Formation surface with reference lines and method for producing partition network

Abstract

A forming surface includes a wall defining a plurality of channels having discrete feature regions. The wall also includes a reference line having a plurality of features. The forming surface can be used to modify a substrate to include a reference thread grommet. The reference cue leads can be used to register the substrate during slitting of the substrate.

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. Contact between body exudates captured in the article, such as semi-solid fecal material, and the wearer's skin can cause discomfort. Moving body exudates through the liner and away from the wearer's skin can reduce or limit this discomfort.

[0002] Nonwoven materials are subjected to various manufacturing processes to form personal care absorbent articles with nonwoven materials. For example, a roll of nonwoven material can be unrolled and cut to form layers in such articles. Registration can help to accurately cut nonwoven materials from a roll. Some registration systems measure the light passing through the nonwoven material. However, this registration is affected by the openings in the nonwoven material. Therefore, a nonwoven material with features that facilitate the alignment of the nonwoven material will be useful. Summary of the invention

[0003] Generally speaking, the present disclosure relates to a forming surface having reference lines, such as multiple features on one side of the forming surface. The forming surface can be used to form a mesh having multiple openings corresponding to the reference lines. The openings formed by the reference lines can be used to align the cutting of the mesh. The forming surface is particularly suitable for slitting a mesh having multiple channels, each channel having discrete open areas. Gaps between discrete open areas can hinder registration using discrete open areas. In contrast, the openings formed by the reference lines can provide a more consistent reference index relative to the discrete open areas. The mesh made with the forming surface can be incorporated into absorbent articles such as pads, diapers, disposable underwear, etc.

[0004] In an example embodiment, the forming surface includes a drum having a plurality of channels spaced apart in an axial direction on the drum. The plurality of channels include a first channel and a second channel. The first channel includes one or more discrete feature areas. The second channel includes one or more discrete feature areas. The drum also includes a reference line. The reference line includes a plurality of features distributed around the drum in a circumferential direction. The features of the reference line are spaced apart from the first channel in the axial direction.

[0005] In another example embodiment, the forming surface includes a wall having a plurality of channels spaced apart in a transverse direction on the wall. The plurality of channels include a first channel and a second channel. The first channel includes one or more discrete feature areas spaced apart in a longitudinal direction on the wall. The second channel includes one or more discrete feature areas spaced apart in a longitudinal direction on the wall. The wall also includes a reference line. The reference line includes a plurality of features distributed on the wall in the longitudinal direction. The features of the reference line are spaced apart from the first channel in the transverse direction.

[0006] In another exemplary embodiment, the nonwoven material includes a plurality of fibers that form a nonwoven web that defines a transverse direction and a longitudinal direction. The transverse direction and the longitudinal direction are perpendicular. The nonwoven web includes a plurality of discrete feature area channels and a reference line. The plurality of discrete feature area channels are spaced apart in the transverse direction. The plurality of discrete feature area channels include a first channel and a second channel. The first channel includes one or more discrete feature areas, and the second channel includes one or more discrete feature areas. The reference line includes a plurality of features distributed in the longitudinal direction. The features of the reference line are spaced apart from the first channel in the transverse direction.

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

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

[0009] Figure 1 is a process diagram depicting a manufacturing method including forming a partitioned network according to example aspects of the present disclosure.

[0010] Figure 2 Such as from Figure 1 A top plan view of the surface of a pattern roll lying flat on a pattern roll used in an apparatus.

[0011] Figure 3 is such as can be used Figure 1 A partial top plan view of a drum having a forming surface in an apparatus of FIG.

[0012] Figure 4 It is taken from Figure 2 Detailed view of the first pattern area of ​​the pattern roller.

[0013] Figure 5 It is taken from Figure 2 Detailed view of the second pattern area of ​​the pattern roller.

[0014] Figure 6 is available Figure 1 A top view of a portion of a modified substrate formed by a device, and the modified substrate includes three channels having a plurality of first discrete open areas and a plurality of second discrete open areas.

[0015] Figure 7 is a top plan view of a nonwoven material according to an example embodiment of the present disclosure.

[0016] Figure 8 Yes Figure 1 An image of a detailed view of the nodes of an example nonwoven material.

[0017] Fig. 9 is a perspective view of an example equipment and facility for performing the "Material Sample Analysis Test Method" as described herein.

[0018] Repeated use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0019] In one embodiment, the present disclosure is generally directed to a forming surface having features for improving the registration of a nonwoven substrate modified by the forming surface. It should be understood by those of ordinary skill in the art that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0020] When introducing elements of the present disclosure or preferred embodiments thereof, the articles "a", "an", "the" and "said" are intended to indicate that there are one or more of the elements. As used herein, the term "includes / including" is intended to be inclusive in a manner similar to the term "comprising". Similarly, the term "or" is generally intended to be inclusive (i.e., "A or B" is intended to mean "A or B or both"). Approximate language as used herein throughout the specification and claims is used to modify any quantitative representation that is permitted to vary without resulting in a change in the basic function associated therewith. Therefore, values ​​modified by one or more terms such as "about", "approximately" and "substantially" are not limited to the exact values ​​specified. In at least some cases, approximate language may correspond to the accuracy of the instrument used to measure the value. For example, approximate language may refer to within a limit of ten percent (10%).

[0021] definition :

[0022] The term "absorbent article" herein refers to an article that can be placed against or close to the wearer's body (i.e., adjacent to the body) to absorb and contain various liquid, solid and semi-solid exudates discharged from the body. Such absorbent articles as described herein are intended to be discarded after a limited period of use, rather than being washed or otherwise restored for reuse. It should be understood that the present disclosure is applicable to various disposable absorbent articles, including but not limited to diapers, diapers, training pants, older children's pants, swim trunks, feminine hygiene products (including but not limited to menstrual pads or menstrual pants), incontinence products, medical garments, surgical pads and bandages, other personal care or health care garments, etc., without departing from the scope of the present disclosure.

[0023] The term "acquisition layer" herein refers to a layer capable of accepting and temporarily holding liquid body exudates to decelerate and diffuse a gush or burst of liquid body exudates and subsequently release the liquid body exudates therefrom into another layer or layers of the absorbent article.

[0024] The term "bonded" or "coupled" herein refers to the joining, adhering, connecting, attaching, etc. of two elements. Two elements will be considered to be bonded or coupled together when they are joined, adhered, connected, attached, etc. directly to each other or indirectly to each other, such as when each element is directly bonded to an intermediate element. The joining or coupling of one element to another element can be performed by continuous or intermittent bonding.

[0025] The term "carded web" refers herein to a web containing natural or synthetic staple length fibers having a fiber length generally less than about 100 mm. The staple fiber bundles may be subjected to an opening process to separate the fibers, which are then fed to a carding process, where the fibers are separated and carded to align them longitudinally (machine direction), after which the fibers are deposited on a moving wire for further processing. Such webs are typically subjected to a bonding process, such as thermal bonding using heat and / or pressure. Additionally or alternatively, the fibers may be subjected to an adhesion process to bind the fibers together, for example, by using a powder adhesive. The carded web may be subjected to fluid entanglement, such as hydroentanglement, to further entangle the fibers and thereby improve the integrity of the carded web. Since the fibers are aligned longitudinally, the carded web, once bonded, will typically have a longitudinal strength (machine direction strength) greater than the cross machine direction strength.

[0026] The term "film" herein refers to thermoplastic films produced using extrusion and / or forming processes such as cast film or blown film extrusion processes. This term includes apertured films, slit films, and other porous films that constitute liquid transfer films, as well as films that do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.

[0027] The terms "fluid entanglement" and "fluid entangled" generally refer to a method of formation for further increasing the degree of fiber entanglement within 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 a fiber nonwoven web on some types of formation or carrier surfaces, which have some permeability for the pressurized fluid that impacts. The pressurized fluid stream (usually multiple streams) is then directed to the surface of the nonwoven web relative 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 each other on a formation / carrier surface and subjected to a pressurized fluid, the result is generally desired that some fibers of at least one web are pressed into an adjacent web or layer, thereby causing fiber entanglement between two surface interfaces, so that due to increased fiber entanglement, the web / layer is bonded or joined together. 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 undergoing the fluid entanglement process, the type of fluid used (liquid, such as water, stream or gas, such as air), fluid pressure, number of fluid streams, process speed, fluid residence time, and the porosity of one or more webs / other layers and the forming / support surface. One of the most common fluid entanglement processes is known as hydroentanglement, which is a process well known to those of ordinary skill in the art of nonwoven webs. Examples of fluid entanglement processes can be found in U.S. Pat. No. 4,939,016 to Radwanski et al., U.S. Pat. No. 3,485,706 to Evans, and U.S. Pat. Nos. 4,970,104 and 4,959,531 to Radwanski, each of which is incorporated herein by reference in its entirety for all purposes.

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

[0029] The term "hydrophilic" herein refers to fibers or fiber surfaces that are wetted by aqueous liquids in contact with the fibers. The degree of wettability of a material can also be described in terms of the contact angle and surface tension of the liquids and materials involved. Equipment and techniques suitable for measuring the wettability of a particular fiber material or fiber material blend can be provided by a Cahn SFA-222 Surface Force Analyzer System, or a substantially equivalent system. When measured using this system, fibers having a contact angle of less than 90 are identified as "wettable" or hydrophilic, and fibers having a contact angle of greater than 90 are identified as "non-wettable" or hydrophobic.

[0030] The term "liquid-impermeable" herein refers to one or more layers of laminated materials wherein, under normal use conditions, liquid body exudates such as urine will not pass through the layer or laminated material in a direction generally perpendicular to the plane of the layer or laminated material at the point of liquid contact.

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

[0032] The term "meltblown" herein refers to fibers formed by extruding molten thermoplastic material through a plurality of fine, usually circular die capillaries as molten strands or filaments into a converging high velocity heated gas (e.g., air) stream, which attenuates the filaments of molten thermoplastic material to reduce their diameter, which may be a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and deposited on a collecting surface to form a web composed of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin et al., which is incorporated herein by reference. Meltblown fibers are microfibers that may be continuous or discontinuous, are typically less than about 0.6 denier, and may be tacky and self-adhesive when deposited on a collecting surface.

[0033] The term "nonwoven" herein refers to a material or web of material that is formed without the aid of a fabric weaving or knitting process. The material or web of material may have a structure of individual fibers, filaments or threads (collectively referred to as "fibers") that may be interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven materials or webs may be formed by many processes, such as, but not limited to, meltblown processes, spunbond processes, carded web processes, and the like.

[0034] The term "flexible" herein refers to materials that are compliant and will readily conform to the general shape and contours of the wearer's body.

[0035] The term "spunbond" herein refers to small diameter fibers formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinning head having a circular or other configuration and then rapidly reducing the diameter of the extruded filaments by conventional processes such as draw-off drawing and the processes described in the following patents, namely, U.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No. 3,502,538 to Peterson, and U.S. Pat. No. 3,542,615 to Dobo et al., each of which is incorporated herein by reference in its entirety. Spunbond fibers are substantially continuous and generally have an average denier greater than about 0.3, and in one embodiment between about 0.6, 5 and 10 and about 15, 20 and 40. Spunbond fibers are generally not tacky when deposited onto a collecting surface.

[0036] The term "superabsorbent" herein refers to a water-swellable, water-insoluble organic or inorganic material that is capable of absorbing at least about 15 times its weight, and in one embodiment at least about 30 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride under most favorable conditions. Superabsorbent materials can be natural, synthetic, and modified natural polymers and materials. Additionally, superabsorbent materials can be inorganic materials such as silica gel or organic compounds such as cross-linked polymers.

[0037] The term "thermoplastic" refers herein to a material that is softenable and shapeable when exposed to heat and that substantially returns to a non-softened state when cooled.

[0038] The term "user" or "caregiver" refers herein to a person who fits an absorbent article such as, but not limited to, a diaper, diapers, training pants, older children's pants, incontinence products or other absorbent articles around the wearer of one of these absorbent articles. The user and the wearer may be the same person.

[0039] Formation method and equipment:

[0040] Figure 1 An example method and apparatus 10 for making a partitioned web 12 is depicted in FIG. As will be described herein, the method 10 for making a partitioned web 12 may include a fluid entanglement process, however, it will be appreciated that other techniques for modifying the substrate 14 to provide the partitioned web 12 are within the scope of example aspects of the present disclosure. Figure 1As shown, method 10 may include providing a substrate 14. Substrate 14 may include a plurality of fibers. Substrate 14 may be formed by a variety of web forming techniques, such as, but not limited to, wet-laid, foam-laid, or carded processes. Figure 1 In the exemplary embodiment shown, substrate 14 may be formed by a wet-laid process in which a fiber and water slurry 16 is deposited from a drum 18 onto a precursor forming surface 20. Figure 1 The precursor forming surface 20 shown may be a precursor material, such as a spunbond web. However, it is also contemplated that the fiber and water slurry 16 may be deposited directly on a belt, screen, or other surface providing the precursor forming surface 20.

[0041] In the case where the precursor forming surface 20 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 having 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 are 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, entitled “Fluid-entangled laminate webs having hollow projections and a process and apparatus for making the same” by Scott Kirby et al., the entire contents of which are hereby incorporated by reference.

[0042] In further exemplary embodiments according to the present disclosure, the precursor forming surface 20 may not be a precursor web, and the method 10 may further include combining the support web with the substrate 14 using a fluid entangling device 46, the function of which is described in more detail below. In such exemplary embodiments, the support web may be similar to the precursor web described above in terms of fiber content and construction. Figure 3Such methods are described in more detail.

[0043] As mentioned, substrate 14 can be formed according to a variety of techniques (e.g., wet-laid, foam-laid, or combing processes). Substrate 14 may 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. Substrate 14 may be formed by typical polyolefin fibers or any suitable polyester fibers. Such fibers may 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. Fibers may have a typical staple length of less than one hundred millimeters (100 mm). In some exemplary embodiments, the fibers of substrate 14 may be similar to the fibers described in Scott Kirby et al., U.S. Patent No. 9,327,473, regarding protruding web 16.

[0044] The substrate 14 may be transferred in the machine direction by a belt 24 driven by a drive roller 26 or other transfer means known to those of ordinary skill in the art. If the substrate 14 is formed by a wet-laid process, the substrate 14 may be dried using a dryer 28 by known techniques.

[0045] In an example embodiment including fluid entanglement, the method can include modifying substrate 14 using fluid entanglement equipment 32. Whether done offline or online, substrate 14 can be transferred to a pattern wall or surface 34. Pattern surface 34 can be the surface of a textured drum 36, such as a forming screen. A portion of an exemplary pattern surface 34 is described in more detail below and is described in detail below. Figure 2 , Figure 3 , Figure 4 and Figure 5 The texturing roller 36 may be as shown in FIG. Figure 1 The textured roller 36 is shown rotating and can be driven by any suitable drive mechanism (not shown) known to those of ordinary skill in the art (such as a motor and gears). The material forming the textured roller 36 can be many suitable materials commonly used for such forming rollers, including but not limited to metal plates, plastics and other polymer materials, rubber, etc. The pattern surface 34 can be perforated to allow fluid to pass through the textured roller 36 and modify the substrate 14 by fluid entanglement. In an exemplary embodiment, the pattern surface 34 can be removably mounted on and above the optional porous inner roller shell 38, so that different pattern surfaces 34 can be used for different final product designs.

[0046] The porous inner drum shell 38 can be connected to a fluid removal system 40 that helps pull the entangling fluid through the pattern surface 34 and, in some patterns of the pattern surface 34, also helps pull the fibers of the substrate 14 through the pattern surface 34 to form a three-dimensional structure on the modified substrate 14', if desired. The porous inner drum shell 38 can also serve as a blocking mechanism to prevent the fibers from moving further downward into the fluid removal system 40 and other parts of the equipment, thereby reducing contamination of the equipment. The porous inner drum shell 38 can rotate in the same direction and at the same speed as the texturing drum 36. In addition, in order to further control the modified substrate 14'

[0047] The height of any three-dimensional feature on the inner drum shell 38 can change the base plane 42 (in Figure 4 In an exemplary embodiment, the spacing between the base plane 42 of the pattern surface 34 and the outer surface of the inner drum shell 38 can be in a range between about zero millimeters (0 mm) and about five millimeters (5 mm). Other ranges can be used depending on the specific end-use application and the desired characteristics of the modified substrate 14' that will ultimately form the partitioned web 12.

[0048] The fluid entangling apparatus 32 may include a plurality of high pressure fluid jets (not shown) to discharge a plurality of pressurized fluid streams 44 from the fluid entangling device 46. In some exemplary embodiments, there may be more than one fluid entangling device 46. The most common fluid in this regard is known as hydroentanglement or hydroentanglement technology, which uses pressurized water as the fluid for entangling. These fluid streams 44 (preferably water) may be directed toward the substrate 14 on the pattern surface 34 and may further entangle the fibers within the substrate 14 and / or the precursor forming surface 20 (in this case, the precursor forming surface is the underlying web of material). As will be described in more detail below, the fluid streams 44 may modify the substrate 14 to provide a modified substrate 14'.

[0049] The entangling fluid stream 44 of the fluid entangling device 46 may be ejected from an ejector via a jet group or jet belt (not shown) comprising one or more rows of pressurized fluid jets having small openings of diameter typically between eight hundredths of a millimeter (0.08 mm) and fifteen hundredths of a millimeter (0.15 mm) and spacing in the transverse direction of about half a millimeter (0.5 mm). The pressure in the jets may be between about five (5) bar and about four hundred (400) bar, but is typically less than two hundred (200) bar except for heavier nonwoven materials and when fibrillation is desired. Other ejector sizes, spacings, numbers of ejectors, and ejection pressures may be used depending on the particular end application. Such fluid entangling devices 66 are well known to those of ordinary skill in the art and are commercially available from, for example, Fleissner of Germany and Andritz-Perfojet of France.

[0050] The fluid entangling device 46 can have jet orifices positioned at 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 pattern surface 34, 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 40, and the speed at which the equipment is operated.

[0051] exist Figure 1 In the exemplary embodiment shown, the fluid entangling device 46 can be 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 the description of hydroentanglement equipment in Honeycomb Systems, Inc., Biddeford, Me., entitled "Rotary Hydraulic Entanglement of Nonwovens", which is reproduced from INSIGHT'86 INTERNATIONAL ADVANCED FORMING / BONDING Conference, the contents of which are incorporated herein by reference for all purposes.

[0052] Although described in the context of fluid entangling using fluid entangling device 46, it should be understood that in alternative exemplary embodiments, other suitable conventional methods and mechanisms may be used to form features of modified substrate 14', such as nodes 74, openings 76, and connecting ties 78 ( Figure 6 ). For example, features of modified substrate 14' may be formed by embossing, perforating, or otherwise appropriately treating substrate 14.

[0053] The rotational speeds of the drive roller 26 and the texturing roller 36 can be set at various speeds relative to each other. In some example embodiments, the rotational speeds of the drive roller 26 and the texturing roller 36 can be the same. In other example embodiments, the rotational speeds of the drive roller 26 and the texturing roller 36 can be different. For example, in some embodiments, the speed of the texturing roller 36 can be less than the speed of the drive roller 26 to provide an overfeed of the substrate 14 on the pattern surface 34 on the texturing roller 36. This overfeed can be used to provide different properties in the modified substrate 14'.

[0054] like Figure 3 As shown, in certain example embodiments, the pattern surface 34 can be formed on the texturing roller 36, for example, by stamping, machining, etc. However, it should be understood that other mechanisms can be used to form the pattern surface 34. For example, a perforated belt or wire (not shown) can be used, which includes holes or three-dimensional features formed at appropriate locations in the belt or wire. Alternatively, a flexible rubber belt (not shown) can be used, which is impermeable to the pressurized fluid entanglement flow except at the location of the holes. 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.

[0055] After the fluid entanglement device 32 generates fluid entanglements from the fluid entanglement stream 44, the modified substrate 14' becomes a hydroentangled web. The method 10 may also include removing the modified substrate 14' from the pattern surface 34 and drying the hydroentangled web to provide a three-dimensional nonwoven material. The drying of the material may be performed by techniques known to those of ordinary skill in the art. In an exemplary embodiment where the precursor web includes binder fibers, the drying of the nonwoven material may activate the binder fibers. The activated binder fibers may help maintain the three-dimensionality of the modified substrate 14' by helping to maintain the geometry of the features extending away from the material.

[0056] As is the case with the manufacture of various materials, e.g. Figure 1 As shown, the modified substrate 14' may also be slit by a slitting device 15. It is common to manufacture materials (such as the fluid-entangled modified substrate 14' described herein) to be larger than the width to be used in various end-use applications. Therefore, the modified substrate 14' may be slit by slitting techniques and equipment known to those of ordinary skill in the art to provide a plurality of webs 12 ( Figure 1 1 ). Web 12 may be slit in-line during manufacture of modified substrate 14', or may be slit in an off-line process, or subsequently as part of another manufacturing asset seeking to utilize a certain width of modified substrate 14', and thus utilize one of webs 12. For purposes of further description herein based on the features of web 12, web 12 may also be referred to as a partitioned web 12.

[0057] The modified substrate 14' may include regions having different morphological features. In various example embodiments, the morphological features may include one or more of the following: discrete perforated regions; discrete recessed and / or raised regions, such as having recessed domains and / or hollow protrusions (such as those formed by embossing or other such web modification processes); discrete openings (whether formed integrally during web formation or by a post-web formation process); and / or discrete filled protrusions extending above or below the generally flat surface of the web, depending on orientation. As a specific example, the modified substrate 14' may include a first feature region 70 having one or more first features and a second feature region 72 having one or more second features. In Figure 1 In the example embodiment shown, the features in the first feature region 70 can be openings extending through the modified substrate 14', and the features in the second feature region 72 can also be openings extending through the modified substrate 14'. The openings in the first feature region 70 and the second feature region 72 can help transfer fluids (such as body exudates) through the modified substrate 14'. However, although described in more detail below in the context of openings, it should be understood that in other example embodiments, each of the first feature region 70 and the second feature region 72 can include one or more alternative structural features. For example, each of the first feature region 70 and the second feature region 72 can include one or more of embossing, protrusions, depressions, perforations, protrusions, depressions, openings, etc. Therefore, each of the first feature region 70 and the second feature region 72 can include discrete structural features on the modified substrate 14', and the structural features in the first feature region 70 can be spaced apart from the structural features in the second feature region 72 on the modified substrate 14'. In certain example embodiments, the size and / or formation of structural features in the first feature region 70 may be different than structural features in the second feature region 72. Thus, for example, the structural features in the first feature region 70 may provide different performance characteristics than the structural features in the second feature region 72. Furthermore, each of the first feature region 70 and the second feature region 72 may be individually arranged, sized, shaped, and / or configured to provide respective performance characteristics therein.

[0058] As discussed in more detail below, the surface 34 may also include features for facilitating the slitting of the modified substrate 14'. In addition, as described below, the modified substrate 14' may include discrete feature areas, such as first areas 70 and second areas 72, spaced apart on the modified substrate 14'. For simplicity, the features of the first areas 70 and second areas 72 will be referred to herein as openings, but this description should not be interpreted as limiting such features of the first areas 70 and second areas 72 to only openings. Due to the arrangement of the first areas 70 and second areas 72 on the modified substrate 14', there may be gaps or spaces across the lateral direction 23 between the discrete open areas 70, 72 on the modified substrate 14'.

[0059] In certain example embodiments, the position of the slitting between the discrete apertured regions 70, 72 may be critical to the conversion and the performance of the resulting slitting substrate, for example, to ensure that the substrate has a zone or channel of sufficient width on either side of the discrete apertured regions 70, 72 after slitting. Controlling the slitting process at high speeds using a registration system by identifying features of the apertured regions 70, 72 and adjusting the relative positions of the slitting blades and the modified substrate 14' may be a challenge. For example, features of the apertured regions may not be suitable for identification by the registration system at the desired processing speed, or such features of the apertured regions may have variability, which makes consistent identification difficult. Alternatively, ensuring that such features of the apertured regions 70, 72 include features suitable for high-speed registration may reduce the desired performance of the regions 70, 72 for their primary functional purpose.

[0060] Therefore, with such systems, tracking the relative position of the modified substrate 14' and the knife used to slit the modified substrate 14' between the discrete open areas 70, 72 on the modified substrate 14' (i.e., at the gap between the discrete open areas 70, 72 on the modified substrate 14') may be difficult, especially at the desired conversion speed. These systems may result in the width of the zone of the channel of the slit substrate on either side of the discrete open areas 70, 72 being too small or too large.

[0061] Additionally, post-processing the modified substrate 14' to include registration features (such as application of colored or UV sensitive inks, bonding to form identifiable bond areas, etc.) can also lead to undesirable results. For example, inconsistent placement of post-process registration features relative to the aperture areas can also lead to poor alignment between the actual relative positions of the slitting blade and the modified substrate 14' and the desired alignment between the slitting blade and the modified substrate 14'. Such conditions can also lead to the width of the area of ​​the channel of the slitting substrate on either side of the discrete aperture areas being too small or too large.

[0062] Thus, as described in more detail below, the pattern surface 34 may include one or more dedicated reference features, such as reference lines 90 ( Figure 2), which reference line can be used to form a plurality of dedicated reference features 96 ( Figure 6 ). Such dedicated reference features can be apertures or protrusions, whether discrete protrusions separated from each other or a continuously extending protrusion. For simplicity, feature 96 will be referred to as aperture 96 in this article, but this description should not be interpreted as limiting such feature 96 to apertures. The registration system can use dedicated reference apertures 96 to control the slitting process. Since the dedicated reference apertures 96 are formed when the material is formed, and more specifically, when the regions 70, 72 are formed, the distance between the dedicated reference apertures 96 and the regions 70, 72 is fixed, and there is no room for the error of the post-processing registration feature. In addition, the use of dedicated reference apertures 96 to register the desired cutting position allows the design of regions 70, 72 based only on the performance of regions 70, 72 to obtain the desired function. In this way, the reference apertures 96 can therefore advantageously provide accurate registration of the nonwoven web with discrete aperture areas while allowing excellent performance of the material relative to the functions of regions 70, 72.

[0063] Despite Figure 6 2 as alternating regions 70, 72 in both the longitudinal direction 22 and the transverse direction 23, but it will be appreciated that this is merely one example configuration of a substrate 14' for which the techniques of the present disclosure would be useful. Alternative configurations contemplated by the present disclosure include those in which the regions 70, 72 may be continuous or discontinuous in the longitudinal direction 22, but do not alternate in the longitudinal direction 22. Instead, the regions 70, 72 may be maintained within discrete channels separated across the width of the modified substrate 14' in the transverse direction 23. In such a configuration, spaces may be provided between laterally adjacent regions 70, 72. In further contemplated example embodiments, the modified substrate 14' may include only a single type of region 70, 72 (whether continuous or discontinuous in the longitudinal direction 22), such single region type being disposed in spaced-apart channels, such as Figure 6 shown.

[0064] Turning the discussion back to the exemplary method for modifying substrate 14 in a fluid entanglement process, it is noted that Figure 2 . Figure 2 A top plan view of a portion of a pattern surface 34 is shown, wherein for clarity, the pattern surface 34 is shown in a flat orientation. The pattern surface 34 may include a plurality of pattern channels 48, 48', 48". The pattern surface 34 includes at least two pattern channels 48, 48'. For example, Figure 2 The illustrated exemplary embodiment includes three pattern channels 48, 48', 48". The pattern channels 48, 48', 48" may include at least two pattern regions 50, 52. For example, each pattern channel 48, 48', 48" may each include a first pattern region 50 and a second pattern region 52. Figure 2As shown, the pattern channels 48, 48', 48" can be configured so that the first pattern areas 50 and the second pattern areas 52 are adjacent to each other in the longitudinal direction 22 and are repeated in an alternating manner, so that each first pattern area 50 is adjacent to two second pattern areas 52 in the longitudinal direction 22, and so that each second pattern area 52 is adjacent to two first pattern areas 50 in the longitudinal direction 22. It is also contemplated and within the scope of the example aspects of the present disclosure that one or more pattern channels 48, 48', 48" may include more than two different pattern areas 50, 52.

[0065] The first pattern region 50 may include different properties than the second pattern region 52. The different properties between the first pattern region 50 and the second pattern region 52 may provide different substrate properties in the modified substrate 14' formed by the pattern surface 34 and related to the processing properties of the modified substrate 14'. As an example, the first pattern region 50 may produce a first region 70 (at Figure 6 The opening area of ​​the first region is larger than the second region 72 (in Figure 6 For purposes herein, "open area" refers to the amount of open area as measured by the analytical techniques in the "Material Sample Analysis Test Methods" described in the "Test Methods" section of this document. Other substrate properties that may differ between the first area 70 and the second area 72 of the modified substrate 14', which are generated by the first pattern area 50 and the second pattern area 52, respectively, can provide different web handling characteristics of the modified substrate 14' and can include differences in properties such as basis weight, density, tensile strength, bulk thickness, surface texture, and / or urine wicking properties.

[0066] Figure 4 Provided by Figure 2 Detailed portion of a first pattern region 50 of the pattern surface 34 of a first pattern channel 48 of the pattern surface 34 of an example pattern surface 34 . Figure 4 The portion of the first pattern area 50 in Figure 2 In the example embodiment, the first pattern area 50 of the pattern surface 34 may include a plurality of formed holes 54, a plurality of protrusions 56, and a plurality of connecting lace forming areas 69. The connecting lace forming area 69 may be disposed between the plurality of formed holes 54 and the plurality of protrusions 56, and may generally be an area of ​​the pattern surface 34 that is neither a formed hole 54 nor a protrusion 56.

[0067] As discussed in more detail below, the geometry, spacing and orientation of the shaped holes 54, protrusions 56 and connecting lacing shaped areas 69 can correspond to the shaping of the nodes 74, open holes 76 and connecting lacing 78' in the modified substrate 14'. The alignment and orientation of these shaped holes 54, protrusions 56 and connecting lacing areas 69 can provide beneficial properties such as tensile strength and desired necking for processability of the material while still allowing for a highly open material, thereby achieving beneficial fluid handling properties. Although relative to Figure 4 The particular pattern of the first pattern area 50 of the pattern surface 34 in describes such alignment and orientation, but it should be understood that example aspects of the present disclosure also contemplate other patterns for the first pattern area 50 of the pattern surface, and that such described alignment and orientation may be achieved in other patterns.

[0068] like Figure 4 As shown, the first pattern region 50 of the pattern surface 34 may include a plurality of shaped holes 54 that correspond to the shape and pattern of the nodes 74 of the modified substrate 14'. Figure 4 The shaped holes 54 shown are 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 54 shapes include, but are not limited to, ovals, crosses, squares, rectangles, diamonds, hexagons, and other polygons.

[0069] The forming holes 54 may be arranged in a plurality of rows 55 ( Figure 4 ), the channels extend in the longitudinal direction 57 of the pattern surface 34. For example, if the pattern surface 34 is part of a cylindrical texturing drum 36, the longitudinal direction 57 of the pattern surface 34 can correspond to the circumferential direction. The columns 55 of forming holes 54 can be formed by longitudinally adjacent forming holes 54. The forming holes 54 are longitudinally adjacent if a straight line 63 drawn between the centers of the forming holes 54 does not pass through any protrusion 56 or any other forming hole 54 and forms an angle with respect to the longitudinal direction 57 that is less than forty-five degrees (45°), such as less than about twenty degrees (20°), such as less than about ten degrees (10°), such as less than about five degrees (5°). In Figure 4, because the angle formed by the straight line 63 relative to the longitudinal direction 57 is zero degrees (0°). Similarly, the forming holes 54 may also be arranged in columns (also referred to as "rows" in such arrangements) extending in the transverse direction 61 of the pattern surface 34 if a straight line drawn between the centers of the forming holes 54 does not pass through any protrusion 56 or any other forming hole 54 and forms an angle of less than forty-five degrees (45°), such as less than about twenty degrees (20°), such as less than about ten degrees (10°), such as less than about five degrees (5°) relative to the transverse direction 61 of the pattern surface 34. The orientation of the forming holes 54 in the pattern surface 34 determines the orientation of the nodes 74 in the modified substrate 14' because the fibers from the substrate 14 are pushed into the forming holes 54 by the fluid jets 44 during the above-mentioned fluid entanglement.

[0070] In some example embodiments, the first pattern area 50 of the pattern surface 34 may preferably have at least three (3) columns 55 of formed holes 54 extending substantially in the longitudinal direction 57, at least four (4) columns 55, at least five (5) columns 55, at least six (6) columns 55, or at least seven (7) or eight (8) columns 55. The length of the columns 55 of formed holes 54 extending substantially in the longitudinal direction 57 of the pattern surface 34 may span the entire longitudinal length of the first pattern area 50 of the pattern surface 34, or may only form a portion of the length of the pattern surface 34 in the longitudinal direction 57 (such as a portion of the circumference of the pattern surface 34).

[0071] The pattern surface 34 may also include a plurality of protrusions 56 extending away from the base plane 42 of the pattern surface 34. Figure 4 As shown, the protrusions 56 can be configured as pyramidal geometries, however, the protrusions 56 can have a variety of other geometries, cross-sectional shapes, spacings, and orientations. In some example embodiments, the cross-sectional areas of the plurality of protrusions 56 can decrease as the protrusions 56 extend further away from the base plane 42 of the pattern surface 34. For example, Figure 4 The pyramidal shape of the illustrated protrusion 56 decreases in area as the protrusion 56 extends further away from the base plane 42 of the pattern surface 34 .

[0072] The protrusions 56 in the first pattern region 50 of the pattern surface 34 may form openings 76 in the first region 70 of the modified substrate 14' (at Figure 6 ), because during the above-mentioned fluid entanglement, the fibers from the substrate 14 are pushed by the fluid jets 44 around the protrusions 56 in the first pattern area 50. Therefore, the orientation, density and size of the protrusions 56 in the first pattern area 50 of the pattern surface 34 can correspond to the orientation, density and size of the openings 76 in the first area 70 of the modified substrate 14'.

[0073] The protrusions 56 may be arranged in a plurality of rows 59 ( Figure 4 The channels extend in the longitudinal direction 57 of the pattern surface 34 in three columns 59 marked in FIG. The columns 59 of protrusions 56 may be formed by a series of connected longitudinally adjacent protrusions 56. The protrusions 56 are longitudinally adjacent, wherein a straight line (such as Figure 4 The protrusions 56 may be laterally adjacent if a straight line drawn between the centers of the protrusions 56 does not pass through any of the forming holes 54 or any other protrusions 56 and spans only a single connecting lace forming area 69 and forms an angle of less than about forty-five degrees (45°) relative to the longitudinal direction 57 of the pattern surface 34. The center of the protrusion 56 may be the geometric center of the protrusion 56. Similarly, the protrusions 56 may also be laterally adjacent if a straight line drawn between the centers of the protrusions 56 does not pass through any of the forming holes 54 or any other protrusions 56 and spans only a single connecting lace forming area 69 and forms an angle of less than forty-five degrees (45°) relative to the transverse direction 61 of the pattern surface 34.

[0074] In some exemplary embodiments, on the lateral sides of the first pattern area 50, the pattern surface 34 may include one or more areas 60a, 60b that are substantially free of protrusions 56. The areas 60a, 60b may correspond to the side areas 80a, 80b (in the modified substrate 14'). Figure 6 In some example embodiments, the regions 60a, 60b corresponding to the side regions 80a, 80b may include openings 71. However, in some example embodiments, if included, the cross-sectional area of ​​the openings 71 in the regions 60a, 60b may be smaller than the formed holes 54 in the first pattern region 50 of the pattern surface 34, and may facilitate the removal of fluid during fluid entanglement. For example, the average area of ​​the openings 71 in the regions 60a, 60b may be smaller than the average area of ​​the formed holes 54 in the first pattern region 50. In some example embodiments, the average area of ​​the openings 71 may be about one square millimeter (1.0 mm 2 ) to about one and a half square millimeters (1.5mm 2 ). Depending on the density of the openings 71 in the regions 60a, 60b and the area of ​​the openings 71, in some example embodiments, the openings 71 may provide from about fifteen percent (15%) to about fifty percent (50%) of the area of ​​the regions 60a, 60b. The openings 71 in the regions 60a, 60b may enable the formation of microbumps in the modified substrate 14'. The areas of the base plane 42 of the forming surface 50 between the openings 71 in the regions 60a, 60b may form micro-openings and / or areas of lower fiber density in the modified substrate 14'.

[0075] Now go to Figure 5 , showing Figure 2 A portion of a second pattern area 52 of the pattern surface 34. Figure 5 The portion of the second pattern area 52 in Figure 2 The second pattern area 52 may include protrusions 56 extending away from the base plane 42 of the pattern surface 34. The protrusions 56 in the second pattern area 52 may have the same size and / or height as the protrusions 56 in the first pattern area 50. In some example embodiments, the protrusions 56 in the second pattern area 52 may have a different size and / or height than the protrusions 56 in the first pattern area 50.

[0076] The protrusions 56 may be arranged in a plurality of rows 59 ( Figure 5 59), the channels extend in the longitudinal direction 57 of the pattern surface 34. The columns 59 of protrusions 56 may be formed by a series of connected longitudinally adjacent protrusions 56, as described above with respect to the protrusions 56 in the first pattern area 50 of the pattern surface 34. In some example embodiments, the first pattern area 50 may include six, seven, or eight or more columns 59 of protrusions 56 extending in the longitudinal direction 57. In some example embodiments, the majority of the channels in the plurality of columns 59 of protrusions 56 extending in the longitudinal direction 57 are laterally offset from the nearest adjacent column 55 of formed holes 54 extending substantially in the longitudinal direction 57.

[0077] The protrusions 56 in the second pattern region 52 of the pattern surface 34 may form openings 76 in the second region 72 of the modified substrate 14' (at Figure 6 ), because during the above-mentioned fluid entanglement, the fibers from the substrate 14 are pushed by the fluid jets 44 around the protrusions 56 in the second pattern area 52. Therefore, the orientation, density and size of the protrusions 56 in the second pattern area 52 of the pattern surface 34 can correspond to the orientation, density and size of the openings 76 in the second area 72 of the modified substrate 14'.

[0078] In some example embodiments, on the lateral sides of the second pattern area 52, the pattern surface 34 may include one or more areas 62a, 62b that are substantially free of protrusions 56. The areas 62a, 62b may correspond to the side areas 82a, 82b (in the modified substrate 14'). Figure 682a, 82b). In some embodiments, the regions 62a, 62b corresponding to the side regions 80a, 80b may include openings 71. However, in example embodiments, if included, the cross-sectional area of ​​the openings 71 in the regions 62a, 62b may be smaller than the forming holes 54 in the first pattern region 50 of the pattern surface 34, and may facilitate the removal of fluid during fluid entanglement. For example, the average area of ​​the openings 71 in the regions 62a, 62b may be smaller than the average area of ​​the forming holes 54 in the first pattern region 50. The openings 71 in the regions 62a, 62b may allow for the formation of microbumps in the modified substrate 14'.

[0079] The second pattern area 52 of the pattern surface 34 may also include a plurality of openings 71 disposed between the protrusions 56 in the second pattern area 52. The openings 71 in the second pattern area 52 may be similar to the openings 71 described above with respect to the areas 62a, 62b on the lateral sides of the second pattern area 52. The openings 71 may aid in fluid management during the fluid entanglement process. In some example embodiments, the second pattern area 52 may be configured to not include any openings 71.

[0080] like Figure 2 As shown, in some example embodiments, the pattern surface 34 may also include one or more transitional pattern areas 51. The transitional pattern areas 51 in the pattern surface 34 may be arranged between the first pattern area 50 and the second pattern area 52 in the longitudinal direction 57 of the pattern surface 34. The transitional pattern area 51 may be an area of ​​the pattern surface 34 that does not contain protrusions 56 or at least has fewer protrusions 56 than the first pattern area 50. In some example embodiments, the transitional pattern area 51 may include openings similar to the openings 71 described above with respect to the areas 60a, 60b on the lateral sides of the first pattern area 50. After the substrate 14 is modified by the fluid entanglement device 32, the transitional pattern area 51 of the pattern surface 34 may correspond to the transition area 73 (at Figure 6 Although not shown, in some example embodiments, the transitional pattern region 51 may also include shaped holes 54 such as described above with respect to the first pattern region 50. Thus, for example, the first pattern region 50 and the second pattern region 52 may be discrete or separated from each other on the pattern surface 34.

[0081] In example embodiments, the pattern channels 48, 48', 48" may be configured such that the first pattern area 50 in the first pattern channel 48 is substantially the same as the first pattern area 50 in the second pattern channel 48'. In some example embodiments, the first pattern area 50 in the third pattern channel 48" may be substantially the same as the first pattern area 50 in the second pattern channel 48' and / or substantially the same as the first pattern area 50 in the first pattern channel 48. Similarly, in some example embodiments, the pattern channels 48, 48', 48" may be configured such that the second pattern area 52 in the first pattern channel 48 is substantially the same as the second pattern area 52 in the second pattern channel 48'. In some example embodiments, the second pattern area 52 in the third pattern channel 48" may be substantially the same as the second pattern area 52 in the second pattern channel 48' and / or substantially the same as the second pattern area 52 in the first pattern channel 48.

[0082] Alternatively, it is also contemplated that the first pattern area 50 in the first pattern channel 48 can be configured to be different from the first pattern area 50 in the second pattern channel 48' and / or the first pattern area 50 in the third pattern channel 48". It is also contemplated that the second pattern area 52 in the first pattern channel 48 can be configured to be different from the second pattern area 52 in the second pattern channel 48' and / or the second pattern area 52 in the third pattern channel 48".

[0083] As described above, and returning a reference Figure 2 , the pattern surface 34 may also include a reference line 90. The reference line 90 may include a plurality of reference features 92. As described above, such dedicated reference features in the modified substrate 14' may be openings or protrusions, whether discrete openings or protrusions separated from each other or one continuously extending opening or protrusion. The features 92 on the pattern surface 34 that may form corresponding openings or protrusions in the modified substrate 14' may be protrusions protruding from the forming surface 34, openings extending through the forming surface 34, or depressions within the forming surface 34 but not extending completely through the forming surface 34. The protrusions on the forming surface 34 may form corresponding openings in the modified substrate 14'. The openings in the forming surface 34 may form corresponding protrusions in the modified substrate 14'. The depressions in the forming surface 34 may form corresponding protruding dense areas on the modified substrate 14'. Each of these openings, protrusions, and protruding dense areas may be detected by the registration system.

[0084] For simplicity, the features 92 will be referred to herein as protrusions 92, but this description should not be construed to limit such features 92 to only the protrusions described above. The protrusions 92 in the reference line 90 of the pattern surface 34 may form a plurality of openings 96 (in the reference line index 94 of the modified substrate 14'). Figure 6), because during the above-described fluid entanglement, fibers from substrate 14 are pushed by fluid jets 44 around protrusions 92 in reference line 90. Thus, the orientation, density, and size of protrusions 92 in reference line 90 of pattern surface 34 may correspond to the orientation, density, and size of open pores 96 in reference line index 94 of modified substrate 14'.

[0085] In an example embodiment, the protrusions 92 of the reference line 90 may be spaced apart from one of the pattern channels 48, 48', 48" (such as the first pattern channel 48), for example, in a transverse direction perpendicular to the longitudinal direction 57 by no less than twenty millimeters (20 mm) and no more than one hundred millimeters (100 mm). In addition, the protrusions 92 of the reference line 90 may be evenly spaced apart along the longitudinal direction 57 on the pattern surface 34. For example, each protrusion 92 may be spaced apart from an adjacent protrusion 92 within the reference line 90 in the longitudinal direction 57 by no less than half a millimeter (0. 5mm) and no greater than ten millimeters (10mm). Thus, for example, the reference line 90 may be continuous along the longitudinal direction 57 of the pattern surface 34. In addition, the corresponding protrusion 92 of the reference line 90 may be positioned adjacent to each of the first pattern area 50, the second pattern area 52, and the transition pattern area 51 on the pattern surface 34 in the transverse direction, so that for each of the pattern channels 48, 48', 48", the reference line 90 is continuous across the first pattern area 50, the second pattern area 52, and the transition pattern area 51 along the longitudinal direction 57. In an example embodiment, the protrusion 92 of the reference line 90 can be a pin having any suitable cross-section, including circular, oval, triangular, square, etc. The diameter or minimum dimension of the protrusion 90 can be as small as one tenth of a millimeter (0.1mm) and no greater than ten millimeters (10mm).

[0086] The protrusion 92 of the reference line 90 may be positioned at a side portion or edge of the pattern surface 34. In a contemplated exemplary embodiment according to the present disclosure, the reference line 90 is disposed at a single side portion or edge of the pattern surface 34. Figure 2 As shown, in certain example embodiments, the pattern surface 34 may include two reference lines 90. Each of the reference lines 90 may be positioned at a respective side portion or edge of the pattern surface 34. Such an arrangement may advantageously form an opening 96 in the reference line index 94 at the edge of the modified substrate 14'. However, it should be understood that Figure 2 The placement of reference line 90 in FIG. 3 is provided as an example only, and other locations, such as at a central portion of pattern surface 34 , are within the scope of the present disclosure.

[0087] In some example embodiments, reference lines 90, wherever they are placed on pattern surface 24, may preferably be separate and discrete from pattern regions 50, 51, and 52. Such pattern regions 50, 51, and / or 52 may provide desired functional performance characteristics for modified substrate 14'. By providing discrete reference lines 90, discrete registration features may be formed in modified substrate 14' without imposing requirements on pattern regions 50, 51, and 52 for registration that may affect the performance characteristics of modified substrate 14'. In addition, by utilizing such discrete reference lines 90 on pattern surface 34, discrete reference features 94 are integrally formed in modified substrate 14' through pattern regions 50, 51, and 52 in the same manner as regions 70 and / or 72 or at the same time. Forming such discrete reference features 94 in modified substrate 14' provides the advantage of ensuring a consistent dimensional relationship between discrete reference features 94 and other portions of modified substrate 14' (e.g., regions 70, 72). In contrast, applying reference features after substrate 14' is formed requires additional equipment to ensure consistent placement of such features on modified substrate 14', and achieving such results even with such additional equipment can be challenging.

[0088] In the case where the modified substrate 14' is a laminated material, a

[0089] The discrete reference features 94 in the modified substrate 14' are particularly advantageous, for example, laminates produced by hydroentangling the substrate 14 with a support web (as described in U.S. Pat. No. 9,327,473 to Scott Kirby et al.). In such exemplary embodiments, these laminates tend to deform (e.g., neck, curl, etc.) when placed under tension, thereby creating challenges in handling such materials in a consistent manner in commercial converting equipment. By providing discrete reference features 94 formed in the modified substrate 14', the reference features are similarly subject to the same forces and are able to provide a consistent reference point for registration better than other alternative reference feature options.

[0090] The protrusions 92 of the reference line 90 may be arranged in a column extending in the longitudinal direction 57 of the pattern surface 34. When the pattern surface 34 is cylindrical, such as Figure 4As shown, the protrusions 92 of the reference line 90 can be arranged in a ring extending circumferentially around the cylindrical texturing drum 36. In addition, the first pattern area 50 and the second pattern area 52 can be circumferentially spaced apart around the cylindrical texturing drum 36, wherein the reference line 90 is axially spaced apart from adjacent areas 50, 52 on the cylindrical texturing drum 36. In an example embodiment, the columns of protrusions 92 in the reference line 90 can be formed by longitudinally adjacent protrusions 92 distributed on the pattern surface 34, for example, in a linear pattern. Because the orientation, density, and size of the protrusions 92 in the reference line 90 of the pattern surface 34 determine the orientation, density, and size of the openings 96 in the reference line index 94 of the modified substrate 14', the openings 96 in the reference line index 94 of the modified substrate 14' can also be arranged in columns extending in the transverse direction 23 of the modified substrate 14'. Thus, for example, as Figure 6 As shown, the rows of openings 96 in reference line index 94 can be formed by longitudinally adjacent openings 96 distributed on modified substrate 14' in a linear pattern in transverse direction 23. As an illustrative example, the rows of openings 96 can be formed by two rows, or three rows, or more rows of transversely adjacent openings.

[0091] In an example embodiment, the openings 96 in the reference line index 94 can be evenly distributed along the longitudinal direction 22 of the modified substrate 14'. Thus, for example, the reference line index 94 can be continuous along the longitudinal direction 22 of the modified substrate 14'. In addition, the corresponding openings 96 of the reference line index 94 can be located adjacent to each of the first region 70, the second region 72, and the transition region 73 on the modified substrate 14' along the transverse direction 23, so that the reference line index 94 is continuous across the first region 70, the second region 72, and the transition region 73 along the longitudinal direction 22. In an example embodiment, adjacent openings 96 of the reference line index 94 can be spaced apart in the longitudinal direction 22 by no less than one tenth of a millimeter (0.1 mm) and no more than one and a half millimeters (1.5 mm), such as about half a millimeter (0.5 mm).

[0092] Compared to reference line index 94, first region 70 and second region 72 may be discrete and spaced apart from each other on modified substrate 14' with transition region 73 therebetween. The arrangement of openings 96 in reference line index 94 may facilitate registration of modified substrate 14', for example, during a slitting process performed in the manner described above.

[0093] Go to Figure 1As described above, the method 10 may include supplying or feeding a continuous modified substrate 14' to a slitting device 15. From the pattern surface 34, the modified substrate 14' may include a series of open areas, namely the first area 70 and the second area 72, and the reference line index 94. The method 10 may also include features for facilitating registration of the reference line index 94, for example, to facilitate accurate slitting of the continuous modified substrate 14' at the slitting device 15. For example, based on the detection of the reference line index 94, the method 10 may affect a change in the position of the modified substrate 14' (e.g., in a transverse direction perpendicular to the longitudinal direction 22) relative to the slitting device 15, and thereby adjust the position on the modified substrate 14' at which the modified substrate 14' is slit by the slitting device 15.

[0094] Utilizing a slitting device 15 with registration of reference line indexes 94 can advantageously allow the slitting device 15 to slit the modified substrate 14' between adjacent channels of an open area (such as a first region 70 and a second region 72) on the modified substrate 14'. For example, the slitting device 15 can slit the modified substrate 14' into three (3) or more partitioned webs by slitting the modified substrate 14' between adjacent channels 88, 88', 88" of the open area. Thus, for example, after the cutting device 15, each partitioned web 12 from the modified substrate 14' can include the first region 70 and the second region 72 as described above.

[0095] In order to adjust the position of the modified substrate 14' (e.g., in a transverse direction perpendicular to the longitudinal direction 22) relative to the slitting device 15, the method 10 may, for example, adjust the tension of the modified substrate 14'. For example, the method 100 may also include a roller that helps feed the modified substrate 14' in the longitudinal direction 22, and the rotation speed of the roller may be adjusted to change the tension of the modified substrate 14'. As another example, the roller may, for example, translate in the transverse direction to adjust the position of the modified substrate 14' in the transverse direction. As another example, the knife in the slitting device 15 may translate in the transverse direction to adjust the cutting of the slitting device 15. Other known techniques, devices and mechanisms for adjusting the position of the modified substrate 14' (e.g., in a transverse direction perpendicular to the longitudinal direction 22) relative to the slitting device 15 are also within the scope of the present subject matter. In general, it should be understood that the specific mechanism or method of changing the position of the modified substrate 14' and / or the slitting device 15 to adjust the slitting of the modified substrate 14' by the slitting device 15 is not important, as long as such functionality is included.

[0096] Return to reference Figure 1According to example aspects of the present disclosure, the method 10 may further include a registration system 110 that may be used to perform a registration process for registering the modified substrate 14'. The registration system 110 may include a registration processing device 120, which may itself include one or more processors 122, one or more data storage devices 124, and at least one communication device 126. The registration system 110 may also include external connection devices, such as image capture devices 130, 132, and the system 110 may also be connected to at least a feed roller, a slitting device 15, or other operating components of the method 10 for adjusting the slitting of the modified substrate 14' by the slitting device 15. The one or more processors 122 may be configured to implement functionality and / or process instructions for execution within the device 120. The one or more processors 122 may be capable of processing instructions stored in the data storage device 124. Examples of the processor 122 may include any one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or an equivalent discrete or integrated logic circuit.

[0097] The communication device 126 can enable communication between the components and modules of the device 120, as well as communication with any externally connected devices such as the image capture devices 130, 132 and / or the feed roller 116. Each of the components 122, 124, and 126 can be interconnected (physically, communicatively, and / or operatively) for inter-component communication. In some examples, a communication channel (not shown) can extend between the components 122, 124, and 126, which can include a system bus, a network connection, an inter-process communication data structure, or any other method for transferring data.

[0098] Where communication device 126 is included, device 120 may utilize communication device 126 to communicate with external devices via one or more networks (such as one or more wired and / or wireless networks). Communication device 126 may be a network interface card, such as an Ethernet card, an optical transceiver, a radio frequency transceiver, or any other type of device capable of sending and receiving information. Other examples of such network interfaces may include 3G and WiFi radio computing devices and Universal Serial Bus (USB).

[0099] One or more storage devices 124 may be configured to store information within device 120 during operation. In some examples, storage device 124 is described as a computer-readable storage medium. Storage device 124 may be a temporary storage, which means that the primary purpose of storage device 124 is not long-term storage. In some examples, storage device 124 may be a volatile memory, such as random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), and other forms of volatile memory known in the art. In some examples, storage device 124 may be used to store program instructions for execution by processor 122. In one example, software or applications (e.g., modules 121, 123, and 125) running on device 120 may use storage device 124 to temporarily store information during program execution.

[0100] In some examples, storage device 124 also includes one or more computer-readable storage media. Storage device 124 can be configured to store larger amounts of information than volatile memory. Storage device 124 can also be configured for long-term storage of information. In some examples, storage device 124 includes a non-volatile storage element, such as a magnetic hard disk, an optical disk, a floppy disk, a flash memory, or various forms of electrically programmable memory (EPROM) or electrically erasable programmable (EEPROM) memory.

[0101] One or more data storage devices 124 may include one or more modules stored therein that may help perform the registration functions of system 110, such as image capture module 121 and image modification module 123 and registration module 125. Although modules 121, 123, and 125 are described as implementing multiple functions of system 110, the functions attributed to such modules may be implemented in more, fewer, and / or different modules. In addition, in some examples, the functions may not be distributed between physical or logical modules, but may be performed by, for example, processor 122 based on instructions and data stored on storage device 124. In addition, although ... in some examples, Figure 1 124, but in other examples, modules 121, 123, and 125 may be implemented separately from storage device 124, including, for example, in discrete hardware components configured to implement the functionality attributed to the modules in the examples disclosed herein.

[0102] The image capture devices 130, 132 may be configured to capture digital images and transmit such captured images to the device 120 for storage in the storage device 124. The image capture devices 130, 132 may be digital devices that include at least an optical system that includes a lens arrangement and an image sensor, such as a charge coupled device (CCD) sensor or a complementary metal oxide semiconductor (CMOS) sensor, among others. The image capture devices 130, 132 may also include a shutter and other typical components of an image capture device. Although not shown, the image capture devices 130, 132 may additionally include an illumination device for illuminating the location or object at which the image capture devices 130, 132 are configured to capture images. In at least some example embodiments of these embodiments, such illumination devices may be positioned opposite the image capture devices 130, 132 such that the illumination provides backlighting. For example, such illumination devices may be disposed relative to the modified substrate 14'. Figure 1 On opposite sides of the image capture devices 130 , 132 .

[0103] The image capture module 121 may be configured to trigger the image capture devices 130, 132 and obtain discrete images of the modified substrate 14' (obtained from the image capture device 130) and the partitioned web 12 (obtained from the image capture device 132). The images captured from the devices 130, 132 may be stored in the storage device 124. The image capture module 121 may generally be configured to capture images of the modified substrate 14' and the partitioned web 12 at regular intervals (such as once per product basis) according to methods known in the art. For example, the image capture module 121 may be connected to a feed roller, and the rate at which the image capture module 121 triggers the image capture devices 130, 132 may be adjusted as the speed of the modified substrate 14' increases or decreases. In addition, the initial setting of the trigger may be performed according to methods known in the art to ensure that the captured image corresponds to the portion of the modified substrate 14' that is ultimately set on a single product. For example, such captured images may be displayed on an output device, and manual adjustments to the trigger may be made to ensure proper timing of the image capture trigger. Alternatively, one or more preset parameters may be loaded into the image capture module 121, and one or more image processing techniques may be used to determine the characteristics of the captured image. A comparison of the one or more preset parameters with the determined characteristics of the captured image may be performed, and automatic adjustment of the trigger may be performed by the image capture module 121 based on the comparison to ensure proper timing of the image capture trigger.

[0104] Where the captured image is stored in storage device 124, image modification module 123 may perform one or more image processing modifications on the stored image. For example, image modification module 123 may be configured to filter the captured image according to one or more filter parameters. Such filtering processes may help minimize features of no interest and highlight features of interest, such as reference line index 94, which may be continuous along the length of modified substrate 14'. Image modification module 123 may be further configured to emphasize features of interest by performing one or more morphological processing techniques on the captured image and / or the filtered captured image.

[0105] Finally, the registration module 125 may be configured to identify features of the modified captured image and adjust the method 10 to ensure that proper registration of the modified substrate 14' relative to the slitting device 15 is achieved. For example, the registration module 125 may be configured to identify or determine the reference line index 94 on the modified substrate 14'. According to some example embodiments, the registration module 125 may be configured to identify the opening 96 within the reference line index 94 within the modified captured image - for example, along the length of the modified substrate 14'. Next, the registration module 125 may be configured to determine one or more metrics related to the determined features - such as positional differences - and adjust the method 10 based on the one or more determined metrics to ensure that proper registration of the modified substrate 14' relative to the slitting device 15 is achieved. Because the reference line index 94 is continuous (compared to the discrete, separate first and second regions 70, 72 on the modified substrate 14'), the registration module 125 can use the continuous transmittance of the openings 96 through the reference line index 94 to set and control the operation of the slitting device 15 so as to use the slitting device 15 to accurately and precisely cut the modified substrate 14' into partitioned webs 12.

[0106] A 3D mesh with nodes:

[0107] Figure 7 is a top plan view of a nonwoven material 200 according to an exemplary embodiment of the present disclosure. Figure 7 , the nonwoven material 200 is shown in a flat or planar configuration. Figure 8It is the image of the first characteristic area 220 of nonwoven material 200. Nonwoven material 200 can be used for absorbent articles, for example as body side lining. However, it should be understood that in alternative exemplary embodiments, nonwoven material 200 can be used in any other articles or clothing. For example, nonwoven material 200 can be used for diapers, diapers, training pants, larger children's pants, swimming trunks, feminine hygiene products (including but not limited to menstrual pads or menstrual pants), incontinence products, medical clothing, surgical pads and bandages, other personal care or health care clothing, for example, as the inner lining for the wearer of such products, and wipes. As discussed in more detail below, nonwoven material 200 can advantageously include a discrete aperture area such as centered along the length of nonwoven material 200.

[0108] like Figure 7 As shown in , the nonwoven material 200 includes a nonwoven fiber web 210, for example, formed by a plurality of fibers. The fiber web 210 may define a transverse direction LA and a longitudinal direction LO. The transverse direction LA and the longitudinal direction LO may be perpendicular to each other. In certain exemplary embodiments, the longitudinal direction LO may correspond to the longitudinal direction 30, and the transverse direction LA may correspond to the transverse direction 23. The fiber web 210 may extend, for example, between the rear end or first end portion 212 and the 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 fiber web 210 may be positioned at or near the rear waist region of the absorbent article, and the second end portion 214 of the fiber web 210 may be positioned at or near the front waist region of the absorbent article. The fiber web 210 may also extend, for example, between the first side portion 216 and the second side portion 218 along the transverse direction LA. Therefore, the first side portion 216 and the second side portion 218 may be spaced apart along the transverse direction LA.

[0109] 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.

[0110] The nonwoven web 210 may include at least one characteristic region. Figure 7As 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 7 As shown in , the nonwoven web 210 may be non-perforated between the first characteristic region 220 and the second characteristic region 230, for example, along the longitudinal direction LO. Thus, for example, the nonwoven web 210 may not be processed to include an opening between the first characteristic region 220 and the second characteristic region 230 along the longitudinal direction LO. In certain example embodiments, the centroid of the first characteristic region 220 may also be arranged in line with the centroid of the second characteristic region 230, for example, in the longitudinal direction LO. In addition, the first characteristic region 220 and the second characteristic region 230 may be positioned at the center of the nonwoven material, for example, along the transverse direction LA. Thus, for example, the first characteristic region 220 and the second characteristic region 230 may be positioned equidistantly from the first side portion 216 and the second side portion 218, for example, along the transverse direction LA. Such placement of the first characteristic region 220 and the second characteristic region 230 within the nonwoven material 200 may advantageously be consistently produced via method 10, because the reference line index 94 provides registration of the modified substrate 14' relative to the slitting device 15. Other suitable placements of first and second characteristic regions 220 , 230 within nonwoven material 200 are within the scope of the present subject matter and can be consistently produced via method 10 because reference line index 94 provides registration of modified substrate 14 ′ relative to slitting device 15 .

[0111] The first characteristic region 220 may include a plurality of openings 221 and a plurality of nodes 222, and the second characteristic region 230 may also include a plurality of openings 231. The openings 221 of the first characteristic region 220 may be larger than the openings 231 of the second characteristic region 230. For example, the area of ​​each of the openings 221 of the first characteristic region 220 may be not less than about five square millimeters (5 mm 2 ) and not larger than approximately 28 square millimeters (28mm 2 ), such as not less than about eight square millimeters (8mm 2 ) and not larger than about 20 square millimeters (20mm 2 ), such as not less than about nine square millimeters (9mm 2 ) and not larger than about twelve square millimeters (12mm 2In contrast, the area of ​​each of the openings 231 of the second characteristic 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 characteristic area 220 and the openings 231 of the second characteristic 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 characteristic area 220 can be designed to transfer and collect low-viscosity feces. Conversely, the size of the smaller openings 231 of the second characteristic 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 characteristic area 220, and the openings 231 can be evenly distributed throughout the second characteristic area 230. The area of ​​the openings 221, 231 in the first characteristic area 220 and the second characteristic area 230 can be measured using analytical techniques in the material sample analysis test method described in the test method section of this article.

[0112] As described above, the nonwoven material 200 may include nodes 222 located at the first characteristic region 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. Furthermore, it will be appreciated that in certain exemplary embodiments, the first characteristic region 220 may include nodes 222 that do not have openings 221. Figure 8 As shown in FIG. 2 , the nonwoven web 210 may also include a plurality of connecting ties 223 located at the first feature area 220. The nodes 222 may extend away from the base surface on the first surface of the nonwoven material 200. The base plane may be defined as a substantially flat area of ​​the first surface of the nonwoven material 200 that is not a portion of the nonwoven material 200 that forms the nodes 222. In other words, for Figure 8 and Fig. 9 In the exemplary embodiment shown, the base plane may be formed by a first surface of the nonwoven material 200 that provides the connecting ties 223. The nonwoven material 200 may also include a second surface positioned opposite the first surface on the nonwoven web 210.

[0113] Nodes 222 may be configured in a variety of shapes and sizes. In some example embodiments, nodes 222 may be in a generally cylindrical shape. In certain example embodiments, nodes 222 may be configured to not include any openings or apertures. In certain example embodiments, nodes 222 may have a height (as measured in a direction perpendicular to the surface of the base) of between about half a millimeter (0.5 mm) to about ten millimeters (10 mm), such as from about one millimeter (1 mm) to about three millimeters (3 mm), such as from about one and one-tenth of a millimeter (1.1 mm) to about one and five-tenths of a millimeter (1.5 mm), such as about one and three-tenths of a millimeter (1.3 mm). The height of nodes 222 may be measured using the analysis techniques described in the node analysis test method described in the test method section of this article. In certain example embodiments, most nodes 222 may each have a height of from about five square millimeters (5 mm 2 ) to about 35 square millimeters (35mm 2 ) (such as from about ten square millimeters (10mm 2 ) to about 20 square millimeters (20mm 2 )) (as measured by the area of ​​the nodes 222 at the base plane). The nodes 222 can be configured in the first feature region 220 so that the nodes 222 provide approximately one node per square centimeter (1.0 node / cm 2 ) to approximately three nodes per square centimeter (3.0 nodes / cm 2 The node area and node density within the first characteristic 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.

[0114] like Figure 7 As shown in Figure 8 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 example embodiments, a majority of the nodes 222 may include at least three (3) connecting ties 223 connected to adjacent nodes 222. In certain example embodiments, a majority of the nodes 222 may include ten (10) or fewer connecting ties 223 connected to adjacent nodes 222. In some example embodiments, the nonwoven material 200 may be configured such that a majority of the nodes 222 may include three (3) to eight (8) connecting ties 223 connected to adjacent nodes 222. For example, in Figure 7 In the example embodiment of , most nodes 222 include six connecting ties 223 connected to adjacent nodes 222.

[0115] 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 8 The image in shows that the open pores 221 have a lower fiber density than the adjacent nodes 222 and the connecting ties 223. The open pores 221 can be formed between the connecting ties 223 and the nodes 222. Each open pore 221 can be disposed between adjacent nodes 222. In certain example embodiments, each open pore 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 pore 221 can be defined between at least four (4) connecting ties 223 and at least four (4) nodes 222.

[0116] As can be seen from the above, the present subject matter can advantageously facilitate slitting and winding nonwoven webs having discrete open areas. In addition, if discrete open areas are used for registration, the spacing or discontinuity between the discrete open areas may cause the visual registration system to lose the detection sequence and erratically control the web when searching for the next sequential hole area. In contrast, the reference line index can be continuous, thus accurately guiding and aligning the passage of the discrete open areas during the slitting and winding process. The visual registration system can detect the openings in the reference line index and guide the web through the slitting knife.

[0117] 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.

[0118] Test Method

[0119] Material sample analysis test methods

[0120] The material sample analysis test method as described herein can be used to determine the size of the openings 221, the roundness of the openings 221, the aspect ratio for the openings 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.

[0121] Material opening area sample analysis setup and determination

[0122] exist Fig. 9An 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).

[0123] The sample ( Fig. 9700) 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 that 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.

[0124] 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.

[0125] 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, an image analysis algorithm is used to obtain and process images and to measure using the language of the quantitative video microscope user interactive programming system (Quantimet User Interactive Programming System, QUIPS). 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.

[0126] Defining variables and opening files

[0127] The following line specifies the location on the computer where the data is sent

[0128] Open the file (C:\Data\94054-Nhan(patent)\data.xls, channel #1)

[0129] TOTCOUNT=0

[0130] TOTFIELDS=0

[0131] MFRAMEH=875

[0132] MFRAMEW=1249

[0133] Sample ID and Setup

[0134] Configuration (image memory 1392x 1040, grayscale image 81, binary 24)

[0135] Input result header

[0136] File Results Header(channel#1)

[0137] File Line(channel#1)

[0138] pauseText("Now enter a sample image prefix name.")

[0139] input(title$)

[0140] pauseText("Setting samples to position.")

[0141] Image Setup DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lights 38.83)

[0142] Measure frame (x 74, y 110, width 1249, height 875)

[0143] Image frame(x 0, y 0, Width 1392, Height 1040)

[0144] --Calculated value = 0.0377mm / px

[0145] Calculated value = 0.0377

[0146] Correction(calculated value in $per pixel)

[0147] FRMAREA=MFRAMEH*MFRAMEW*(CALVALUE**2)

[0148] Clear Accept

[0149] For (sample=1 to 1, step 1)

[0150] Clear Accept

[0151] file("field number", channel #1, field width: 9, left justified)

[0152] File("Opening Area %", Channel #1, Field Width: 7, Left Justified)

[0153] file("Bump Density", channel #1, field width: 13, left justified)

[0154] file("Bump Spacing", Channel #1, Field Width: 15, Left Justified)

[0155] File Line(channel#1)

[0156] Stage(Define Origin)

[0157] Stage (scan pattern, 1×5 field, size 82500.000000×39000.000000)

[0158] Image Collection I - Neurite Isolation

[0159] For (field=1 to 5, step 1)

[0160] Measure frame (x 74, y 110, width 1249, height 875)

[0161] display(image0(on), frame(on, on), planes(off, off, off, off, off, off), lut 0, x 0, y 0, z 1, downscaling off)

[0162] PauseText("Ensure incident light illumination is correct (WL = 0.88-0.94) and acquire image.")

[0163] Image Setup DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lights 38.83)

[0164] Get (enter image 0)

[0165] Detection - protrusions only

[0166] 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.")

[0167] Detect [PAUSE] (whiter than 129, from image 0 into depicted binary 0)

[0168] Binary Image Processing

[0169] Binary modification (from binary 0 to binary 1 off, loop 10, operator disk, edge erosion on)

[0170] Binary recognition (filling holes from binary 1 to binary 1)

[0171] Binary modification (from binary 1 to binary 2 on, loop 20, operator disk, edge erosion on)

[0172] Binary modification (from binary 2 to binary 3 off, loop 8, operator disk, edge erosion on)

[0173] Pause text ("while pressing <control>and key to check protrusion detection and correct if necessary. ")

[0174] BINARY EDIT [PAUSE] (from binary3 to binary3 reject, nibble fill, width 2)

[0175] Binary logic (copy binary 3, invert to binary 4)

[0176] Image acquisition 2-opening area and opening size percentage

[0177] Measure frame (x 74, y 110, width 1249, height 875)

[0178] display(image0(on), frame(on, on), planes(off, off, off, off, off, off), lut 0, x 0, y 0, z 1, downscaling off)

[0179] PauseText("Turn off incident light and ensure incident light illumination is correct (WL=0.95) and acquire image.")

[0180] Image Setup DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lights 38.83)

[0181] Get (enter image 0)

[0182] ACQFILE$="C:\Images\94054-Nhan\"+TITLE$+"_"+STR$(FIELD)+".jpg"

[0183] Write image (from ACQOUTPUT to file ACQFILE$)

[0184] Detection - Opening area only

[0185] Detect (whiter than 127, going from image 0 into the depicted binary 10)

[0186] Binary Image Processing

[0187] Binary modification (from binary 10 to binary 11 off, loop 5, operator disk, edge erosion on)

[0188] Binary recognition (filling holes from binary 11 to binary 12)

[0189] Binary modification (from binary 12 to binary 13 on, loop 10, operator disk, edge erosion on)

[0190] Binary recognition (edge ​​characterization from binary 13 to binary 14)

[0191] PauseText("Ensure accurate detection of openings.")

[0192] BINARY EDIT [PAUSE] (from binary14 to binary14 reject, nibble fill, width 2)

[0193] Field measurements - open area percentage, bump density and spacing

[0194] --% Opening Area

[0195] MFLDIMAGE=10

[0196] Measure field(plane MFLDIMAGE,into FLDRESULTS(1),statistics intoFLDSTATS(7,1))

[0197] Selected parameters: Area%

[0198] Field Histogram #1 (Y parameter number, X parameter area%, from 0. to 60., linear, 20 bins)

[0199] PERCOPENAREA=FLDRESULTS(1)

[0200] --Bump density and spacing

[0201] MFLDIMAGE=3

[0202] Measurement fields (flat MFLDIMAGE, into FLDRESULTS(5), statistics into FLDSTATS(7,5))

[0203] Selected parameters: Area, Intercept H, Intercept V, Area %,

[0204] Count / Area

[0205] BUMPDENSITY=FLDRESULTS(5)

[0206] MNSPACE1=(FRMAREA-FLDRESULTS(1)) / (FLDRESULTS(2)+FLDRESULTS(3)) / 2

[0207] Field Histogram #2 (Y parameter number, X parameter MNSPACE1, from 0. to 50., linear, 25 bins)

[0208] File(field, channel #1, 0 digits after '.')

[0209] File(PERCOPENAREA, channel #1, 1 digit after '.')

[0210] file(BUMPDENSITY, channel #1, 1 digit after '.')

[0211] File(MNSPACE1, channel #1, 1 digit after '.')

[0212] File Line(channel#1)

[0213] Feature measurement - hole and bump size

[0214] --Bump size

[0215] Measure features (plane binary 3, 8feret, minimum area: 24, grayscale image: image0)

[0216] Selected parameters: Area, X FCP, Y FCP, Equivalent diameter

[0217] Feature histogram #1 (Y parameter is number, X parameter is area, from 1. to 100., logarithmic, 20 bins)

[0218] Feature histogram #2 (Y parameter number, X parameter equivalent diameter, from 1. to 100., logarithmic, 20 bins)

[0219] --Opening size

[0220] Measure features (flat binary 14, 8feret, minimum area: 24, grayscale image: image0)

[0221] Selected parameters: Area, X FCP, Y FCP, Circularity, Aspect Ratio,

[0222] Equivalent diameter

[0223] Feature Histogram #3 (Y parameter is number, X parameter is area, from 1. to 100., logarithmic, 20 bins)

[0224] Feature histogram #4 (Y parameter number, X parameter equivalent diameter, from 1. to 100., logarithmic, 20 bins)

[0225] Feature Histogram #5 (Y parameter number, X parameter circularity, from 0.8999999762 to 2.900000095, linear, 20 bins)

[0226] Feature Histogram #6 (Y parameter number, X parameter aspect ratio, from 1. to 3., linear, 20 bins)

[0227] phase(step, wait until stop + 1100 ms)

[0228] Next(field)

[0229] Next (sample)

[0230] File Line(channel#1)

[0231] File Line(channel#1)

[0232] Output feature histogram

[0233] file("Bump Size (Area - mm2)", channel #1)

[0234] File Line(channel#1)

[0235] File feature histogram results (#1, differential, statistics, bin details, channel #1)

[0236] File Line(channel#1)

[0237] File Line(channel#1)

[0238] File("Bump Size (ECD - mm)", Channel #1)

[0239] File Line(channel#1)

[0240] File feature histogram results (#2, differential, statistics, bin details, channel #1)

[0241] File Line(channel#1)

[0242] File Line(channel#1)

[0243] File("Opening Size (Area - mm2)", Channel #1)

[0244] File Line(channel#1)

[0245] File feature histogram results (#3, differential, statistics, bin details, channel #1)

[0246] File Line(channel#1)

[0247] File Line(channel#1)

[0248] File("Opening Size (ECD - mm)", Channel #1)

[0249] File Line(channel#1)

[0250] File feature histogram results (#4, differential, statistics, bin details, channel #1)

[0251] File Line(channel#1)

[0252] File Line(channel#1)

[0253] File("Opening Roundness", channel #1)

[0254] File Line(channel#1)

[0255] File feature histogram results (#5, differential, statistics, bin details, channel #1)

[0256] File Line(channel#1)

[0257] File Line(channel#1)

[0258] File("Aperture Aspect Ratio", channel #1)

[0259] File Line(channel#1)

[0260] File feature histogram results (#6, differential, statistics, bin details, channel #1)

[0261] File Line(channel#1)

[0262] File Line(channel#1)

[0263] Close file (channel #1)

[0264] Finish

[0265] 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.

[0266] 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.

[0267] 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.

[0268] 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.

[0269] Next, the analyst is prompted to turn off the incident annular fluorescent light 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).

[0270] 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.

[0271] The algorithm will then automatically take the measurements and output the data to a specified EXCEL spreadsheet file.

[0272] 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.

[0273] After the analysis is complete, after the measurement and data transfer has occurred, the following measurement parameter data will be in the EXCEL file:

[0274] Opening area percentage

[0275] Node density (number per square meter)

[0276] Node spacing (mm)

[0277] Node size (a histogram representing the area in mm 2 , a histogram represents the equivalent circle diameter in mm)

[0278] Opening size (a histogram representing the area in mm 2 , a histogram represents the equivalent circle diameter in mm)

[0279] Hole roundness

[0280] Aperture aspect ratio

[0281] 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 (pore) size, and other parameters derived by the algorithm between different samples can be made using Student's T analysis at a 90% confidence level.

[0282] Example Implementation

[0283] First exemplary embodiment: A forming surface comprises: a roller, the roller defining a plurality of channels spaced apart along an axial direction on the roller, the plurality of channels comprising a first channel and a second channel, the first channel comprising one or more discrete feature areas, the second channel comprising one or more discrete feature areas, wherein the roller further defines a reference line, the reference line comprising a plurality of features distributed around the roller in a circumferential direction, the features of the reference line being spaced apart from the first channel along the axial direction.

[0284] Second example embodiment: The formed surface of the first example embodiment, wherein the feature of the reference line is spaced apart from the first channel in the axial direction by no less than twenty millimeters and no more than one hundred millimeters.

[0285] Third example embodiment: The forming surface of the first example embodiment or the second example embodiment, wherein the features of the reference lines are evenly spaced along the circumferential direction on the drum.

[0286] Fourth example embodiment: The formed surface of any one of the first to third example embodiments, wherein each feature of the reference line is spaced apart from an adjacent feature of the reference line in the circumferential direction by no less than half a millimeter and no more than ten millimeters.

[0287] Fifth example embodiment: The forming surface as described in any one of the first to fourth example embodiments, wherein the reference line is positioned at an end portion of the drum, the reference line being disposed between the first channel and the end portion of the drum in the axial direction.

[0288] Sixth example embodiment: The forming surface of any one of the first to fifth example embodiments, wherein the feature of the reference line comprises a plurality of pins extending in a radial direction from the outer surface of the drum.

[0289] Seventh example embodiment: The formed surface as described in the sixth example embodiment, wherein the smallest dimension of the pins is no less than one tenth of a millimeter and no more than ten millimeters.

[0290] Eighth example embodiment: The forming surface of any one of the first to seventh example embodiments, wherein the plurality of channels includes no less than four channels.

[0291] Ninth exemplary embodiment: A forming surface comprises: a wall, the wall defining a plurality of channels spaced apart along a transverse direction on the wall, the plurality of channels comprising a first channel and a second channel, the first channel comprising one or more discrete feature regions spaced apart along a longitudinal direction on the wall, the second channel comprising one or more discrete feature regions spaced apart along the longitudinal direction on the wall, wherein the wall further defines a reference line, the reference line comprising a plurality of protrusions distributed on the wall along the longitudinal direction, the protrusions of the reference line being spaced apart from the first channel along the transverse direction.

[0292] Tenth example embodiment: The forming surface of the ninth example embodiment, wherein the protrusion of the reference line is spaced apart from the first channel in the lateral direction by no less than twenty millimeters and no more than one hundred millimeters.

[0293] Eleventh example embodiment: The forming surface as described in the ninth example embodiment or the tenth example embodiment, wherein the protrusions of the reference line are evenly spaced apart on the wall along the longitudinal direction.

[0294] Twelfth example embodiment: The forming surface as described in any one of the ninth to eleventh example embodiments, wherein each protrusion of the reference line is spaced apart from an adjacent protrusion of the reference line in the longitudinal direction by not less than half a millimeter and not more than ten millimeters.

[0295] Thirteenth example embodiment: A forming surface as described in any one of the ninth to twelfth example embodiments, wherein the reference line is positioned at an end portion of the wall, and the reference line is arranged between the first channel and the end portion of the wall along the transverse direction.

[0296] Fourteenth Example Embodiment: The forming surface of any one of the ninth to thirteenth example embodiments, wherein the protrusion of the reference line comprises a plurality of pins extending outwardly from an outer surface of the wall.

[0297] Fifteenth example embodiment: The forming surface as described in the fourteenth example embodiment, wherein the smallest dimension of the pins is not less than one tenth of a millimeter and not more than ten millimeters.

[0298] Sixteenth example embodiment: The forming surface of any one of the ninth to fifteenth example embodiments, wherein the plurality of channels includes no less than four channels.

[0299] Seventeenth exemplary embodiment: A forming system comprising: a forming surface as described in any one of the ninth exemplary embodiment to the sixteenth exemplary embodiment, wherein the forming surface is configured to modify a substrate to include a plurality of discrete feature area channels corresponding to the plurality of channels, and includes a plurality of reference openings corresponding to reference lines; a divider, wherein the divider is configured to divide the substrate into a plurality of webs, each of the plurality of webs including one or more corresponding discrete feature area channels of the plurality of discrete feature area channels; and a registration system, wherein the registration system is configured to adjust the position of the substrate relative to the divider based at least in part on an image of the reference line.

[0300] Eighteenth exemplary embodiment: A nonwoven material comprises: a plurality of fibers, the plurality of fibers forming a nonwoven fiber web, the nonwoven fiber web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, the nonwoven fiber web comprising a plurality of discrete feature area channels and a reference line, the plurality of discrete feature area channels being spaced apart along the transverse direction, the plurality of discrete feature area channels comprising a first channel and a second channel, the first channel comprising one or more discrete feature areas, the second channel comprising one or more discrete feature areas, the reference line comprising a plurality of features distributed along the longitudinal direction, the features of the reference line being spaced apart from the first channel along the transverse direction.

[0301] Nineteenth exemplary embodiment: The nonwoven material of the eighteenth exemplary embodiment, wherein the features of the reference lines include openings.

[0302] Twentieth exemplary embodiment: The nonwoven material of the eighteenth exemplary embodiment or the nineteenth exemplary embodiment, wherein the features of the one or more feature regions include open apertures.

[0303] Twenty-first exemplary embodiment: The nonwoven material of any one of the eighteenth to twentieth exemplary embodiments, wherein the features of the reference line include protrusions.

[0304] Twenty-second exemplary embodiment: The nonwoven material of any one of the eighteenth to twenty-first exemplary embodiments, wherein the features of the reference line and the one or more feature areas of the first and second channels are integrally formed in the nonwoven material. < / control>

Claims

1. A formed surface comprising: A roller, the roller defining a plurality of channels spaced apart in an axial direction on the roller, the plurality of channels comprising a first channel and a second channel, the first channel comprising one or more discrete feature regions, the second channel comprising one or more discrete feature regions, Wherein the drum further defines a reference line comprising a plurality of features distributed circumferentially around the drum, the features of the reference line being spaced apart from the first channel in the axial direction.

2. The forming surface of claim 1, wherein the feature of the reference line is spaced apart from the first channel in the axial direction by no less than twenty millimeters and no more than one hundred millimeters.

3. The forming surface of claim 1 wherein said features of said reference lines are evenly spaced along said circumferential direction on said drum.

4. The formed surface of claim 1, wherein each feature of the reference line is spaced apart from an adjacent feature of the reference line in the circumferential direction by no less than half a millimeter and no more than ten millimeters.

5. The forming surface of claim 1, wherein the reference line is positioned at an end portion of the drum, the reference line being disposed between the first channel and the end portion of the drum in the axial direction.

6. The forming surface of claim 1 wherein said features of said reference line comprise a plurality of pins extending in a radial direction from an outer surface of said drum.

7. A forming surface as claimed in claim 6, wherein the smallest dimension of the pins is not less than one tenth of a millimeter and not more than ten millimeters.

8. The forming surface of claim 1, wherein the plurality of channels comprises no less than four channels.

9. A formed surface comprising: a wall, the wall defining a plurality of channels spaced apart in a transverse direction on the wall, the plurality of channels comprising a first channel and a second channel, the first channel comprising one or more discrete feature regions spaced apart in a longitudinal direction on the wall, the second channel comprising one or more discrete feature regions spaced apart in the longitudinal direction on the wall, The wall further defines a reference line, the reference line comprising a plurality of protrusions distributed on the wall along the longitudinal direction, the protrusions of the reference line being spaced apart from the first channel along the transverse direction.

10. The forming surface of claim 9, wherein the protrusion of the reference line is spaced apart from the first channel in the lateral direction by no less than twenty millimeters and no more than one hundred millimeters.

11. The forming surface of claim 9, wherein the protrusions of the reference line are evenly spaced on the wall along the longitudinal direction.

12. The forming surface of claim 9, wherein each protrusion of the reference line is spaced apart from an adjacent protrusion of the reference line in the longitudinal direction by no less than half a millimeter and no more than ten millimeters.

13. The forming surface of claim 9, wherein the reference line is positioned at an end portion of the wall, the reference line being disposed between the first channel and the end portion of the wall in the transverse direction.

14. The forming surface of claim 9, wherein the protrusion of the reference line comprises a plurality of pins extending outwardly from an outer surface of the wall.

15. A forming surface as claimed in claim 14, wherein the smallest dimension of the pins is no less than one tenth of a millimeter and no more than ten millimeters.

16. The forming surface of claim 9, wherein the plurality of channels comprises no fewer than four channels.

17. A forming system comprising: The formation surface of claim 9, the formation surface being configured to modify the substrate to include a plurality of discrete feature area channels corresponding to the plurality of channels, and including a plurality of reference features corresponding to the reference lines; a slitter configured to slit the substrate into a plurality of webs, each web of the plurality of webs comprising a corresponding one or more discrete feature area channels of the plurality of discrete feature area channels; as well as A registration system is configured to adjust a position of the substrate relative to the slitter based at least in part on the image of the reference line.

18. A nonwoven material comprising: a plurality of fibers, the plurality of fibers forming a nonwoven web, the nonwoven web defining a transverse direction and a longitudinal direction, the transverse direction and the longitudinal direction being perpendicular, The nonwoven web comprises a plurality of discrete feature area channels and a reference line, wherein the plurality of discrete feature area channels are spaced apart along the transverse direction, the plurality of discrete feature area channels comprise a first channel and a second channel, the first channel comprising one or more discrete feature areas, the second channel comprising one or more discrete feature areas, the reference line comprising a plurality of features distributed along the longitudinal direction, the features of the reference line being spaced apart from the first channel along the transverse direction.

19. The nonwoven material of claim 18, wherein the features of the reference lines include openings.

20. The nonwoven material of claim 18, wherein the one or more feature areas are characterized by openings.

21. The nonwoven material of claim 18, wherein the features of the reference line include protrusions.

22. The nonwoven material of claim 18, wherein the features of the reference line and the one or more feature areas of the first and second channels are integrally formed in the nonwoven material.

Images