophilicity. The surfactant can be applied by any conventional mechanism such as spraying, printing, brushing, etc. The surfactant can be applied to the entire body side liner 28, or the surfactant can be selectively applied to specific sections of the body side liner 28.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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).

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 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 openings (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.

[0098] 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 apertures extending through the body side liner 28. The apertures 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 disposed away from the wearer's skin. However, although described in more detail below in the context of apertures, 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, apertures, etc. Therefore, each of the first feature area 21 and the second feature area 25 may include discrete structural features 23, 27 on the body side liner 28, and the structural features 23 in the first feature area 21 may be spaced apart from the structural features 27 in the second feature area 25 on the body side liner 28. In certain example embodiments, the size and / or formation of the structural features 23 in the first feature region 21 may be different than the structural features 27 in the second feature region 25. Thus, for example, the structural features 23 in the first feature region 21 may provide different performance characteristics than the structural features 27 in the second feature region 25. Furthermore, each of the first feature region 21 and the second feature region 25 may be individually arranged, sized, shaped, and / or configured to provide respective performance characteristics therein.

[0099] Portions of the body-side liner 28 that include apertures 27 may be particularly suitable for transferring and collecting low-viscosity feces away from the wearer's skin. This effect can help maintain the comfort and skin health of the wearer by preventing prolonged contact between feces and the skin of the wearer of the article 10. Portions of the body-side liner 28 that include apertures 27 or other relatively large apertures may be less than ideal for managing urine exudates. For example, where the apertures 27 are large enough or numerous enough to provide a relatively large open area of ​​the liner 28, such apertures 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.

[0100] 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.

[0101] The portion of the body-side liner 28 that forms the first feature area 21 may be particularly suitable for handling fluids, such as urine, for example, by transferring and collecting liquid away from the skin of the wearer of the article 10. This effect can help maintain the comfort and skin health of the wearer by preventing prolonged contact between urine and the skin of the wearer of the article 10. As described above, the first feature area 21 can achieve this function by using a single structural feature or any combination of structural features. In at least some example embodiments, the structural feature 23 of the first feature area 21 includes an opening. In the case where the feature 23 includes an opening, such an opening can be a relatively small opening for managing urine exudate.

[0102] 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 less than the longitudinal length LAA of the article 10. More specifically, the longitudinal extent of the first feature area 21 may be less than half, one-third, or one-quarter of the longitudinal extent LAA of the article 10. In addition, the lateral extent of the first feature area 21 may be less 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.

[0103] A 3D mesh with nodes:

[0104] Figure 2 is a top plan view of a nonwoven material 200 according to an exemplary embodiment of the present disclosure. Figure 2 , the nonwoven material 200 is shown in a flat or planar configuration. Figure 3 It is the image of the first characteristic area 220 of nonwoven material 200.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 in 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 the inner lining for the wearer of such products, and wipes.As discussed in more detail below, nonwoven material 200 can advantageously include the three-dimensional topography with desired physical properties.

[0105] like Figure 2As shown in , the nonwoven material 200 includes a nonwoven web 210, for example, formed by a plurality of fibers. The 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 web 210 may extend, for example, between a rear end or first end portion 212 and a front 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 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 web 210 may be positioned at or near the front waist region 12 of the absorbent article 10. The 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.

[0106] 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.

[0107] The nonwoven web 210 may include at least one feature region. Figure 3 As shown in , 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). As Figure 2As shown in , the nonwoven web 210 may be non-perforated between the first feature area 220 and the second feature area 230, for example, along the longitudinal direction LO. Thus, for example, the nonwoven web 210 may not be processed to include openings 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 arranged colinearly with the centroid of the second feature area 230, for example, on the longitudinal axis 29.

[0108] The first feature area 220 may include a plurality of openings 221 and a plurality of nodes 222, and the second feature area 230 may also include a plurality of openings 231. The openings 221 of the first feature area 220 may be larger than the openings 231 of the second feature area 230. For example, the area of ​​each of the openings 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 20 square millimeters (20mm 2 ), such as not less than about nine square millimeters (9mm 2 ) and not larger than about twelve square millimeters (12mm 2 In contrast, the area of ​​each of the openings 231 of the second feature region 230 may be no less than about a 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 openings 221 of the first feature area 220 and the openings 231 of the second feature area 230 can advantageously facilitate the movement of body exudates through the nonwoven fiber web 210. In addition, the size of the larger openings 221 of the first feature area 220 can be designed to transfer and collect low-viscosity feces. Conversely, the size of the smaller openings 231 of the second feature area 230 can be designed to transfer and collect urine exudates. In certain example embodiments, the openings 221 can be evenly distributed throughout the first feature area 220, and the openings 231 can be evenly distributed throughout the second feature area 230. The area of ​​the openings 221, 231 in the first feature area 220 and the second feature area 230 can be measured using analytical techniques in the material sample analysis test method described in the test method section of this article.

[0109] As described above, the nonwoven material 200 may include nodes 222 located at the first feature area 220. It will be appreciated that in alternative exemplary embodiments, the nonwoven material 200 may include nodes located at other locations on the nonwoven material 200. In addition, it will be appreciated that in certain exemplary embodiments, the first feature area 220 may include nodes 222 that do not have openings 221. Figure 3 As shown in , the nonwoven web 210 may also include a plurality of connecting ties 223 located at the first feature area 220. Figure 4 , the nodes 222 can extend away from the base plane 241 on the first surface 240 of the nonwoven material 200. The base plane 241 can be defined as a substantially flat area of ​​the first surface 240 of the nonwoven material 200, rather than a portion of the nonwoven material 200 that forms the nodes 222. In other words, for Figures 2 to 4 In the exemplary embodiment shown, the base plane 241 can be formed by the first surface 240 of the nonwoven material 200 that provides the connecting ties 223. The nonwoven material 200 can also include a second surface 242. Figure 4 As depicted in , the first surface 240 can be opposite to the second surface 242 on the nonwoven fiber web 210.

[0110] Node 222 can be configured to a variety of shapes and sizes, as will be discussed in further detail below in the discussion of the manufacture of nonwoven material 200. In some example embodiments, node 222 can be a generally cylindrical shape. In certain example embodiments, node 222 can be configured to not include any opening or perforation. In certain example embodiments, node 222 can have a height H between about half a millimeter (0.5mm) and about ten millimeters (10mm) (as measured, for example, from base plane 241 to the distal end portion 250 of node 222 in a direction perpendicular to base plane 241), such as about one millimeter (1mm) to about three millimeters (3mm), such as about one and one tenth millimeter (1.1mm) to about one and five tenth millimeters (1.5mm), such as about one and three tenth millimeters (1.3mm) of height H. In addition, the average height H of node 222 can be not less than one thousand two hundred microns (1200μm) and not more than one thousand four hundred microns (1400μm). It will be appreciated that the height H of the nodes 222 can be measured after the nonwoven material 200 has been wound into a manufacturing spool, or after being unwound directly from such a spool, or as part of a commercial absorbent article product. The height H of the nodes 222 can be measured using the analytical techniques described in the "Node Analysis Test Method" described in the "Test Methods" section of this document. In certain example embodiments, most of the nodes 222 can each have a height of about five square millimeters (5 mm 2 ) to about 35 square millimeters (35mm2 ) (measured by the area of ​​the node 222 at the base plane 241), such as about ten square millimeters (10mm 2 ) to about 20 square millimeters (20mm 2 The nodes 222 may be configured to be located in the first feature region 220 such that the nodes 222 provide approximately one node per square centimeter (1.0 node / cm 2 ) to about three nodes per square centimeter (3.0 nodes / cm 2 The node area and node density within the first feature region 220 can be measured using the analysis techniques described in the “Material Sample Analysis Test Method” described in the “Test Method” section of this document.

[0111] like Figure 2 As shown in Figure 3 As depicted in more detail in , the connecting ties 223 may interconnect the nodes 222. In addition, each connecting tether 223 may be said to extend between only 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 'land areas' and interconnected 'land 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 constructed 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 3 In the example embodiment of , most nodes 222 include six connecting ties 223 connected to adjacent nodes 222.

[0112] The openings 221 may be areas of the nonwoven web 210 that have a lower fiber density of the nonwoven web 210 than the nodes 222 and connecting ties 223. In some exemplary embodiments, the openings 221 may be substantially free of fibers. As used herein, the openings 221 are to be distinguished from the normal interstitial fiber spacing that is typically present in a fibrous nonwoven material. For example, Figure 2The image in shows that the open holes 221 have a lower fiber density than the adjacent nodes 222 and the connecting ties 223. The open holes 221 can be formed between the connecting ties 223 and the nodes 222. Each open hole 221 can be arranged between adjacent nodes 222. In certain example embodiments, each hole 221 can be defined between at least three (3) connecting ties 223 and at least three (3) nodes 222. In some example embodiments, each discrete open hole 221 can be defined between at least four (4) connecting ties 223 and at least four (4) nodes 222. It will be understood that at certain portions of the nonwoven web 210, such as at the edge of the first feature area 220, the open holes 221 can be defined between less than three (3) connecting ties 223 and / or less than three (3) nodes 222.

[0113] refer to Figure 4 , each of the nodes 222 may include a cap 252 and a wall 254. The cap 252 may be positioned at the distal end portion 250 of each node 222. The wall 254 may extend, for example, along the transverse direction TT between the first surface 240 and the cap 252. In certain example embodiments, the wall 254 may extend between the first surface 240 and the distal end portion 250 of each node 222 at a height H of the node 222. The wall 254 and the cap 252 may be formed using the process and equipment described below. Using such a process and equipment, the nonwoven material 200 having nodes 222 may have advantageous properties relative to known nonwoven materials. As Figure 4 As shown in , the cap 252 can have a thickness TC. In addition, the thickness TC of the cap 252 can be defined by the fibers of the nonwoven fiber web 210 forming the cap 252, for example, along the transverse direction TT. In certain example embodiments, the cap 252 can be generally circular. In alternative example embodiments, the cap 252 can be generally spherical, hemispherical, triangular, rectangular, etc. The wall 254 can also have a thickness TW. In addition, the thickness TW of the wall 254 can be defined by the fibers of the nonwoven fiber web 210 forming the wall 254, for example, perpendicular to the transverse direction TT. In certain example embodiments, the wall 254 can be generally cylindrical. In alternative example embodiments, the wall 254 can be generally triangular prism-shaped, rectangular prism-shaped, etc.

[0114] The thickness TC of the cap 252, the thickness TW of the wall 254, and / or the height H of the node 222 can provide advantageous properties for the nonwoven material 200. For example, the ratio between the average thickness TW of the wall 254 of the node 222 and the average thickness TC of the cap 232 of the node 222 can be between 1.1:1 and 1.5:1, such as about 1.2:1. The ratio between the average thickness TW of the wall 254 of the node 222 and the average thickness TC of the cap 232 of the node 222 can correspond to a uniform ratio for the node 222. Thus, for example, the closer the ratio between the average thickness TW of the wall 254 of the node 222 and the average thickness TC of the cap 232 of the node 222 is to 1:1, the more uniform the thickness of the fibers of the nonwoven web 210 forming the node 222 may be throughout the node 222. In exemplary aspects of the present disclosure, the average thickness TW of the wall 254 of the node 222 can be greater than the average thickness TC of the cap 232 of the node 222. The increased average thickness TW of the wall 254 relative to the reduced average thickness TC of the cap 232 can advantageously increase the strength of the wall 254 of the node 222 to resist compression, for example, as demonstrated by the improved compression linearity described below. Without wishing to be bound by any particular theory, it is believed that the reflected energy of the fluid that impacts the bottom of the blind hole in the forming surface used to form the node 222 can push the fibers of the nonwoven material 200 back toward the wall 254, rather than into the cap 232 as in the open holes in the known forming surface. Therefore, more fibers can be present in the wall 254 of the node 222 (relative to the node with a thicker cap), thereby increasing the strength of the wall 254. However, it will be understood that it may be disadvantageous to move too many fibers away from the cap 232 of the node 222. Utilizing blind holes to form the nodes 222 may advantageously provide a ratio between an average thickness TW of the walls 254 of the nodes 222 and an average thickness TC of the caps 232 of the nodes 222 of between 1.1:1 and 1.5:1, such as about 1.2:1, thereby providing a strong, compression-resistant node 222. Thus, a less uniform node 222 may have a relatively non-uniform thickness throughout the node 222. Such non-uniformity may advantageously improve handling capabilities and / or compression resistance.

[0115] In another example aspect, it is believed that other comparative dimensions of the nodes 222 contribute to their resistance to compression. For example, the ratio of the average height H of the nodes 222 to the average thickness TW of the walls 254 of the nodes 222 may preferably be between 3.2:1 and 2.6:1, such as between 3.1:1 and 2.7:1, such as between 3:1 and 2.8:1, such as about 2.9. The ratio between the average height H of the nodes 222 and the average thickness TW of the walls 254 of the nodes 222 may correspond to a slenderness ratio for the nodes 222. Thus, for example, a smaller ratio between the average height H of the nodes 222 and the average thickness TW of the walls 254 of the nodes 222 may correspond to a stronger node 222, such as resulting in a thinner cap 232 and a thicker wall 254 due to a smaller volume loss at the cap 252. Such robustness may advantageously improve handling capabilities and / or resistance to compression.

[0116] The above ratios of wall-cap thickness in combination with the above slenderness ratios may represent preferred example embodiments of material 200. However, it is further understood that such features alone are believed to contribute to improved handling capabilities and / or compression resistance. Thus, exemplary examples of material 200 include those example embodiments having the above wall-cap thickness ratios while having slenderness ratios outside the above preferred example ranges. Similarly, exemplary examples of material 200 include those example embodiments having the above preferred slenderness ratios while having wall-cap thickness ratios outside the above preferred ranges.

[0117] In certain example embodiments, the average thickness TW of the wall 254 of the node 222 may be no less than three hundred micrometers (300 μm) and no more than six hundred micrometers (600 μm), such as no less than four hundred and twenty-five micrometers (425 μm) and no more than four hundred and seventy-five micrometers (475 μm), such as approximately four hundred and fifty micrometers (450 μm). In certain example embodiments, the average thickness TC of the cap 232 of the node 222 may be no less than two hundred and forty micrometers (240 μm) and no more than five hundred micrometers (500 μm), such as no less than three hundred and forty micrometers (340 μm) and no more than four hundred micrometers (400 μm), such as approximately three hundred and seventy micrometers (370 μm). It will be understood that the example dimensions for the thickness TC of the cap 252 and the thickness TW of the wall 254 are provided by way of example and are different from the dimensions listed above in alternative example embodiments. The thickness TC of the cap 252 and the thickness TW of the wall 254 may be determined using image analysis measurement methods, such as those described in the Nodal Analysis Test Method.

[0118] Example processes and apparatus for forming the nonwoven material will now be described. Figure 5 An example process and apparatus 500 for making the nonwoven material 200 of the present disclosure is shown. Figure 5 In the present invention, a precursor web 510 including a plurality of fibers is provided. The precursor web 510 can be formed by a variety of web forming techniques, such as but not limited to wet web forming, foam web forming, or carding processes. Figure 5 In the exemplary embodiment shown, the precursor web 510 can be formed by a wet-laid process in which a fiber and water slurry 512 is deposited from a drum 514 onto a precursor forming surface 516. Figure 5 The precursor forming surface 516 shown in the figure can be a precursor material, such as a spunbond web - or another preformed nonwoven web formed by other web forming techniques such as meltblowing, thermal bonding, wet-laid, air-laid, or hydroentangled. However, it is contemplated that the fiber and water slurry 512 can be deposited directly on a belt, screen, or other surface 518 that provides the precursor forming surface 516.

[0119] In the case where the precursor forming surface 516 is a precursor material, example suitable materials include spunbond materials, bonded carded materials (e.g., such as through air bonded carded webs (TABCW)), spunlace materials, and any laminates of such materials, including spunbond-meltblown-spunbond (SMS) webs and similar classes of materials. Preferred basis weights for such precursor materials include materials with a basis weight between about 10 gsm and about 80 gsm, such as between about 10 gsm and about 50 gsm, such as between about 10 gsm and about 30 gsm. However, other basis weights may also be expected depending on the end use of the final material. The fibers of the precursor web material may be any suitable fiber type, including being formed from polyolefin materials, as is typical in the art for such nonwoven webs. In addition, the fibers may have a denier number between about 0.5 and 5.0, such as between about 0.7 and 4.0, such as between about 0.9 and 3.0, such as between about 1.0 and about 2.0. The fibers may have a typical staple length of less than one hundred millimeters (100 mm). In some exemplary embodiments, the fibers of the precursor web may be similar to the fibers described with respect to the support web 14 in U.S. Pat. No. 9,327,473 to Scott Kirby et al., entitled "Fluid-entangled laminate webs having hollow projections and a process and apparatus for making the same," which is hereby incorporated by reference in its entirety.

[0120] As mentioned, the precursor web 510 can be formed according to a variety of techniques (e.g., wet-laid, foam-laid, or carded processes). The precursor web 510 can preferably have a basis weight between about 10 gsm and about 80 gsm, such as between about 20 gsm and about 70 gsm, such as between about 30 gsm and about 60 gsm. The precursor web 510 can be formed by typical polyolefin fibers or any suitable polyester fibers. Such fibers can preferably have a denier number between about 0.5 and 5.0, such as between about 0.7 and 4.0, such as between about 0.9 and 3.0, such as between about 1.0 and about 2.0. The fibers can have a typical staple length of less than one hundred millimeters (100 mm). In some exemplary embodiments, the fibers of the precursor web 510 can be similar to the fibers described by Scott Kirby et al. in U.S. Patent No. 9,327,473 regarding the protruding web 16.

[0121] The precursor web may be transferred by surface 518 driven by drive rollers 520 or other transfer devices known to those of ordinary skill in the art. If precursor web 510 is formed by a wet-laid process, precursor web 510 may be dried using dryer 522 by known techniques.

[0122] Whether done off-line or in-line, the precursor web 510 can be transferred to a forming surface 530. The forming surface 530 can be the surface of a textured drum 532, such as a forming screen. Fig. 9 and Fig.10 The shaping surface 530 is shown in more detail in FIG. The texturing roller 532 may be as follows: Figure 7 The textured roller 532 is shown rotating and can be driven by any suitable drive mechanism (not shown) known to those skilled in the art (such as a motor and gears). The material forming the textured roller 532 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.

[0123] like Fig. 9 As shown in , the forming surface 530 may include a plurality of forming holes 534. The geometry, spacing, and orientation of the forming holes 534 may correspond to the formation of the nodes 222 in the nonwoven material 200. In addition, the forming holes 534 may correspond to the shape and pattern of the desired nodes 222 of the nonwoven material 200. Thus, for example, the forming holes 534 may be arranged in a plurality of columns and / or a plurality of rows on the forming surface 530. Although Fig. 9The shaped holes 534 are shown as being circular, but it should be understood that any number of shapes and combinations of shapes may be used depending on the end-use application. Examples of additional or alternative possible shaped holes 534 include, but are not limited to, ovals, crosses, squares, rectangles, diamonds, hexagons, and other polygons. Again, for illustration purposes only, Fig. 9 The forming hole 534 is depicted as extending through the forming surface 530. Figures 10 to 15 It will be further appreciated that the forming hole 534 may comprise a blind hole that does not extend completely through the surface of the forming surface 530 .

[0124] Back to Figure 7 , the perforated forming surface 530 can be removably mounted on and over the optional porous inner drum shell 536 so that different forming surfaces 530 can be used for different final product designs. It will be understood that in other example embodiments, a flat or other shaped forming surface 530 can be utilized. Figure 7 and Fig. 9 In the exemplary embodiment of the present invention, the porous inner drum shell 536 is engaged with the fluid removal system 538, which helps to pull the entangled fluid and fiber downward into the forming holes 534 in the forming surface 530, thereby forming nodes 222 in the nonwoven material 200. The porous inner drum shell 536 can also be used as a blocking mechanism to prevent the fiber from moving further downward into the other parts of the fluid removal system 60 and the equipment to reduce the pollution of the equipment. The porous inner drum shell 536 can be in the same direction as the textured drum 532 and rotate at the same speed. In addition, in order to further control the height of the nodes 222 on the nonwoven material 200, the distance between the outer surface of the inner drum shell 536 and the forming surface 530 can be changed. In general, the spacing between the inner surface of the forming surface 530 and the outer surface of the inner drum shell 536 can be in the range of about zero millimeter (0mm) and about five millimeters (5mm). Other ranges can be used according to the characteristics of specific end-use applications and desired nonwoven materials 200.

[0125] refer to Fig. 9 and Fig.10The depth of the forming holes 534 in the textured roller 532 or other raised forming surface 530 can be between one millimeter (1 mm) and ten millimeters (10), such as between about two millimeters (2 mm) and six millimeters (6 mm), such as about four millimeters (4 mm), to produce nodes 222 with shapes that are most useful in the intended common applications. The cross-sectional diameter (or major dimension) of the forming holes 534, as measured along the major axis, can be between about two millimeters (2 mm) and ten millimeters (10 mm), such as between three millimeters (3 mm) and six millimeters (6 mm), such as about five millimeters (5 mm), and the spacing of the forming holes 534 on a center-to-center basis can be between three millimeters (3 mm) and ten millimeters (10 mm), such as between four millimeters (4 mm) and seven millimeters (7 mm). The spacing pattern between the forming holes 534 can be varied and selected depending on 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, figures, and objects.

[0126] The cross-sectional dimensions of the forming holes 534 and the depth of the forming holes 534 may affect the cross-section and height of the nodes 222 produced in the nonwoven material 200. Generally speaking, forming hole 534 shapes having sharp or narrow angles at the leading edge of the forming holes 534 as viewed in the machine direction should be avoided because sharp or narrow angles may sometimes impair the ability to cleanly remove the nonwoven material 200 from the forming surface 530 without damaging the nodes 222. In addition, the thickness / hole depth in the forming surface 530 generally tends to correspond to the depth or height of the nodes 222 in the nonwoven material 200. However, it should be noted 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 nonwoven material 200 to be formed.

[0127] Without being bound by theory, it is believed that a specific aspect ratio of the depth of the forming hole 534 to the diameter (or major dimension) of the forming hole 534 helps to increase the anisotropy of the nodes 222 in the nonwoven material 200. If the shape of the forming hole 534 is not circular, the term "major dimension" is used in the context, for example, if the forming hole 534 is formed as an ellipse, the major dimension will be the length of the ellipse along the major axis of the ellipse. It is believed that an aspect ratio of the depth of the forming hole 534 to the diameter (or major dimension) of the forming hole 534 greater than one (1.0) will increase the anisotropy of the nodes 222 of the nonwoven material 200. In some exemplary embodiments, the aspect ratio of the depth of the forming hole 534 to the diameter (or major dimension) of the forming hole 534 can be between one (1.0) and one and two tenths (1.2). As described above, the increase in anisotropy in the nodes 222 in the nonwoven material 200 can provide the nonwoven material 200 with improved compression properties.

[0128] exist Fig. 9 and Fig.10 In the exemplary embodiment of the present invention, the forming surface 530 is shown in the form of a forming screen placed on a textured roller 532. However, it should be understood that other mechanisms can be used to produce the forming surface 530. For example, a 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, but is at the position of the forming hole 534. 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 532 may be more advantageous for the formation of the nonwoven material 200 according to the present disclosure, because the textured roller 532 can be manufactured to have a smooth outer surface that is impermeable to the entanglement fluid at certain positions, and will not tend to leave a metal wire weave pattern on the nonwoven material 200 like a metal ribbon. In the exemplary embodiment in which the forming surface 530 forms a part of the textured roller 532 as a forming screen, the forming surface 530 can be achieved by using a variety of techniques. For example, the shaped surface 530 and the shaped holes 534 may be formed by casting, molding, punching, stamping, machining, laser cutting, water jet cutting, and 3D printing, or any other suitable method.

[0129] Now go to Fig.10 and Fig.11 , the forming surface 530 and the forming hole 534 may include features for forming the node 222 having the advantageous properties described herein. In addition, the forming surface 530 may include a wall 600 having a first surface 612 and a second surface 614. The first surface 612 may be positioned opposite the second surface 614 on the wall 600. For example, the first surface 612 may face away from the roller 532 ( Fig. 9 ), and the second surface 614 may face the drum 532. The wall 600 may define a shaped hole 534. In addition, as shown, the shaped hole 534 may include a blind hole 620 and at least one outlet channel 630. Thus, the shaped hole 534 may be a socket such that the shaped hole 534 is open at one end of the shaped hole 534 and at least partially closed at an opposite end of the shaped hole 534 (e.g., relative to the open end of the shaped hole 534).

[0130] Fig.10 and Fig.11 Only one forming hole 534 is shown in FIG; however, it will be understood that other forming holes 534 on the forming surface 530 may be formed in the same manner as Fig.10 and Fig.11600. As shown, the blind hole 620 can extend from a first end portion 622 to a second end portion 624. The first end portion 622 of the blind hole 620 can be positioned at the first surface 612 of the wall 600. Thus, the shaped hole 534 can be open at the first end portion 622 of the blind hole 620. The blind hole 620 can also extend into the wall 600 toward the second surface 614 of the wall 600, such as such that the second end portion 624 of the blind hole 620 is recessed into the wall 600. Furthermore, for example, the blind hole 620 can only partially extend into the wall 600, such that the second end portion 624 of the blind hole 620 is at least partially closed relative to the open first end portion 622 of the blind hole 620 at the first surface 612 of the wall 600.

[0131] The outlet channel 630 may also extend from the first end portion 632 to the second end portion 634. The first end portion 632 of the outlet channel 630 may be positioned at the second end portion 624 of the blind hole 620. Thus, for example, the first end portion 632 of the outlet channel 630 may be adjacent to the blind hole 620, such that fluid within the blind hole 620 may flow out of the blind hole 620 through the outlet channel 630. The second end portion 634 of the outlet channel 630 may be positioned at the second surface 614 of the wall 600. Thus, for example, fluid from the blind hole 620 may exit the outlet channel 630 at the second end portion 634 of the outlet channel 630, such that the fluid passes through the wall 600 from the first surface 612 to the second surface 614 via the blind hole 620 and the outlet channel 630. In certain example embodiments. The wall 600 may include two (2), three (3), four (4), five (5), six (6) or more outlet channels 630. In certain example embodiments, the outlet channels 630 may be distributed in a circular pattern. The outlet channels 630 may also be referred to herein as "dehydration holes."

[0132] like Fig.11As shown in FIG. 5 , during the formation of the node 222, the nonwoven web 210 can be positioned on the wall 600 at the first surface 612 of the wall 600. The pressurized fluid stream 542 can impact the nonwoven web 210 so as to guide the nonwoven web 210 into the blind hole 620. The shape and size setting of the blind hole 620 can assist in forming the node 222 with favorable characteristics. For example, the pressurized fluid stream 542 can impact the material of the nonwoven web 210 and the wall 600 at the second end portion 624 of the blind hole 620. In addition, the wall 600 can define a forming surface 640 at the second end portion 624 of the blind hole 620. Due to the pressurized fluid stream 542, the nonwoven web 210 can impact the forming surface 640 at the second end portion 624 of the blind hole 620, and the forming surface 640 can support the nonwoven web 210, for example, to prevent the volume loss at the distal end portion 250 of the node 222. In contrast, in known forming surfaces, the forming holes may be cylindrical along the length of the forming holes, such that the distal end portion of the node does not contact any surface and is not supported during forming. The lack of support may result in less formation and concentration of fibers at the distal end portion of the node - some of which may even escape from the forming holes 534. In addition, the pressurized fluid stream may pass directly through the cylindrical forming holes, thereby dissipating the hydroentanglement energy supplied by the pressurized fluid stream, thereby causing poor formation of the node. The forming holes 534 according to example aspects of the present disclosure may advantageously address such disadvantages and form nodes 222 with advantageous characteristics.

[0133] Fluid from the pressurized fluid stream 542 may exit the shaped orifice 534 via the outlet passage 630. The outlet passage 630 may be arranged to facilitate the formation of the node 222. For example,

[0134] The first end portion 622 and the second end portion 624 of the blind hole 620 can be spaced apart along the central axis X of the blind hole 620. In example embodiments, the central axis X of the blind hole 620 can extend perpendicular to the rotational axis of the texturing drum 532, such as so that the central axis X of the blind hole 620 extends radially on the texturing drum 532. The first end portion 632 of each outlet channel 630 can be offset from the central axis X of the blind hole 620. Thus, for example, the central axis X can intersect the wall 600 at the second end portion 624 of the blind hole 620 instead of at the first end portion 632 of the outlet channel 630. This arrangement of the outlet channels 630 can assist in supporting the nonwoven fibrous web 210 during the formation of the node 222, such as to prevent volume loss at the distal end portion 250 of the node 222. In certain example embodiments, each second end portion 634 of the outlet channels 630 can also be offset from the central axis X of the blind hole 620. In some of these example embodiments, the outlet channels 630 can extend generally parallel to the central axis of the socket 620. However, other arrangements of outlet passages 630 are within the scope of the present subject matter.

[0135] The outlet channels 630 and the blind holes 620 may be sized differently to assist in supporting the nonwoven web 210 during the formation of the nodes 222. For example, the cross-sectional area of ​​the blind holes 620 at the first end portions 622 of the blind holes 620 (e.g., in a plane perpendicular to the central axis X) may be greater than the total cross-sectional area of ​​the outlet channels 630 at the first end portions 632 of the outlet channels 630 (e.g., in a plane perpendicular to the central axis X). The total cross-sectional area of ​​the outlet channels 630 at the first end portions 632 of the outlet channels 630 may correspond to the sum of each cross-sectional area of ​​the outlet channels 630 at the first end portions 632 of the outlet channels 630 (e.g., in a plane perpendicular to the central axis X). Furthermore, in certain example embodiments, the ratio of the cross-sectional area of ​​the blind hole 620 at the first end portion 622 of the blind hole 620 to the total cross-sectional area of ​​the outlet channel 630 at the first end portion 632 of the outlet channel 630 may be between 2.75:1 and 11:1, such as between 4:1 and 9:1, such as between 5:1 and 6:1, such as about 5.5:1. In certain example embodiments, the cross-sectional area of ​​the blind hole 620 at the first end portion 622 of the blind hole 620 may be not less than two percent (2%) and not more than fifteen percent (15%) of the total cross-sectional area of ​​the outlet channel 630 at the first end portion 632 of the outlet channel 630, such as not less than three percent (3%) and not more than ten percent (10%), such as not less than three and a half percent (3.5%) and not more than seven percent (7%). Such a difference in cross-sectional area can configure the blind holes 620 to support the nonwoven web 210 during the formation of the nodes 222, while also configuring the outlet channels 630 to exhaust the pressurized fluid flow 542 during the formation of the nodes 222. In addition, the relative size difference between the cross-sectional area of ​​the blind holes 620 at the first end portions 622 of the blind holes 620 and the cross-sectional area of ​​the outlet channels 630 at the first end portions 632 of the outlet channels 630 can allow the nonwoven web 210 to deform into the blind holes 620 due to the pressurized fluid flow 542; however, the nonwoven web 210 may be blocked or restricted from entering the smaller outlet channels 630.

[0136] The forming surface 640 can be shaped to assist in forming the node 222. For example, the forming surface 640 can be positioned at the second end portion 624 of the blind hole 620, such as such that the forming surface 640 is disposed within the wall 600 and faces the first surface 612. Thus, the forming surface 640 can form a bottom wall or bottom surface of the blind hole 620. Furthermore, in certain example embodiments, the central axis X of the blind hole 620 can intersect the centroid of the forming surface 640. Fig.10 and Fig.11In the example embodiment shown in , the shaping surface 640 has a hemispherical shape. Such shaping can advantageously assist in forming a node 222 having a generally cylindrical shape while also forming a node 222 having advantageous properties, such as less volume loss at the cap 252. As described above, the hemispherical shaping surface 640 can support the node 222 (e.g., the cap 252 of the node 222) and also redirect or reflect the pressurized fluid flow 542, which can cause the wall thickness TW of the wall 254 of the node 222 to be increased.

[0137] It will be appreciated that in other example embodiments, the shaped surface 640 may have other shapes. Fig.12 , the forming surface 640 can have a conical shape. Such forming can advantageously assist in forming the node 222 having a generally cylindrical shape while also forming the node 222 having advantageous properties, such as less volume loss at the cap 252 and increased wall thickness TW of the wall 254 of the node 222. The conical forming surface 640 can support the node 222 (e.g., the cap 252 of the node 222) and also redirect or reflect the pressurized fluid flow 542. As another example, the forming surface 640 can be flat, such as Fig.13 Other shapes for the forming surface 640 are also within the scope of the present disclosure.

[0138] Back to Fig.10 , the wall 600 may also define a connecting surface 642, such as a forming surface 640 that extends from the first surface 612 to the forming hole 534. Fig.10In the example embodiment shown in , the connecting surface 642 has a cylindrical shape. Such shaping can advantageously assist in forming a node 222 having a generally cylindrical shape while also forming a node 222 having advantageous properties, such as a smaller volume loss at the cap 252 and an increased wall thickness TW of the wall 254 of the node 222. Other shapes for the connecting surface 642 are also within the scope of the present disclosure. In an example embodiment, the shape of the connecting surface 642, for example, along the central axis X, can be constant. Thus, for example, the cross-sectional area of ​​the blind hole 620, for example, in a plane perpendicular to the central axis X, can be substantially constant at the connecting surface 642. In contrast, the cross-sectional area of ​​the blind hole 620, for example, in a plane perpendicular to the central axis X, can decrease toward the second end portion 624 of the blind hole 620 and / or at the shaping surface 640. Furthermore, the cross-sectional area of ​​the blind hole 620 may be substantially constant, for example, from a first end portion 622 of the blind hole 620 to at least a middle portion of the blind hole 620 in a plane perpendicular to the central axis X, for example, equidistantly positioned between the first end portion 622 and the second end portion 624 of the blind hole 620. Thus, the connecting surface 642 may be oriented perpendicular to the first surface 612, at least perpendicular to a middle portion of the blind hole 620 and / or a second end portion 624 of the blind hole 620 at the forming surface 640.

[0139] The shaped hole 534 can be formed in the wall 600 by drilling, casting, molding, punching, stamping, machining, laser cutting, water jet cutting, and 3D printing, or any other suitable method. In addition, the blind hole 620 can be formed by drilling into the wall 600, and the tip of the drill bit can form the shaped surface 640 in the wall 600. As another example, the wall 600 can be a multi-piece assembly, and the shaped hole 534 can be formed from at least two separate pieces of material. Thus, for example, Fig.14 , the wall 600 may include a first wall section 650 and a second wall section 652 mounted to each other to form the shaped hole 534. The blind hole 620 may be defined in the first wall section 650, and the outlet channel 630 may be defined in the second wall section 652. In addition, the blind hole 620 may be formed by drilling the first wall section 650, and the outlet channel 630 may be formed by drilling the second wall section 652. As yet another example, the wall 600 may include an insert 660. The insert 660 may be shaped to form the blind hole 620 and may also form the outlet channel 630. The insert 660 may be press-fit, adhered, welded, or mounted in other suitable manners within the wall 600 to form the shaped hole 534. Other configurations for the shaped hole 534 and combinations of the above configurations may also be used in other example embodiments.

[0140] Back to Figure 5, the process and apparatus 500 may also include one or more fluid entanglement devices 540. The most common fluid in this regard is known as hydroentanglement or hydroentanglement technology, which uses pressurized water as the fluid for entanglement. Thus, the fluid entanglement device 540 may include a plurality of high-pressure fluid jets (not shown) to discharge a plurality of pressurized fluid streams 542. These fluid streams 542 (preferably water) may be directed toward the precursor web 510 on the forming surface 530 and may cause the fibers to be further entangled within the nonwoven material 200 and / or the precursor forming surface 516 (in this case, the precursor forming surface is the underlying material web). The fluid streams 542 may also cause the fibers in the precursor web 510 to be directed into the forming holes 534 and out of the base plane 241 of the first surface 240 of the nonwoven material 200 and in a transverse direction TT perpendicular to the base plane 241 to form nodes 222 in the nonwoven material 200 (see Figure 2 , 3 and 4). The fluid flow 542 can also provide at least a majority of the plurality of nodes 222 configured such that the nodes 222 have an anisotropy value greater than one (1.0), as discussed above.

[0141] exist Figure 5 In the embodiment of the present invention, a single fluid entangling device 540 is shown, depending on the desired degree of entanglement and the specific size and mass of the nonwoven material 200 required, however, multiple such fluid entangling devices 540 may be used. The entangling fluid stream 542 of the fluid entangling device 540 may be ejected from an ejector via a jet group or jet belt (not shown) consisting of one or more rows of pressurized fluid jets having small openings of diameters typically between eight tenths of a millimeter (0.08 mm) and fifteen tenths of a millimeter (0.15 mm) and spacings of about half a millimeter (0.5 mm) in the transverse direction. The pressure in the jet may be between about five (5) bars and about four hundred (400) bars, but is typically less than two hundred (200) bars except for heavier nonwoven materials 10 and when fibrillation is desired. Other ejector sizes, spacings, number of ejectors, and ejection pressures may be used depending on the specific end application. Such fluid entangling devices 540 are well known to those of ordinary skill in the art and are commercially available from, for example, Fleissner in Germany and Andritz-Perfojet in France.

[0142] The fluid entangling device 540 can have jet orifices positioned on or spaced between about five millimeters (5 mm) and about twenty millimeters (20 mm), more typically between about five millimeters (5 mm) and about ten millimeters (10 mm), from the forming surface 530, although the actual spacing can vary depending on the basis weight of the material being acted upon, the fluid pressure, the number of individual jets used, the amount of vacuum used via the fluid removal system 538, and the speed at which the equipment is operated.

[0143] exist Figure 5 In the illustrated embodiment, the fluid entangling device 540 is a conventional hydroentanglement device, the construction and operation of which are well known to those skilled in the art, such as U.S. Pat. No. 3,485,706 to Evans, the contents of which are incorporated herein by reference in their entirety for all purposes. See also Honeycomb Systems, Inc., Biddeford, Me., for a description of hydroentanglement equipment in an article entitled "Rotary Hydraulic Entanglement of Nonwovens," reprinted from INSIGHT'86 INTERNATIONAL ADVANCED FORMING / BONDING Conference, the contents of which are incorporated herein by reference for all purposes.

[0144] The rotational speeds of the drive roller 520 and the textured drum 532 can be set to various speeds relative to each other. In some exemplary embodiments, the rotational speeds of the drive roller 520 and the textured drum 532 can be the same. In other exemplary embodiments, the rotational speeds of the drive roller 520 and the textured drum 532 can be different. For example, in some exemplary embodiments, the speed of the textured drum 532 can be less than the speed of the drive roller 520 to provide an overfeed of the precursor web 510 on the forming surface 530 on the textured drum 532. This overfeed can be used to provide various properties in the nonwoven material 200, such as improving the formation of the nodes 222 in the nonwoven material 200 and increasing the height of the nodes 222.

[0145] After fluid entanglement occurs from the fluid entanglement stream 542 by the fluid entanglement device 540, the precursor web 510 becomes a hydraulically entangled web forming the nonwoven material 200 described above, the hydraulically entangled web including a plurality of nodes 222, for example wherein ties 223 interconnect the nodes 222 and / or the openings 221, as described above. The process and apparatus 500 may also include removing the hydraulically entangled web of the nonwoven material 200 from the forming surface 530 and drying the hydraulically entangled web to provide a three-dimensional nonwoven material 200. The drying of the nonwoven material 200 may be performed by techniques known to those of ordinary skill in the art. In an exemplary embodiment in which the precursor web includes bonding fibers, the drying of the nonwoven material 200 may activate the bonding fibers. The activated bonding fibers may help maintain the three-dimensionality of the nonwoven material 200 by helping to maintain the geometry and height of the nodes 222, which extend away from the base plane 241 on the first surface 240 of the nonwoven material 200 (e.g., Figures 2 to 4 shown).

[0146] Figure 6 An alternative configuration of a process and apparatus 500' for making a nonwoven material 200 as described herein is provided. Figure 6 In the apparatus and method 100", the support web 550 may include a support web 550 that contacts the precursor web 510 before the fluid entangling unit 540. By separating the precursor web 510 from the support web 550, different feeding options for the precursor web 510 and the support web 550 can be achieved. For example, the precursor web 510 can be overfed to the fluid entangling unit 540 by the size and speed of the drive roller 520 compared to the texturing drum 532, while the support web 550 can be fed to the fluid entangling unit 540 by the drive roller 552 at a speed that matches the speed of the texturing drum 532. This is further described in U.S. Patent No. 9,474,660 invented by Kirby, Scott SC et al., which is incorporated herein in its entirety to the extent not inconsistent with this document.

[0147] In addition, Figure 7As shown, in some exemplary embodiments, the nonwoven material 200 can be combined with an additional web, such as a carrier material 560. The carrier material 560 can be bonded to the nonwoven material 200 by any suitable bonding mechanism, such as by adhesive bonding or mechanical bonding (e.g., ultrasonic bonding, pressure bonding, thermal bonding, or any other suitable bonding mechanism). The carrier material 560 can be bonded to the nonwoven material 200 after the fluid entanglement unit 540. In some exemplary embodiments, the carrier material 560 can be bonded to the nonwoven material 200 after drying the nonwoven material 200. In other exemplary embodiments, the carrier material 560 can be bonded to the nonwoven material 200 before drying the nonwoven material 200. The carrier material 560 can provide additional tensile strength to the nonwoven material 200 and can improve handling in high-speed conversion and / or manufacturing environments. The carrier material 560 can be a liquid permeable material and can be coupled to the nonwoven material 200 so that the carrier material 560 is adjacent to the first surface 240 of the nonwoven material 200 including the nodes 222. It is also worth noting that the carrier material 560 can be added to the bonding Figure 6 The process and apparatus 500" is depicted and described wherein a support web 550 is supplied to a fluid entangling unit 540 separate from a precursor web 510.

[0148] although Figures 5 to 7 Example processes and apparatuses 500, 500' and 500" for fluid entanglement of the nonwoven material 200 are depicted, but variations of these processes and apparatuses 500, 500' and 500" are contemplated as being useful. For example, as described above, the precursor web 510 may be provided using a variety of techniques other than a wet-laid process, such as being formed by a foam-laid process or a carding process. Additionally, the precursor web 510 may be provided on a separate line and wound around a core roll (not shown) and then delivered to a separate production line to participate in a fluid entanglement process via a fluid entanglement device 540 as discussed above.

[0149] Figure 8 Additional apparatus 500 and associated processes are depicted that may be particularly suitable for aspects of the present disclosure. In some example embodiments, the apparatus 500 and associated processes may be the same or similar to the apparatus and processes 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 hereby incorporated by reference.

[0150] The apparatus and method 500 may include entanglement and thereby bonding of a support web 513 and a precursor web 510, sometimes referred to as a projection web 510. In some exemplary embodiments, the fibers of the support web 513 may be similar to the fibers described by Scott Kirby et al. in U.S. Pat. No. 9,327,473 with respect to support web 14. Similarly, the fibers of the projection web 510 may be similar to the fibers described in U.S. Pat. No. 9,327,473 with respect to projection web 16.

[0151] The apparatus 500'" and associated processes may include a first conveyor belt 518, a conveyor belt drive roller 520, a protrusion forming surface 530, a fluid entangling device 540, an optional overfeed roller 551, and a fluid removal system 538 (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 protruding fiber web 510 to the apparatus 500'". If you want to Figure 8 If any pre-entanglement or wet forming of the raised web 510 is performed on the raised web 510 upstream of the process 500'' shown in FIG. 5, the conveyor belt 518 may be porous (e.g., as Figures 5 to 7 ). The conveyor belt 518 runs at a first speed or velocity V1 along a first direction (i.e., longitudinal direction) indicated by arrow 512. The conveyor belt 518 may be driven by a conveyor belt drive roller 520 or other suitable mechanism such as those well known to those skilled in the art.

[0152] The protrusion forming surface 530 is along Figure 8 The projection forming surface 530 moves at a speed or rate V3 in the longitudinal direction indicated by the middle arrow 531. The projection forming surface 530 is driven and speed controlled by any suitable drive mechanism (not shown), such as a motor and gears well known to those of ordinary skill in the art. The projection web 510 is fed into the apparatus and process 500'' at a speed V1, the support layer 513 is fed into the apparatus and process 500 at a speed V2, and the fluid-entangled laminated web 200 leaves the apparatus and process 500 at a speed V3 (also referred to as the projection forming surface speed) which is the speed of the projection forming surface 530. As will be explained in more detail below, these speeds V1, V2 and V3 can be the same or different from each other to change the forming process and the characteristics of the resulting fluid-entangled laminated web 200. Feeding both the projection web 510 and the support layer 513 into the process 500'' at the same speeds (V1 and V2) can produce a fluid-entangled laminated web 200 having desired nodes 222 according to exemplary aspects of the present disclosure. Feeding both the raised web 501 and the support layer 513 at the same speed that is faster than the longitudinal speed ( V3 ) of the raised forming surface 530 may also form the desired nodes 222 .

[0153] Also in Figure 8 Shown is an optional overfeed roller 551 which can be set at a speed or velocity V f The overfeed roller 551 may be driven at the same speed as the speed V1 of the protruding web 510, in which case V f Can be equal to V1 or V f When overfeeding is desired, the overfeed roller may be run at a faster speed to tension the protrusion web 510 upstream of the overfeed roller 551. Overfeeding occurs when one or both of the incoming webs / layers (510, 513) are fed onto the protrusion forming surface 530 at a speed that is higher than the protrusion forming surface speed of the protrusion forming surface 530. It has been found that improved protrusion formation in the protrusion web 510 can be achieved by feeding the protrusion web 510 onto the protrusion forming surface 530 at a speed that is higher than the introduction speed V2 of the support layer 513. In addition, however, it has been found that improved properties and protrusion formation can be achieved by varying the feed rate of the webs / layers (510, 513) and by using an overfeed roller 551 just upstream of the texturing drum 530 to supply a greater amount of fibers through the protrusion web 510 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 510 onto the texturizing drum 530, improved projection formation, including increased projection height, may be achieved.

[0154] In order to provide excess fiber so that the height of the nodes 222 can be increased or maximized, the raised web 510 can be fed onto the texturing drum 530 at a surface speed (V1) that is greater than the surface speed (V3) at which the texturing drum 530 is traveling. Figure 8 , when overfeed is required, the raised web 510 is fed onto the texturing drum 530 at a speed V1, while the support layer 513 is fed at a speed V2, and the texturing drum 530 travels at a speed V3 that is slower than V1 and may be equal to V2. The overfeed percentage or ratio (the ratio at which the raised web 510 is fed onto the texturing drum 530) may be defined as OF = [(V1 / V3)-1]×100, where V1 is the input speed of the raised web 510, and V3 is the output speed of the resulting fluid-entangled laminated web 200 and the speed of the texturing drum 530. (When an overfeed roller 550 is used to increase the speed of the material introduced onto the texturing drum 530, it should be noted that the speed V1 of the material after the overfeed roller 551 may be faster than the speed V1 upstream of the overfeed roller 551. This faster speed V1 should be used when calculating the overfeed ratio. f. ) It has been found that the nodes 222 are well formed 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 for the raised web 510, but also for the combination of the raised web 510 and the support layer 513, because the webs 513, 510 are fed together onto the raised forming surface 530.

[0155] In order to minimize the length of the raised web 510 that supports its own weight before it is subjected to the entanglement fluid 542 and to avoid wrinkling and folding of the raised web 510, an overfeed roller 551 may be used to carry the raised web 510 at a speed V1 to a position close to the texturing zone 544 on the texturing drum 530. Figure 8 In the example shown in , the overfeed roller 551 is driven away from the conveyor belt 518, but it is also possible to drive the overfeed roller 551 separately so as not to apply excessive stress to the introduced raised web material 510. The support layer 513 can be fed into the texturing zone 544 separately from the raised web 510 at a speed V2, which can be greater than, equal to, or less than the texture drum speed V3 and greater than, equal to, or less than the raised web 510 speed V1. Preferably, the support layer 513 is drawn into the texturing zone 544 by frictional engagement with the raised web 510 positioned on the texture drum 530, and once on the texture drum 530, the support layer 513 has a surface speed close to the texture drum 530 speed V3, or the support layer 513 can be actively fed into the texturing zone 544 at a speed close to the texture drum speed V3. The texturing process causes some shrinkage of the support layer 513 in the machine direction 531. The overfeed of the support layer 513 or the raised web 510 can be adjusted according to 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 wrinkles in the resulting fluid-entangled laminated web 200. Therefore, the two webs / layers (510, 513) are always under some tension despite the overfeed process. The removal speed of the fluid-entangled laminated web 200 must be arranged to be close to the texturing drum speed V3 so that no excess tension is applied to the fluid-entangled laminated web 200 when the laminate 200 is removed from the texturing drum 530, as such excess tension would be detrimental to the definition and size of the nodes 222.

[0156] After fluid entanglement from the fluid entanglement stream 542 by the fluid entanglement device 540, the protruding fiber web 510 and the supporting fiber web 513 become a laminated nonwoven fiber web forming the nonwoven material 200 described above, which includes the nodes 222, the ties 223 connecting the nodes 222 to each other, and / or the openings 221 as described above. Such nonwoven materials 200 may not contain any binder, such as adhesives, etc., and may be held together only by fiber entanglement. The process and apparatus 500'' may also include removing the web of 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 may be performed by techniques known to those of ordinary skill in the art. In example embodiments where the precursor web includes binder fibers, the drying of the nonwoven material 200 may activate the binder fibers. The activated binder fibers may help maintain the three-dimensionality of the nonwoven material 200 by helping to maintain the geometry and height of the nodes 222 that extend away from the base plane 241 on the first surface 240 of the nonwoven material 200 (e.g., Figure 3 and Figure 4 shown).

[0157] Suitable materials for the raised web 510 can be similar to the materials described above with respect to the precursor web 510 of the apparatus and methods 500, 500' and 500'". Suitable materials for the support layer 513 can include a fibrous nonwoven web made from a plurality of randomly deposited fibers, which can be short length fibers, such as used in, for example, a carded web, an air-laid web, etc. Alternatively, the material can be more continuous fibers, such as those found in a meltblown or spunbond web. Due to the functions that the support layer 513 must perform, the support layer 513 can have a higher degree of integrity than the raised web 510. In this regard, when the support layer 513 is subjected to fluid entanglement discussed in more detail below, The support layer 513 may be able to remain substantially intact during the node 222 of the protruding web 510. The degree of integrity of the support layer 513 may be such that the material forming the support layer 513 resists being pressed down into and filling the nodes 222 of the protruding web 510. Thus, when the support layer 513 is a fibrous nonwoven web, it may be desirable for the support layer 513 to have a higher degree of fiber-to-fiber bonding and / or fiber entanglement than the fibers in the protruding web 510. While it is desirable to have the fibers of the support layer 513 entangled with the fibers of the protruding web 510 near the interface between the two layers, it is generally advantageous that the fibers of the support layer 513 not be so joined or entangled into the protruding web 510 that a substantial portion of these fibers penetrate into the interior of the nodes 222.

[0158] As mentioned above, relative to known nonwoven materials, the node 222 of nonwoven material 200 can have improved characteristics--particularly after being wound and unwound from a roll for transmission and / or after being placed on an absorbent article and compressed in a package.For example, an example beneficial characteristic of nonwoven material 200 can include fiber orientation.In an example embodiment, such as below with reference to example B, at least most of the nodes in node 222 can be configured to make node 222 have anisotropy value greater than ninety-two percent (0.92), as measured by the node analysis test method described in the test method chapters and sections in this article.Therefore, on the first surface 240 of nonwoven material 200, node 222 can have a higher level of fiber alignment in the transverse direction TT perpendicular to base plane 241.Nonwoven material has a node formed in a cylindrical hole so that the distal end portion of the node does not contact any surface--for example, a hole not embedded--is provided as a comparative example (example A). Anisotropy values ​​for nonwoven materials (formed with embedded forming holes 534) made according to example aspects of the present disclosure and comparative examples (not formed with embedded forming holes 534) are shown below. The basis weight for both examples was 70 gsm.

[0159] The materials of comparative example A and example B are based on Figure 8 and apparatus 500"' described. The forming surface description is indicated in Table 1 below. The material of comparative example A is formed with cylindrical hole forming holes 534 having the indicated depth and diameter, which extend through the entire thickness of the forming surface. The material of example B is formed with forming holes 534 having a cylindrical diameter and forming blind holes having a hemispherical shape at the second end 642 of the forming surface 640 defining the forming holes 534. Both materials A and B are formed from a support layer consisting of a spunbond material having a basis weight of 17 gsm. The spunbond material is formed from polypropylene fibers having a denier of 1.8. The protruding layers of materials A and B include a carded web having a basis weight of 53 gsm. The carded web includes polyester fibers having a denier of 1.3.

[0160] Table 1

[0161]

[0162] As shown in Table 1 above, the nonwoven material (formed with embedded forming holes 534-Example B) manufactured according to the exemplary aspects of the present disclosure includes an anisotropy value greater than 0.92 (e.g., and less than 1.1), i.e., has an anisotropy value of 0.97. Other exemplary nonwoven materials of the present disclosure may have an anisotropy value between 0.92 and 0.97 or even greater than 0.97 (such as up to 1.0 or 1.1). These values ​​can be achieved by adjusting the specific fiber properties of the precursor web 510 (e.g., fiber length, fiber denier, etc.) as well as the fluid pressure and nozzle spacing.

[0163] Without being bound by theory, it is believed that because the blind holes 620 support the nodes 222 and also redirect or reflect the pressurized fluid flow 542 to avoid volume loss and improved wall thickness TW of the walls 254 of the nodes 222, improved anisotropy values ​​in the nodes 222 of the nonwoven material 200 described herein may be formed.

[0164] In addition, it is believed that compared with other nonwoven materials, the anisotropy value of the increase of the nonwoven material 200 according to this specification provides improved compression resistance for the nonwoven material 200. Due to the improved compression resistance, the nonwoven material 200 can be applied and used to maintain fluffy in the various environments where the nonwoven material 200 may be exposed to compressive force. For example, when used for absorbent articles, if the wearer wears the absorbent article in a sitting or supine position, the nonwoven material 200 can be applied to the wearer from the initial wrapping state of the compression package under the compressive force. By providing improved compression resistance, the nonwoven material 200 can help maintain the void volume, so as to accept, transfer and / or store the body exudates from the wearer. In this case, the nonwoven material 200 can provide the wearer with enhanced skin benefits by helping to keep the body exudates away from the wearer's skin, and provide potential product improvements by keeping the body exudates away from the edge (this may be the source of leakage) of the absorbent article.

[0165] As described in detail in the "Test Methods" section of this article, the compression linearity test is designed to measure the compression properties of nonwoven materials by compressing the material at a constant rate between two plungers until the maximum preset force is reached. The displacement of the upper plunger of the compressed material is detected by a potentiometer. The relationship between the amount of pressure (P, gf / cm2) required for compressing the sample and the thickness (displacement) (T, mm) of the material is plotted. The compression linearity value represents the linearity of the compression curve. The higher the compression linearity value, the stronger the compression resistance of the material. The compression linearity of the nonwoven material manufactured according to the example aspects of the present disclosure (formed with embedded forming holes 534) and the comparative example (formed with embedded forming holes 534) is shown below.

[0166] Table 2

[0167]

[0168] The nonwoven material manufactured according to the exemplary aspects of the present disclosure (formed with embedded forming holes 534) exhibits a compression linearity of about 1.03, while the comparative example (not formed with embedded forming holes 534) exhibits a compression linearity of less than 0.849. Therefore, in exemplary embodiments, the nonwoven material 200 may have a compression linearity greater than 0.90, more preferably greater than 0.95, more preferably greater than 0.975, even more preferably greater than 0.99, and most preferably greater than 1.0. In some exemplary embodiments, the nonwoven material 200 may have a compression linearity between about 0.9 and 1.2, such as between about 0.9 and 1.1, such as between about 0.9 and 1.05, such as between about 0.9 and 1.03, such as between about 0.95 and about 1.1, such as between about 0.95 and 1.05.

[0169] As described above, the openings 221 and nodes 222 can enhance the ability of a material (such as nonwoven material 200) to absorb and distribute BM matter (also referred to herein as feces or excrement), thereby causing less feces to collect on the nonwoven material 200, and therefore less feces to be on the skin of the wearer of an absorbent article including the nonwoven material 200. In order to determine the ability of different nonwoven materials to effectively handle simulated BM, according to an exemplary aspect of the present disclosure, a nonwoven material (material B) was tested using a test method for determining a BM collection percentage value. This test method is described as a "Determination of Residual Fecal Simulant" test method in U.S. Patent No. 9,480,609, entitled "Absorbent Articles," the entire contents of which are hereby incorporated by reference to the extent not in conflict with this document. A nonwoven material having nodes formed in cylindrical holes so that the distal end portion of the node does not contact any surface is provided as a first comparative example (comparative material A), and a nonwoven material from a commercial As a second comparative example, a three-dimensional localized absorbent material from the Special Delivery diaper product included nodes protruding from the base plane of the material but did not have any openings.

[0170]

[0171] First, it can be seen that the nonwoven material 200 has openings 221 and nodes 222.

[0172] The degree of effectiveness in reducing the amount of pooled BM on such materials. For example, as shown in Table 2 above, material B formed with embedded shaped holes 534 performs better than material A (not formed with embedded shaped holes 534) and Special Delivery material is all good.Therefore, in exemplary embodiments, measure according to the residual feces simulant test method, after being polluted by feces simulant, the amount of the residual feces simulant remaining on the nonwoven material 200 can be less than about 2.0 grams, such as less than 1.9 grams, such as less than 1.8 grams, such as less than 1.7 grams, such as less than 1.6 grams, such as less than 1.5 grams, such as less than 1.47 grams.In any example in these examples, measure according to the residual feces simulant test method, after being polluted by feces simulant, the amount of the residual feces simulant remaining on the nonwoven material 200 can be greater than or equal to about 1.46 grams, such as greater than or equal to about 1.5 grams, such as greater than or equal to about 1.6 grams, such as greater than or equal to about 1.7 grams, such as greater than or equal to about 1.8 grams, such as greater than or equal to about 1.9 grams.

[0173] 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 foregoing description is by way of example only and is not intended to limit the present invention as further described in such appended claims.

[0174] Test Method

[0175] The test methods and measurements detailed herein are performed on previously compressed material. For example, sample material is selected from material that is wound and unwound from a roll of material - as is typical in the commercial manufacture and transportation of nonwoven web materials - or removed from a commercial product that is placed in a compressed package prior to any measurements being made.

[0176] Node Analysis Test Method

[0177] The anisotropy of the fibers in the nodes 222 can be determined by using the image analysis measurement method described herein. The test method can also measure the node height and the percentage of fibers and voids within the nodes 222.

[0178] In this regard, the fiber anisotropy of multiple nodes 222 from each corresponding material is considered. Typically, image analysis methods determine the value of anisotropy from a cross-sectional image of the node 222 via a specific image analysis measurement parameter called anisotropy. The anisotropy of the node 222 can be measured by using X-ray micro-computed tomography (also known as Micro-CT) to non-destructively acquire images, then using image analysis techniques to detect fiber components, and then measuring the anisotropy of the components only within the node 222 area. The image analysis algorithm performs the detection, image processing and measurement, and also digitally transmits the data to a spreadsheet database. The resulting measurement data is used to compare the anisotropy of different structures having fiber node 222 components.

[0179] The method for determining the anisotropy in the fibers of each structural node includes the first step of obtaining a digital X-ray Micro-CT image of the sample. These images are collected using a SkyScan 1272 Micro-CT system available from Bruker microCT (2550 Kontich, Belgium). The sample is attached to a mounting device provided by Bruker with the SkyScan 1272 system so that it does not move under its own weight during the scan. The following SkyScan 1272 conditions are used during the scan:

[0180] - Camera pixel size (μ) = 9.0

[0181] - Source voltage (kV) = 35

[0182] -Source current (uA) = 225

[0183] - Image pixel size (μ) = 6.0

[0184] - Image Format = TIFF

[0185] - Depth (bits) = 16

[0186] -Rotation step (degrees) = 0.10

[0187] -Use 360 ​​degree rotation = No

[0188] -Frame Averaging = On (6)

[0189] -Random Move = On (1)

[0190] -Flat Field Correction = On

[0191] -Filter = No filter

[0192] After the sample scan is completed, the resulting image set is then reconstructed using the NRecon program provided with the SkyScan 1272 Micro-CT system. While the reconstruction parameters may be somewhat sample dependent and should be known to those skilled in the art, the following parameters should provide basic guidance to the analyst:

[0193] -Image file type = JPG

[0194] -Pixel size (μ) = 6.00

[0195] -smoothing=1(Gaussian)

[0196] -Ring artifact correction = 10

[0197] -Beam hardening correction (%) = 10

[0198] After the reconstruction is complete, the resulting image dataset can now be used to extract cross-sectional image slices using a Bruker SkyScan software package called DataViewer. After downloading the entire reconstructed image dataset into DataViewer, the technical analyst in the field of Micro-CT technology must then select and extract cross-sectional image slices located at or near the center of the nodes present in each sample. For each selected image, a central node 222 should be obtained. For a typical sample, this process will generate 4-6 images, and 4-6 nodes 222 can be used for analysis. The analyst should then renumber the images sequentially (e.g., 1, 2, 3, etc.) by changing the image file suffix number.

[0199] Once a set of cross-sectional Micro-CT images have been acquired and renumbered from each specimen, anisotropy measurements can now be performed using image analysis software.

[0200] The image analysis software platform used to perform anisotropy measurements was QWIN Pro (version 3.5.1) available from Leica Microsystems (having offices in Heerbrugg, Switzerland).

[0201] Thus, the method for determining the anisotropy of a given sample comprises the steps of performing several anisotropy measurements on a set of Micro-CT images. Specifically, an image analysis algorithm is used to read and process the images and to perform the measurements using the Quantimet User Interactive Programming System (QUIPS) language. The image analysis algorithm is reproduced below.

[0202] Defining variables and opening files

[0203] The following line specifies the location on the computer where the data is sent

[0204] Open the file (C:\Data\94054-Nhan(patent)\z-micro-ct data.xls, channel #1)

[0205] pauseText("Enter the number of the final image in the collection.")

[0206] Input (image)

[0207] Sample ID and Setup

[0208] Input result header

[0209] File Results Header(channel#1)

[0210] File Line (Channel #1)

[0211] Measure frame (x 31, y 61, width 1737, height 793)

[0212] Image frame (x 0, y 0, width 1768, height 854)

[0213] --Calvalue 6.0μm / pixel

[0214] Calculated value = 6.0

[0215] Correction(calculated value in $per pixel)

[0216] --Enter the image prefix name of the image set to be analyzed

[0217] pauseText("Enter the image file prefix.")

[0218] input(title$)

[0219] File("Rep.#", Channel #1)

[0220] file("%Fiber", channel #1)

[0221] file("%Voids", channel #1)

[0222] file("Height (μm)", channel #1)

[0223] File("Anisotropy", channel #1)

[0224] File Line (Channel #1)

[0225] for (repeat=1 to image, step 1)

[0226] Clear Accept

[0227] IMAGE ACQUISITION AND DETECTION

[0228] ACQOUTPUT=0

[0229] The following two lines indicate the computer location of the Micro-CT image to be read during image analysis.

[0230] ACQFILE$="C:\Images\94054-Nhan\Z-slices\"+TITLE$+""+STR$(REPLICATE)+".jpg"

[0231] Read image (from file ACQFILE$ to ACQOUTPUT)

[0232] Color conversion (monochrome mode)

[0233] Grayscale transformation (WSharpen from image 0 to image 1, cycle 3, operator disk)

[0234] Detect (whiter than 64, from image 1 to binary 0)

[0235] Image Processing

[0236] PauseText("Select the region of interest for analysis.")

[0237] Binary Edit [PAUSE] (accept from binary 0 to binary 1, nibble fill, width 2)

[0238] Binary modification (from binary 1 to binary 2 off, loop 30, operator disk, edge erosion on)

[0239] Binary recognition (filling holes from binary 2 to binary 3)

[0240] Binary modification (from binary 3 to binary 4 on, loop 40, operator disk, edge erosion on)

[0241] pauseText("Clear any area within the expanded ROI region.")

[0242] BINARY EDIT [PAUSE] (from binary 4 to binary 5 reject, nibble fill, width 2)

[0243] pauseText("Draw a vertical line through the thickest region of binary.")

[0244] BINARY EDIT [PAUSE] (accept from binary 5 to binary 7, nibble rectangle, width 2)

[0245] Binary logic (C = A AND B: C binary 6, A binary 1, B binary 5)

[0246] Measurement analysis area

[0247] --Analysis of regional fiber area

[0248] MFLDIMAGE=6

[0249] Measurement fields (flat MFLDIMAGE, into FLDRESULTS(2), statistics into FLDSTATS(7,2))

[0250] Selected parameters: Area, Anisotropy

[0251] FIBERAREA=FLDRESULTS(1)

[0252] ANISOTROPY=FLDRESULTS(2)

[0253] --Analysis area

[0254] MFLDIMAGE=5

[0255] Measurement fields (flat MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1))

[0256] Selected Parameters: Area

[0257] ROIAREA=FLDRESULTS(1)

[0258] PERCFIBER=FIBERAREA / ROIAREA*100

[0259] PERCVOIDS=100-PERCFIBER

[0260] --Measure node height

[0261] Measure features (plane binary 7, 8feret, minimum area: 24, grayscale image: image0)

[0262] Selected parameters: X FCP, Y FCP, Length

[0263] LENGTH = Sum of fields where (PLENGTH(FTR))

[0264] Output Data

[0265] file(REPLICATE, channel #1, 0 digits after '.')

[0266] file(PERCFIBER, channel #1, 1 digit after '.')

[0267] FILE(PERCVOIDS, channel #1, 1 digit after '.')

[0268] file(LENGTH, channel #1, 1 digit after '.')

[0269] File(ANISOTROPY, channel #1, 2 digits after '.')

[0270] File Line (Channel #1)

[0271] Next (repeat)

[0272] Close file (channel #1)

[0273] Finish

[0274] The QUIPS algorithm was performed using the QWIN Pro software platform. The analyst was initially prompted to enter the number of images for a particular sample in the set. The analyst was then prompted to enter sample identification information, which was sent to an EXCEL file.

[0275] The analyst is then prompted via an interactive command window and an input window to enter the image file prefix of the Micro-CT image to be analyzed. After this step, all subsequent images of a given sample will be automatically read by the above-mentioned image analysis algorithm.

[0276] The analyst is then prompted to manually select the node region of interest for analysis using the computer mouse. Care should be taken to select the entire node to include the tapered portion just at the base plane 241 of the material 200.

[0277] After several automated steps of image processing, the analyst will be prompted again to clean up any overextended regions of interest (ROI) areas. This is done using the computer mouse and by simultaneously pressing and releasing the overlapping binary images using the "Control" and "b" keys on the computer keyboard. After this step, the binary should only cover the nodes.

[0278] Finally, the analyst will be prompted to use the computer mouse to draw a vertical line through the highest area of ​​the binary image. This line will be used by the computer algorithm to measure the height of node 222.

[0279] The process of selecting a node 222 region of interest, cleaning overextended regions, and drawing a vertical line through the highest region of the node 222 is repeated until all images of a particular sample have been analyzed.

[0280] After all images have been analyzed, the following measurement parameter data will be located in the corresponding EXCEL files:

[0281] repeat#

[0282] %fiber

[0283] % Void

[0284] high

[0285] Anisotropy

[0286] There will be 4-6 values ​​listed in the columns for each of these parameters. To compare anisotropy values ​​between samples, the data in the columns labeled "Anisotropy" can be compared between different samples by performing a Student's T analysis at a 90% confidence level.

[0287] Material sample analysis test methods

[0288] The material sample analysis test method as described herein can be used to determine the size of the holes 221, the roundness of the holes 221, the aspect ratio for the holes 221, the two-dimensional area of ​​the nodes 222, and the density and spacing of the nodes 222. The test method involves obtaining two separate digital images of the sample.

[0289] Material opening area sample analysis setup and determination

[0290] exist Fig.15 An exemplary arrangement for acquiring an image of an aperture region is representatively shown in . Specifically, a CCD camera 700 (e.g., a Leica DFC 300FX camera, obtained from Leica Microsystems (Heerbrugg, Switzerland)) is fixed to a standard bracket 702 (such as a Polaroid MP-4 Land Camera standard bracket, previously obtained from the Polaroid Resource Center (Cambridge, MS), currently available from sources such as eBay). The standard bracket 702 is connected to a large lens viewfinder 704, such as a KREONITE large lens viewfinder available from Dunning Photo Equipment, Inc. (with an office in Bixby, Oklahoma). An automatic sample stage 706 is placed on the upper surface of the large lens viewfinder 704. The automatic sample stage 706 is used to automatically move the position of a given sample for observation by the camera 700. A suitable automatic sample stage 706 is model H112 available from Prior Scientific Inc. (with an office in Rockland, MA).

[0291] The sample ( Fig.15 700) is placed on an automatic stage 706 of a Leica Microsystems QWIN Pro image analysis system (such as a Nikon AF Micro Nikkor manufactured by Nikon Corporation (having offices in Tokyo, Japan) under the optical axis of a sixty millimeter (60 mm) lens 708 with an f-stop setting of four (4). The lens 708 is connected to the camera 700 using a c-mount adapter. The distance from the front of the lens 708 to the sample is approximately fifty-five centimeters (55 cm). The sample is laid flat on the automatic stage surface 710 and any wrinkles are removed by gently stretching and / or fastening the material to the automatic stage surface 710 at the outer edges of the sample using clear adhesive tape. The sample surface was illuminated with incident fluorescent light provided by a sixteen inch (16") diameter, forty watt (40W) annular fluorescent lamp 712, such as manufactured by General Electric Company having offices in Boston, Massachusetts. The lamp 712 was contained in a fixture positioned so that the lamp 712 was centered over the sample and approximately three centimeters (3 cm) above the sample surface. The illumination level of the lamp 712 was controlled using a variable autotransformer model 3PN1010 available from Staco Energy Products Co. having offices in Dayton, OH. Transmitted light was also provided by a dimmable and available from Fulight Optoelectronics A set of four two-foot (2-foot) EMC double-ended powered LED light tubes 714 obtained from Materials, LLC are provided to the sample from below the automated sample stage. The LED lights 714 are covered by a diffuser plate 716. The diffuser plate 716 is inserted into and forms a portion of the upper surface 718 of the large lens viewfinder 704. The illumination source is covered with a black mask 720 having a 3-inch by 3-inch opening 722. The opening 722 is positioned so that the opening 722 is centered below the optical axis of the camera 700 and lens 708 system. The distance D3 from the fluorescent light opening 722 to the surface 710 of the automated sample stage 706 is approximately seventeen centimeters (17 cm). The illumination level of the fluorescent light set 714 is also controlled by a separate power control box (not shown) configured for dimmable LED lights.

[0292] The image analysis software platform used to perform the open area percentage and aperture size measurements is QWIN Pro (version 3.5.1) available from Leica Microsystems (with an office in Heerbrugg, Switzerland). Alternatively, LAS Macro Editor (the next generation software after QWIN Pro) can be used for analysis. The system and image are also accurately calibrated using QWIN software and a standard ruler with metric markings at least as small as one millimeter. Calibration is performed on the horizontal dimension of the camera image. Units of millimeters / pixel are used for calibration.

[0293] Therefore, the method for determining the percentage of open area and the size of the opening of a given sample includes the step of measuring the transmitted light image. Specifically, the image analysis algorithm is used to obtain and process the image and to measure using the quantitative video microscope user interactive programming system (Quantimet User Interactive Programming System, QUIPS) language. The image analysis algorithm is reproduced below. For clarity, the reference to "bump" or "protrusion" in the algorithm refers to the node 222 of the nonwoven material 200, and the reference to "open area" or "opening" refers to the opening 221 of the nonwoven material 200.

[0294] Defining variables and opening files

[0295] The following line specifies the location on the computer where the data is sent

[0296] Open the file (C:\Data\94054-Nhan(patent)\data.xls, channel #1)

[0297] TOTCOUNT=0

[0298] TOTFIELDS=0

[0299] MFRAMEH=875

[0300] MFRAMEW=1249

[0301] Sample ID and Setup

[0302] Configuration (image memory 1392x 1040, grayscale image 81, binary 24)

[0303] Input result header

[0304] File Result Header (Channel #1)

[0305] File Line (Channel #1)

[0306] pauseText("Now enter a sample image prefix name.")

[0307] input(title$)

[0308] pauseText("Setting samples to position.")

[0309] Image Setup DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lights 38.83)

[0310] Measure frame (x 74, y 110, width 1249, height 875)

[0311] Image frame (x 0, y 0, width 1392, height 1040)

[0312] --Calculated value = 0.0377mm / px

[0313] Calculated value = 0.0377

[0314] Correction(calculated value in $per pixel)

[0315] FRMAREA=MFRAMEH*MFRAMEW*(CALVALUE**2)

[0316] Clear Accept

[0317] For (sample=1 to 1, step 1)

[0318] Clear Accept

[0319] file("field number", channel #1, field width: 9, left justified)

[0320] File("Opening Area %", Channel #1, Field Width: 7, Left Justified)

[0321] file("bump density", channel #1, field width: 13, left justified)

[0322] file("Bump Spacing", channel #1, field width: 15, left justified)

[0323] File Line (Channel #1)

[0324] Phase (Define Origin)

[0325] Stage (scan pattern, 1×5 field, size 82500.000000×39000.000000)

[0326] Image Collection I - Neurite Isolation

[0327] For (field=1 to 5, step 1)

[0328] Measure frame (x 74, y 110, width 1249, height 875)

[0329] display(image0(on), frame(on, on), planes(off, off, off, off, off, off), lut 0, x 0, y 0, z 1, downscaling off)

[0330] PauseText("Ensure incident light illumination is correct (WL = 0.88-0.94) and acquire image.")

[0331] Image Setup DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lights 38.83)

[0332] Get (enter image 0)

[0333] Detection - protrusions only

[0334] Pause Text ("Make sure the threshold is set at least to the right of the left gray-level histogram peak, which corresponds to the "base" region.")

[0335] Detect [PAUSE] (whiter than 129, from image 0 into depicted binary 0)

[0336] Binary Image Processing

[0337] Binary modification (from binary 0 to binary 1 off, loop 10, operator disk, edge erosion on)

[0338] Binary recognition (filling holes from binary 1 to binary 1)

[0339] Binary modification (from binary 1 to binary 2 on, loop 20, operator disk, edge erosion on)

[0340] Binary modification (from binary 2 to binary 3 off, loop 8, operator disk, edge erosion on)

[0341] Pause text ("while pressing <control>and key to check protrusion detection and correct if necessary. ")

[0342] BINARY EDIT [PAUSE] (from binary3 to binary3 reject, nibble fill, width 2)

[0343] Binary logic (copy binary 3, invert to binary 4)

[0344] Image acquisition 2-opening area and opening size percentage

[0345] Measure frame (x 74, y 110, width 1249, height 875)

[0346] display(image0(on), frame(on, on), planes(off, off, off, off, off, off), lut 0, x 0, y 0, z 1, downscaling off)

[0347] PauseText("Turn off incident light and ensure incident light illumination is correct (WL=0.95) and acquire image.")

[0348] Image Setup DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lights 38.83)

[0349] Get (enter image 0)

[0350] ACQFILE$="C:\Images\94054-Nhan\"+TITLE$+"_"+STR$(FIELD)+".jpg"

[0351] Write image (from ACQOUTPUT to file ACQFILE$)

[0352] Detection - Opening area only

[0353] Detect (whiter than 127, going from image 0 into the depicted binary 10)

[0354] Binary Image Processing

[0355] Binary modification (from binary 10 to binary 11 off, loop 5, operator disk, edge erosion on)

[0356] Binary recognition (filling holes from binary 11 to binary 12)

[0357] Binary modification (from binary 12 to binary 13 on, loop 10, operator disk, edge erosion on)

[0358] Binary recognition (edge ​​characterization from binary 13 to binary 14)

[0359] PauseText("Ensure accurate detection of openings.")

[0360] BINARY EDIT [PAUSE] (from binary14 to binary14 reject, nibble fill, width 2)

[0361] Field measurements - open area percentage, bump density and spacing

[0362] --% Opening Area

[0363] MFLDIMAGE=10

[0364] Measurement fields (flat MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1))

[0365] Selected parameters: Area%

[0366] Field Histogram #1 (Y parameter number, X parameter area%, from 0. to 60., linear, 20 bins)

[0367] PERCOPENAREA=FLDRESULTS(1)

[0368] --Bump density and spacing

[0369] MFLDIMAGE=3

[0370] Measurement fields (flat MFLDIMAGE, into FLDRESULTS(5), statistics into FLDSTATS(7,5))

[0371] Selected parameters: Area, Intercept H, Intercept V, Area %,

[0372] Count / Area

[0373] BUMPDENSITY=FLDRESULTS(5)

[0374] MNSPACE1=(FRMAREA-FLDRESULTS(1)) / (FLDRESULTS(2)

[0375] +FLDRESULTS(3)) / 2

[0376] Field Histogram #2 (Y parameter number, X parameter MNSPACE1, from 0. to 50., linear, 25 bins)

[0377] File(field, channel #1, 0 digits after '.')

[0378] File(PERCOPENAREA, channel #1, 1 digit after '.')

[0379] file(BUMPDENSITY, channel #1, 1 digit after '.')

[0380] File(MNSPACE1, channel #1, 1 digit after '.')

[0381] File Line (Channel #1)

[0382] Feature measurement - hole and bump dimensions

[0383] --Bump size

[0384] Measure features (plane binary 3, 8feret, minimum area: 24, grayscale image: image0)

[0385] Selected parameters: Area, X FCP, Y FCP, Equivalent diameter

[0386] Feature histogram #1 (Y parameter is number, X parameter is area, from 1. to 100., logarithmic, 20 bins)

[0387] Feature histogram #2 (Y parameter number, X parameter equivalent diameter, from 1. to 100., logarithmic, 20 bins)

[0388] --Opening size

[0389] Measure features (flat binary 14, 8feret, minimum area: 24, grayscale image: image0)

[0390] Selected parameters: Area, X FCP, Y FCP, Circularity, Aspect Ratio,

[0391] Equivalent diameter

[0392] Feature Histogram #3 (Y parameter is number, X parameter is area, from 1. to 100., logarithmic, 20 bins)

[0393] Feature histogram #4 (Y parameter number, X parameter equivalent diameter, from 1. to 100., logarithmic, 20 bins)

[0394] Feature Histogram #5 (Y parameter number, X parameter circularity, from 0.8999999762 to 2.900000095, linear, 20 bins)

[0395] Feature Histogram #6 (Y parameter number, X parameter aspect ratio, from 1. to 3., linear, 20 bins)

[0396] phase(step, wait until stop + 1100 ms)

[0397] Next(field)

[0398] Next (sample)

[0399] File Line (Channel #1)

[0400] File Line (Channel #1)

[0401] Output feature histogram

[0402] file("Bump size (area - mm2)", channel #1)

[0403] File Line (Channel #1)

[0404] File feature histogram results (#1, differential, statistics, bin details, channel #1)

[0405] File Line (Channel #1)

[0406] File Line (Channel #1)

[0407] File("Bump Size (ECD - mm)", Channel #1)

[0408] File Line (Channel #1)

[0409] File feature histogram results (#2, differential, statistics, bin details, channel #1)

[0410] File Line (Channel #1)

[0411] File Line (Channel #1)

[0412] File("Opening Size (Area - mm2)", Channel #1)

[0413] File Line (Channel #1)

[0414] File feature histogram results (#3, differential, statistics, bin details, channel #1)

[0415] File Line (Channel #1)

[0416] File Line (Channel #1)

[0417] File("Opening Size (ECD - mm)", Channel #1)

[0418] File Line (Channel #1)

[0419] File feature histogram results (#4, differential, statistics, bin details, channel #1)

[0420] File Line (Channel #1)

[0421] File Line (Channel #1)

[0422] File("Opening Roundness", channel #1)

[0423] File Line (Channel #1)

[0424] File feature histogram results (#5, differential, statistics, bin details, channel #1)

[0425] File Line (Channel #1)

[0426] File Line (Channel #1)

[0427] File("Aperture Aspect Ratio", channel #1)

[0428] File Line (Channel #1)

[0429] File feature histogram results (#6, differential, statistics, bin details, channel #1)

[0430] File Line (Channel #1)

[0431] File Line (Channel #1)

[0432] Close file (channel #1)

[0433] Finish

[0434] The QUIPS algorithm was implemented using the QWIN Pro software platform. Initially the analyst was prompted to enter the sample set information, which was sent to an EXCEL file.

[0435] The analyst then enters the image file prefix name that corresponds to the sample identification. The algorithm will use this to save the images acquired during the analysis process to the specified file location. The analyst is then prompted by the real-time image setup window on the computer monitor screen to place the sample on the automatic sample stage. The sample should be laid flat and gentle force should be applied to the edges of the sample to remove any large wrinkles that may be present. At this time, the annular fluorescent light 712 can be turned on to help position the sample. Next, the analyst is prompted to adjust the incident annular incident fluorescent light 712 to a white level reading of approximately 0.9 via the variable autotransformer. The transmitted light under the sample stage should be turned off or covered with a piece of light-blocking black art paper placed over the three (3) inch by three (3) inch opening 722.

[0436] The analyst is now prompted to use the detection window displayed on the computer monitor screen to ensure that the detection threshold is set to an appropriate level for detecting node 222. Typically, the threshold is set at a point (e.g., 127) approximately near the center of the 8-bit grayscale range using the white mode. If necessary, the threshold level can be adjusted up or down so that the resulting detected binary region will optimally include the node 222 displayed in the acquired image.

[0437] After the algorithm automatically performs several binary image processing steps on the binary region of the detected node 222, the analyst will be given the opportunity to recheck the node detection and correct any errors. The analyst can press the "control" and "b" combination simultaneously to recheck the node detection against the acquired grayscale image below. If necessary, the analyst can select from a set of binary editing tools (e.g., drag, reject, etc.) to make any fine adjustments. If care is taken to ensure proper illumination and detection in the previous steps, little or no correction is needed at this point.

[0438] Next, the analyst is prompted to turn off the incident annular fluorescent lamp 712 and turn on the substage transmitted light or remove the light shield. The substage transmitted light is adjusted to a white level reading of about 0.95 by the LED power controller. At this point, the image focus can be optimized for the open area of ​​the material 200 including the opening 221 (such as the first feature area 220).

[0439] After additional manipulation of the resulting separate binary image for openings 221, the algorithm will prompt the analyst to recheck the opening 221 detection against the base grayscale image. If necessary, the analyst can select from a set of binary editing tools (e.g., drag, reject, etc.) to make any fine-tuning.

[0440] The algorithm will then automatically take the measurements and output the data to a specified EXCEL spreadsheet file.

[0441] After the data transfer, the algorithm will direct the automated stage to move to the next field of view, and the process of turning on the incident annular fluorescent lamp 712 and blocking the transmitted substage lamp will begin again. This process will be repeated four times so that each single sample replicate will have five sets of data from five separate field of view images.

[0442] After the analysis is complete, after the measurement and data transfer has occurred, the following measurement parameter data will be in the EXCEL file:

[0443] Opening area percentage

[0444] Node density (number per square meter)

[0445] Node spacing (mm)

[0446] Node size (a histogram representing the area in mm 2 , a histogram represents the equivalent circle diameter in mm)

[0447] Opening size (a histogram representing the area in mm 2 , a histogram represents the equivalent circle diameter in mm)

[0448] Hole roundness

[0449] Aperture aspect ratio

[0450] The final sample mean diffusion value is typically based on N=5 analyses from five separate sample subsample replicates. Comparisons of percent open area, pore 221 (aperture) size, and other parameters derived by the algorithm between different samples can be made using Student's T analysis at a 90% confidence level.

[0451] Compression Linearity Test

[0452] Compression linearity was measured using a Kawabata Evaluation System KES Model FB-3 (available from Kato Tech Company).

[0453] The instrument is designed to measure the compressive properties of a material by compressing the sample between two plungers. To measure the compressive properties, the upper plunger is placed onto the sample at a constant rate until the maximum preset force is reached. The displacement of the plunger is detected by a potentiometer. The amount of pressure required to compress the sample (P, gf / cm2) is plotted on the computer screen versus the thickness (displacement) of the material (T, mm). For all materials in this study, the following instrument settings were used:

[0454] Sensitivity = 2 × 5

[0455] Gear (speed) = 1 mm / 50 sec

[0456] Fm group = 5.0

[0457] Stroke selection = max. 5 mm

[0458] Compression area = 2 cm 2

[0459] Time lag = standard

[0460] Maximum compression force = 50gf

[0461] The KES algorithm calculates the following compressed eigenvalues ​​and displays them on the computer screen:

[0462] Compression Linear (LC).

[0463] Five measurements were performed for each sample.

[0464] Residual feces simulant determination test

[0465] As described above, this test method is described as the "Determination of Residual Feces Simulant" test method in U.S. Pat. No. 9,480,609, entitled "Absorbent Articles," the entire contents of which are hereby incorporated by reference to the extent not inconsistent with this document. Generally, urine and BM simulated excreta from a silicone composite mannequin (representing a typical-sized NB-S2 infant) are collected in a biologically relevant-sized and fitted diaper (sample) when the mannequin is in an acceptable supine (sleeping) position. The simulant can represent or simulate flowing breast-fed infant BM. The volumes and flow rates for urine and BM simulated excreta are provided below.

[0466]

[0467]

[0468] The BM mimic on the mannequin can be measured after the waiting time to determine the amount of residual feces on the sample.

[0469] Reference Numbers

[0470] 10 Absorbent products

[0471] 11 Negatives

[0472] 12 Frontal area

[0473] 14. Back waist area

[0474] 16 Crotch area

[0475] 18 longitudinal side edges

[0476] 19 Body-facing surface

[0477] 20 longitudinal side edges

[0478] 21 Perforation Area

[0479] 22 Front edge

[0480] 23 Opening

[0481] 24 Back edge

[0482] 25 Perforation Area

[0483] 26 Outer layer

[0484] 27 Opening

[0485] 28 Body side lining

[0486] 29 Longitudinal axis

[0487] 30 Vertical direction

[0488] 31 Horizontal axis

[0489] 32 Horizontal direction

[0490] 34 Absorption body

[0491] 36 Vertical Edge

[0492] 38 longitudinal edge

[0493] 40 First end edge

[0494] 42 Second end edge

[0495] 44 Absorption components

[0496] 45 Body-facing surface

[0497] 50 Leak-proof flap

[0498] 52 Leak-proof flap

[0499] 54 Elastic waist member

[0500] 56 Body-facing surface

[0501] 60 Leg elastic member

[0502] 62 Leg elastic member

[0503] 64 base part

[0504] 64a Proximal end

[0505] 64b Distal end

[0506] 66 protrusion

[0507] 68 flap elastic member

[0508] 70 Active flap elastic area

[0509] 71 Pinning Area

[0510] 72 first longitudinal side edge

[0511] 74 second longitudinal side edge

[0512] 84 Pinning Area

[0513] 86 Elastic member

[0514] 91 Rear fastener

[0515] 92 Front fastener

[0516] 94 Stretch parts

[0517] 96 Nonwoven carrier or hook seat

[0518] 98 Fastening parts

[0519] 200 Nonwoven Materials

[0520] 210 Fiber Net

[0521] 212 first end portion

[0522] 214 second end portion

[0523] 216 first side portion

[0524] 218 Second side portion

[0525] 220 First perforation area

[0526] 221 Opening

[0527] 222 nodes

[0528] 230 Second perforation area

[0529] 231 Opening

[0530] 240 First Surface

[0531] 241 base plane

[0532] 242 Second Surface

[0533] 250 Distal end portion

[0534] 252 caps (nodes)

[0535] 254 walls (nodes)

[0536] LAA Length of absorbent article

[0537] Length of L1 network

[0538] WAA Width of absorbent article

[0539] W1 Width of the mesh

[0540] TT Transverse direction

[0541] H height (node)

[0542] TW thickness (node ​​wall)

[0543] TC thickness (node ​​cap)

[0544] Example Implementation

[0545] First exemplary embodiment: A nonwoven material comprises: a plurality of fibers, the plurality of fibers forming a nonwoven web having a first surface and a second surface, the first surface being opposite to the second surface on the nonwoven web, wherein the nonwoven web defines a plurality of nodes extending away from a base plane on the first surface, wherein each of the plurality of nodes comprises a wall and a cap, the cap being positioned at a distal end portion of each of the plurality of nodes, the wall being positioned between the first surface and the cap, and wherein a ratio of an average thickness of the wall to an average thickness of the cap is between 1.1:1 and 1.5:1.

[0546] Second example embodiment: The nonwoven material of the first example embodiment, wherein the ratio of the average thickness of the wall to the average thickness of the cap is between 1.1:1 and 1.3:1.

[0547] Third exemplary embodiment: The nonwoven material of the first exemplary embodiment or the second exemplary embodiment, wherein the average thickness of the wall is not less than four hundred and twenty-five microns and not greater than four hundred and seventy-five microns.

[0548] Fourth exemplary embodiment: The nonwoven material of any one of the first to third exemplary embodiments, wherein the average thickness of the cap is not less than three hundred and forty microns and not more than four hundred microns.

[0549] Fifth exemplary embodiment: The nonwoven material of any one of the first to fourth exemplary embodiments, wherein the nonwoven fibrous web has a Compression Linearity greater than between 0.9 and 1.1 as determined by the Compression Linearity Test Method.

[0550] Sixth exemplary embodiment: The nonwoven material of any one of the first to fifth exemplary embodiments, wherein at least a majority of the plurality of nodes have an anisotropy value between 0.92 and 1.1 as determined by the Nodal Analysis Test Method.

[0551] Seventh exemplary embodiment: An absorbent article comprising: a nonwoven material as described in any one of the first to sixth exemplary embodiments; an outer cover; and an absorbent body, wherein the absorbent body is positioned between the nonwoven material and the outer cover, wherein the amount of residual feces on the nonwoven material after being contaminated with feces simulant is less than about 2.0 grams as measured according to the residual feces simulant test method.

[0552] Eighth exemplary embodiment: A nonwoven material as described in any of the first to seventh exemplary embodiments, wherein the wall extends a certain height between the first surface and the distal end portion of each of the plurality of nodes, and the ratio of the average height of the nodes to the average thickness of the wall is between 3.2:1 and 2.6:1.

[0553] Ninth exemplary embodiment: The nonwoven material of the eighth exemplary embodiment, wherein the ratio of the average height of the nodes to the average thickness of the walls is about 2.9.

[0554] Tenth exemplary embodiment: A nonwoven material comprising: a plurality of fibers forming a nonwoven web having a first surface and a second surface, wherein the first surface is opposite to the second surface on the nonwoven web, wherein the nonwoven web defines a plurality of nodes extending away from a base plane on the first surface, wherein each of the plurality of nodes comprises a wall located between the first surface and a distal end portion of each of the plurality of nodes, the wall being spaced apart from the first surface by a height of each of the plurality of nodes, and wherein a ratio of an average height of the nodes to an average thickness of the wall is between 3.2:1 and 2.6:1.

[0555] Eleventh exemplary embodiment: The nonwoven material of the tenth exemplary embodiment, wherein the ratio of the average height of the nodes to the average thickness of the walls is between 3:1 and 2.7:1.

[0556] Twelfth exemplary embodiment: The nonwoven material of the tenth exemplary embodiment or the eleventh exemplary embodiment, wherein the average thickness of the wall is not less than four hundred and twenty-five micrometers and not more than four hundred and seventy-five micrometers.

[0557] Thirteenth exemplary embodiment: The nonwoven material of any one of the tenth to twelfth exemplary embodiments, wherein the average height of the nodes is not less than one thousand two hundred microns and not more than four thousand microns.

[0558] Fourteenth exemplary embodiment: The nonwoven material of any one of the tenth to thirteenth exemplary embodiments, wherein the nonwoven fibrous web has a Compression Linearity greater than between 0.9 and 1.1 as determined by the Compression Linearity Test Method.

[0559] Fifteenth exemplary embodiment: The nonwoven material of any one of the tenth to fourteenth exemplary embodiments, wherein at least a majority of the plurality of nodes have an anisotropy value between 0.92 and 1.1 as determined by the Nodal Analysis Test Method.

[0560] Sixteenth exemplary embodiment: An absorbent article comprising: a nonwoven material as described in any one of the tenth to fifteenth exemplary embodiments; an outer cover; and an absorbent body, wherein the absorbent body is positioned between the nonwoven material and the outer cover, wherein the amount of residual feces on the nonwoven material after being contaminated with a feces simulant is less than about 2.0 grams as measured according to the residual feces simulant test method.

[0561] Seventeenth exemplary embodiment: A nonwoven material comprises: a plurality of fibers, wherein the plurality of fibers form a nonwoven web having a first surface and a second surface, wherein the first surface is opposite to the second surface on the nonwoven web, wherein the nonwoven web defines a plurality of nodes extending away from a base plane on the first surface, wherein each of the plurality of nodes comprises a wall located between the first surface and a distal end portion of each of the plurality of nodes, the wall being spaced apart from the first surface by a height of each of the plurality of nodes, and wherein the material has a compression linearity greater than about 0.9 as measured by a compression linearity test method.

[0562] Eighteenth exemplary embodiment: The nonwoven material of the seventeenth exemplary embodiment, wherein the material has a Compression Linearity greater than about 0.9 and less than about 1.1 as determined by the Compression Linearity Test Method.

[0563] Nineteenth exemplary embodiment: The nonwoven material of the seventeenth exemplary embodiment or the eighteenth exemplary embodiment, wherein the material has a Compression Linearity greater than about 0.9 and less than about 1.05 as determined by the Compression Linearity Test Method. < / control>

Claims

1. A nonwoven material comprising: a plurality of fibers, the plurality of fibers forming a nonwoven web having a first surface and a second surface, the first surface being opposite to the second surface on the nonwoven web, wherein the nonwoven web defines a plurality of nodes on the first surface extending away from a base plane, wherein each of the plurality of nodes comprises a wall and a cap, the cap being positioned at a distal end portion of each of the plurality of nodes, the wall being positioned between the first surface and the cap, and Wherein a ratio of an average thickness of the wall to an average thickness of the cap is between 1.1:1 and 1.5:

1.

2. The nonwoven material of claim 1, wherein the ratio of the average thickness of the wall to the average thickness of the cap is between 1.1:1 and 1.3:

1.

3. The nonwoven material of claim 1, wherein the average thickness of the wall is not less than four hundred and twenty-five microns and not more than four hundred and seventy-five microns.

4. The nonwoven material of claim 1, wherein the average thickness of the cap is not less than three hundred and forty microns and not more than four hundred microns.

5. The nonwoven material of claim 1, wherein the nonwoven web has a Compression Linearity between 0.9 and 1.1 as measured by the Compression Linearity Test Method.

6. The nonwoven material of claim 1, wherein at least a majority of the plurality of nodes have an anisotropy value between 0.92 and 1.1 as determined by the Nodal Analysis Test Method.

7. An absorbent article comprising: The nonwoven material according to claim 1; External covering; as well as an absorbent body positioned between the nonwoven material and the outer cover, wherein the amount of residual feces on the nonwoven material after being contaminated with a feces simulant is less than about 2.0 grams as measured according to the Residual Feces Simulant Test Method.

8. The nonwoven material of claim 1 , wherein the wall extends a height between the first surface and the distal end portion of each of the plurality of nodes, and a ratio of an average height of the nodes to an average thickness of the wall is between 3.2:1 and 2.6:

1.

9. The nonwoven material of claim 8, wherein the ratio of the average height of the nodes to the average thickness of the walls is between 3:1 and 2.7:

1.

10. A nonwoven material comprising: a plurality of fibers, the plurality of fibers forming a nonwoven web having a first surface and a second surface, the first surface being opposite to the second surface on the nonwoven web, wherein the nonwoven web defines a plurality of nodes on the first surface extending away from a base plane, wherein each of the plurality of nodes comprises a wall between the first surface and a distal end portion of each of the plurality of nodes, the wall being spaced apart from the first surface by a height of each of the plurality of nodes, wherein a ratio of an average height of the nodes to an average thickness of the walls is between 3.2:1 and 2.6:

1.

11. The nonwoven material of claim 10, wherein the ratio of the average height of the nodes to the average thickness of the walls is between 3:1 and 2.7:

1.

12. The nonwoven material of claim 10, wherein the average thickness of the wall is not less than four hundred and twenty-five microns and not greater than four hundred and seventy-five microns.

13. The nonwoven material of claim 10, wherein the average height of the nodes is not less than 1,200 microns and not more than 1,400 microns.

14. The nonwoven material of claim 10, wherein the nonwoven fibrous web has a Compression Linearity greater than between 0.9 and 1.1 as determined by the Compression Linearity Test Method.

15. The nonwoven material of claim 10, wherein at least a majority of the plurality of nodes have an anisotropy value between 0.92 and 1.1 as determined by the Nodal Analysis Test Method.

16. An absorbent article comprising: The nonwoven material according to claim 10; External covering; as well as an absorbent body positioned between the nonwoven material and the outer cover, wherein the amount of residual feces on the nonwoven material after being contaminated with a feces simulant is less than about 2.0 grams as measured according to the Residual Feces Simulant Test Method.

17. A nonwoven material comprising: a plurality of fibers, the plurality of fibers forming a nonwoven web having a first surface and a second surface, the first surface being opposite to the second surface on the nonwoven web, wherein the nonwoven web defines a plurality of nodes on the first surface extending away from a base plane, wherein each of the plurality of nodes comprises a wall between the first surface and a distal end portion of each of the plurality of nodes, the wall being spaced apart from the first surface by a height of each of the plurality of nodes, wherein the material has a compression linearity greater than about 0.9 as measured by the Compression Linearity Test Method.

18. The nonwoven material of claim 17, wherein the material has a Compression Linearity greater than about 0.9 and less than about 1.1 as determined by the Compression Linearity Test Method.

19. The nonwoven material of claim 17, wherein the material has a Compression Linearity greater than about 0.9 and less than about 1.05 as determined by the Compression Linearity Test Method.

Images