Female panty liner with different functional arrangements of topsheet apertures

Abstract

A female panty liner is disclosed. The disclosed panty liner has a longitudinal axis and a transverse axis, and has a topsheet comprising a nonwoven web, a backsheet, and an absorbent structure interposed between the topsheet and the backsheet. The nonwoven web includes at least a first arrangement of first pores having a first average size and a second arrangement of second pores having a second average size. The first average size is larger than the second average size. The first arrangement occupies a rectangular central region centered on the longitudinal axis and spanning the transverse axis. The first average size is 0.4 mm < 2 > to 0.6 mm < 2 >; and the central region has an average open area percentage of 1% to 12%. The second arrangement occupies one or more regions laterally and / or longitudinally outward of the central region, and the second average size is from 0.05 mm2 to 0.2 mm2.

Description

BACKGROUND OF THE INVENTION

[0001] Feminine hygiene pads (sometimes also referred to as sanitary napkins) have been on the market and used by women for many years to intercept and absorb menstrual secretions and prevent soiling of undergarments, outer garments, bedding, etc. Manufacturers of feminine hygiene pads are constantly striving to improve their products to enhance performance and consumer / user satisfaction.

[0002] The focus of development has been on the topsheet material of the pad. Generally speaking, users prefer such materials that feel soft, flexible and comfortable to the touch; are breathable and do not have the feel of a plastic film; perform the following functions: quickly receive the discharged menstrual fluid and allow the discharged menstrual fluid to pass downward through it to the underlying absorbent component, and, either alone or in combination with the underlying component, maintain a relatively dry feeling after discharge by the combination of quickly transferring the discharged fluid downward to the underlying absorbent component, avoiding absorbing the fluid itself, and avoiding or resisting "back - leakage" of the fluid residing in the absorbent component. For some users, it may be important that the topsheet has a certain degree of opacity and thus can reduce the visibility of the absorbent component being soiled by the absorbed fluid to the greatest feasible extent.

[0003] Since these functional objectives of the topsheet material are generally somewhat contradictory to each other in terms of material performance characteristics, it remains a challenge to produce a topsheet material that fully meets all these objectives, and there is still room for improvement. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Figure 1 is a schematic plan view depicting an example of an absorbent article in the form of a feminine hygiene pad.

[0005] Figure 2A is along Figure 1 in Figure 1 a schematic cross - section in a non - limiting example of a feminine hygiene pad taken along line 2 - 2 of

[0006] Figure 2B is along Figure 1 in Figure 1 a schematic cross - section in a possible alternative non - limiting example of a feminine hygiene pad taken along line 2 - 2 of

[0007] Figure 3 is a schematic perspective view of a pair of apertured rollers operating on a non - woven web.

[0008] Figure 4 is a schematic side view of an apparatus on a production line including a pair of apertured rollers operating on a non - woven web.

[0009] Figure 5A and Figure 5BSchematic side view depictions of different alternative non - limiting examples of multiple pairs of perforated rollers.

[0010] Figure 6A and Figure 6B are a schematic intermediate cross - sectional view and a perspective view, respectively, of an example of a perforated pin.

[0011] Figure 7 is a schematic enlarged cross - sectional (taken along the y - z plane) depiction of a perforated pin operating on a portion of a non - woven web in the nip between perforated rollers.

[0012] Figure 8 is a schematic enlarged cross - sectional (taken along the y - z plane) depiction of a portion of a non - woven web having holes therethrough.

[0013] Figure 9 is Figure 8 a schematic further enlarged cross - sectional (taken along the y - z plane) depiction of the portion of the non - woven web shown within circle 9 shown in

[0014] Figure 10A is a schematic enlarged plan view (along the z - direction) depiction of a portion of a non - woven web including holes.

[0015] Figure 10B is an enlarged photograph of a portion of a non - woven web after leaving the nip between a perforated roller and a counter - roller.

[0016] Figure 10C is a further enlarged photograph of a portion of a non - woven web after leaving the nip between a perforated roller and a counter - roller.

[0017] Figure 11 is an image of a plan view (along the z - direction) of a portion of a non - woven web material having a pattern of holes therethrough.

[0018] Figure 12 is an enlarged image of a plan view (along the z - direction) of a portion of a non - woven web material having holes therethrough.

[0019] Figure 13 is an enlarged image of a plan view (along the z - direction) of a portion of a non - woven web material having holes therethrough.

[0020] Figure 14 is a schematic developed plan view (along the z - direction) of an example of the path of holes.

[0021] Figure 15 is a schematic developed z - direction cross - section of a combination of a topsheet and a fluid management layer having holes formed therethrough in the combination. Detailed Description

[0022] Definition

[0023] As used herein, the following terms shall have the meanings specified hereinafter:

[0024] As used herein, the term "integrated" is used to describe the fibers of a nonwoven material that have been interlaced, entangled, and / or pushed / pulled in the positive and / or negative Z direction (the thickness direction of the nonwoven material). Some exemplary methods for integrating the fibers of a nonwoven web include hydroentangling and needling. Hydroentangling (also known as "hydroneedling" or ("water enhanced")) uses multiple high-pressure water jets directed at a precursor batt or aggregate of fibers being conveyed in the machine direction to entangle the fibers. Needling (also known as "needlepunching") involves using specially configured needles to mechanically push and / or pull the fibers, a precursor batt or aggregate of fibers, in the z direction to entangle them with other fibers in the batt or aggregate.

[0025] As used herein, the term "carded" is used to describe the structural characteristics of a particular type of nonwoven web material contemplated herein for use as the topsheet material in some examples. A carded nonwoven web is formed from fibers that have been cut to a specific, limited length, which are alternatively referred to as "short length fibers". The short length fibers can have any selected length. For example, the short length fibers can be cut to lengths of up to 120 mm, as short as 10 mm. However, if a particular group of fibers are short length fibers, then each fiber in the carded nonwoven has a length that is substantially the same, i.e., short. In the case where a nonwoven web (e.g., a web comprising polypropylene fibers and viscose fibers) includes more than one composition of fibers, the length of each fiber of the same composition can be substantially the same, while the corresponding short fiber lengths of the respective fiber compositions can be different.

[0026] In contrast to short fibers, filaments such as those produced by textile processes, e.g., in spunbond or meltblown nonwoven web manufacturing processes, are generally not short length fibers. Instead, these filaments are sometimes characterized as "continuous" fibers, which means they have a relatively long and indefinite length and are not cut to a specific length after being textile processed, as are their short fiber counterparts.

[0027] "Lateral", with respect to a feminine hygiene pad or a component thereof, means the direction parallel to the horizontal line tangent to the front surface of the upper portion of the wearer's leg adjacent to the torso when the pad is worn normally and the wearer has adopted a uniform, square, normal standing posture. The "width" dimension of any component or feature of a feminine hygiene pad is measured along the lateral direction. When the pad or a component thereof is placed flat on a horizontal surface, the "lateral" direction corresponds to the lateral direction with respect to the structure when it is worn, as defined above. With respect to a feminine hygiene pad opened and placed flat on a horizontal flat plane, "lateral" means the direction perpendicular to the longitudinal direction and parallel to the horizontal flat plane. With respect to a feminine hygiene pad, the "x-direction" is also the lateral direction.

[0028] The "lateral axis" of a feminine hygiene pad or a component thereof is a lateral line located in the x-y plane, and when the pad or the component is placed flat on a horizontal surface, the lateral line bisects the length of the pad or the component. The lateral axis 500 (see Figure 1 ) is perpendicular to the longitudinal axis 400.

[0029] "Longitudinal", with respect to a feminine hygiene pad or a component thereof, means the direction perpendicular to the lateral direction. The "length" dimension of any component or feature of the pad is measured along the longitudinal direction from its forward extent to its rearward extent. When a feminine hygiene pad or a component thereof is placed flat on a horizontal surface, the "longitudinal" direction is perpendicular to the lateral direction with respect to the pad when it is worn, as defined above. With respect to the pad, the "y-direction" is also the longitudinal direction.

[0030] The "longitudinal axis" of a feminine hygiene pad is a longitudinal line located in the x-y plane, and when the pad is placed flat on a horizontal surface, the longitudinal line bisects the width of the pad or the component. The longitudinal axis 400 (see Figure 1 ) is perpendicular to the lateral axis 500.

[0031] The "path" of the holes is a set of five or more holes 321 having the following characteristics, as Figure 14 illustrated by way of example in

[0032] - Each hole in the set of five or more holes is located at a distance SD not greater than 3 times the maximum x-y dimension LD of the holes in the set from its farthest adjacent hole, where the distance SD is measured between the nearest parts of the perimeters of adjacent holes.

[0033] - There is no bend angle BA less than 120 degrees within the set, where the bend angle BA is the larger angle at the intersection of the path lines 326 passing through the geometric centers of adjacent holes along the x-y plane.

[0034] The relative terms "outer" and "inner" refer to positions on the pad along the x-y direction relative to the longitudinal axis 400 and the transverse axis 500 of the pad, where the intersection of the longitudinal axis and the transverse axis is the most medial position, both longitudinally and transversely, on the pad, and all positions on the pad spaced apart from this intersection are on its outer side. The outermost positions of the pad are along its peripheral edge. When a first position is closer to the intersection than a second position and both positions are on the same side of the longitudinal axis and the transverse axis, the first position is inner to the second position and the second position is outer to the first position. When a first position is closer to the longitudinal axis than a second position and both positions are on the same side of the longitudinal axis, the first position is transversely inner to the second position and the second position is transversely outer to the first position. When a first position is closer to the transverse axis than a second position and both positions are on the same side of the transverse axis, the first position is longitudinally inner to the second position and the second position is longitudinally outer to the first position.

[0035] The "size" of a hole is the maximum x-y plane dimension of its perimeter. As a non-limiting example, the size of a hole with a circular perimeter is the diameter of that perimeter. In another non-limiting example, the size of a hole with an oval perimeter is the length of the major axis of the oval.

[0036] The "x-y plane" with respect to a feminine hygiene pad or its components refers to any horizontal plane that is occupied by the horizontal surface or any layer of the pad or component when it is lying flat on a horizontal surface.

[0037] The "z direction" with respect to a feminine hygiene pad or its components refers to the direction that is perpendicular / orthogonal to the x-y plane when the pad is lying flat on a horizontal surface.

[0038] The terms "top", "bottom", "upper", "lower", "above", "below", "beneath", "adjacent above", "adjacent below", and similar terms characterizing relative vertical positioning, when used herein to refer to a layer, component, or other feature of a feminine hygiene pad, refer to positioning along the z direction and should be interpreted relative to the pad as it would appear when lying flat on a horizontal surface, where its surface facing the wearer is oriented upward and its surface facing outward is oriented downward.

[0039] With respect to a feminine hygiene pad, or its components or structure, "facing the wearer" is a relative position term that refers to a component or structure that is closer to the wearer during use than another feature of the component or structure. For example, the topsheet has a surface that faces the wearer and is closer to the wearer than the opposite, outward-facing surface of the topsheet.

[0040] With respect to a feminine hygiene pad, or a component or structure thereof, "facing outward" is a relative position term that refers to a component or structure that, in use, is further from the wearer than another feature of the component or structure. For example, the topsheet has a surface that faces outward and is further from the wearer than the opposite, wearer-facing surface of the topsheet.

[0041] As used herein, "machine direction" or "MD" with respect to a feminine hygiene pad or a component thereof refers to the direction parallel to the flow of the pad or component through a processing / manufacturing apparatus. With respect to the manufacture of a web material, the "y-direction" is the direction parallel to the machine direction.

[0042] As used herein, "cross direction" or "CD" with respect to a feminine hygiene pad or a component thereof refers to the direction perpendicular / orthogonal to the machine direction and the z-direction. With respect to the manufacture of a web material, the "x-direction" is the direction parallel to the cross direction.

[0043] When used to characterize an amount such as the weight, volume, surface area, etc. of a feminine hygiene pad or a component thereof that is composed of a composition, material, feature, etc., "substantially" and its forms mean that such weight, volume, surface area, etc. of the pad or component is mostly composed of the composition, material, feature, etc.

[0044] General description - Feminine sanitary pad

[0045] Reference Figure 1 and Figure 2A, as envisioned herein, the feminine hygiene pad 300 will have a longitudinal axis 400 and a transverse axis 500 and will include a wearer-facing surface and an opposite outward-facing surface. The liquid-permeable topsheet 301 may form at least a portion of the wearer-facing surface, and the liquid-impermeable backsheet 303 may form at least a portion of the outward-facing surface. An absorbent structure 302 is disposed between the topsheet and the backsheet. The absorbent structure 302 may include a fluid management layer 302a and a storage layer 302b. (The fluid management layer 302 as described herein is sometimes referred to in the art as a "collection / distribution layer", a "distribution layer", or a "second topsheet" and is intended to dissipate the energy from a fluid gush to the desired extent, provide a space volume for the discharged fluid to temporarily occupy during the time required for the underlying absorbent structure (e.g., the storage layer) to receive and absorb the fluid, and distribute the fluid through the absorbent structure to maximize its effective and efficient use). Non-limiting examples of absorbent articles sharing these features include feminine hygiene pads, disposable incontinence pads, disposable incontinence undergarments, disposable baby diapers, and disposable baby / child training pants. Non-limiting examples of suitable absorbent structures / storage layers are described in co-pending U.S. Provisional Application Serial No. 63 / 256,164, which is incorporated herein by reference. Non-limiting examples of suitable absorbent structures / storage layers are described in co-pending U.S. Provisional Application Serial No. 63 / 316,097, which is incorporated herein by reference.

[0046] The topsheet 301 and the backsheet 303 may be joined together to form and define the outer perimeter of the pad. The absorbent structure 302 and its components or layers (e.g., the fluid management layer 302a and the storage layer 302b) will be sized such that their outer perimeters are disposed laterally and longitudinally inside the outer perimeter. The components or layers of the absorbent structure 302 may be substantially similar or identical to each other in size and shape in the x-y direction, or they may have correspondingly different x-y dimensions and / or shapes. The individual layers may be manufactured to have a rectangular shape as Figure 1 suggested in, or one or both may be manufactured to have any other suitable shape, such as an oval shape, a stadium shape, a rounded rectangle shape, an hourglass shape, a peanut shape, etc. A shape having a concave profile along the longitudinal edges (e.g., an hourglass shape) may provide enhanced comfort and / or conformity to the body between the wearer's legs in some examples.

[0047] The topsheet 301 can be joined to the backsheet 303 by any suitable attachment mechanism. The topsheet 301 and the backsheet 303 can be joined directly to each other in the pad perimeter, and can be joined indirectly together by joining them directly to the absorbent structure 302, the fluid management layer 302a, and / or the storage layer 302b and / or additional layers disposed between the topsheet 301 and the backsheet 303. This indirect or direct joining can be achieved by any suitable attachment mechanism known in the art. Non-limiting examples of attachment mechanisms can include, for example, melt bonding, ultrasonic bonding, pressure bonding, adhesive bonding, or any suitable combination thereof.

[0048] The pad 300 can include a pair of laterally extending portions (sometimes referred to as "wings") 304 that are oppositely disposed and that do not include absorbent components. The wings 304 can be formed by or include laterally extending portions of one or both of the topsheet 301 and the backsheet 303 materials. The wings 304 can also include deposits of adhesive (not shown) on their outward-facing surfaces. With this configuration, the user can properly position and place the pad 300 within the crotch region of her underwear, and wrap and fold the wings 304 downwardly over and around the respective edges of the leg openings, and then adhere the wings 304 to the outside / lower side of the crotch region of the underwear. So positioned, the wings 304 can help hold the pad in place during wear / use and help protect the underwear from contamination around the leg edges.

[0049] Top sheet

[0050] General description

[0051] It is generally desirable for the topsheet 301 to be compliant, feel soft, and non-irritating to the wearer's skin. Suitable topsheet materials will include liquid-permeable materials that are disposed on the wearer-facing side of the pad, where they will contact the wearer's body. Preferably, the topsheet will be constructed to allow the discharged fluid to penetrate through it as quickly as possible, and desirably, not readily allow the fluid to move back upward through the topsheet and contact the wearer's skin. The topsheet may also be adapted to carry and / or provide the transfer or migration of a selected lotion composition provided with the pad to the wearer's skin. The topsheet can include or be formed of a nonwoven material.

[0052] The nonwoven fiber web of the component to be used as the topsheet can be produced by any known procedure for manufacturing nonwoven fiber webs, non-limiting examples of such procedures including spunbonding, carding, wet-laying, air-laying, meltblowing, needling, mechanical winding, thermo-mechanical winding, and hydroentangling.

[0053] The nonwoven material suitable for use as the top sheet component material may include a layer of gathered fibers or a laminate or combination of a plurality of layers of gathered fibers, which may include similar or different compositions (e.g., spunbond-meltblown laminates). In a specific example, the top sheet may be formed by a carded through-air bonded nonwoven web material.

[0054] The top sheet contemplated herein does not include any major portion of the top sheet xy surface area occupied by the film. Some currently known top sheets for feminine hygiene pads include an apertured film, such as a hydroformed film or a vacuum formed film, alone or in combination with an adjacently disposed nonwoven web material. The film can help prevent liquid from resurfacing (re-seepage) and contacting the wearer. However, it is believed that the top sheet having the features described herein, for example, when combined with a properly constructed and constructed fluid management layer (e.g., as disclosed in co-pending U.S. Provisional Application Serial No. 63 / 256164), can effectively prevent re-seepage to a degree comparable to or better than a pad having a top sheet of a film comprising a major portion of the top sheet xy surface area. It is not intended to be bound by theory, and it is believed that careful selection of the fiber type and the linear density of the fiber type in each layer in the layered fluid management layer can cause a desired combination of appropriately low liquid acquisition time and low re-seepage, overcoming the typical compromises in these conflicting goals associated with existing nonwoven top sheets. This performance is evident in the combination of the nonwoven top sheet and the fluid management layer described herein.

[0055] In addition to the features described herein, the nonwoven web material used to form the top sheet may also have any of the features, structures, components and / or compositions described in, for example, co-pending U.S. provisional application serial numbers 63 / 256,164 and 63 / 316,097, the disclosures of which are incorporated herein by reference.

[0056] Basis weight

[0057] The topsheet nonwoven fabric can be manufactured to have a basis weight of at least about 15 gsm, more preferably at least about 40 gsm, or most preferably at least about 60 gsm, specifically listing all values within these ranges and any ranges established therefrom. In some examples, the nonwoven topsheet contemplated herein can be manufactured to have a basis weight of about 15 gsm to 80 gsm, more preferably about 20 gsm to 60 gsm, or most preferably about 20 gsm to 40 gsm, specifically listing all values within these ranges and any subranges established therefrom. In a specific example, the topsheet nonwoven fabric can be manufactured to have a basis weight of about 18 gsm to 40 gsm, more preferably about 20 gsm to 30 gsm, even more preferably about 22 gsm to 26 gsm, specifically listing all values within these ranges and any subranges established therefrom. The lower limit of the range of the desired basis weight is affected by the need for the web tensile strength level required for processing and the consumer's substantial preference for opacity level and thickness, feel, and appearance. The upper limit of the range of the desired basis weight is affected by the need for suitable rapid fluid collection and fluid passage through the topsheet and material cost issues.

[0058] Fiber composition

[0059] Non-limiting examples of the constituent materials suitable for use in the topsheet nonwoven fabric include fibrous materials made from natural fibers (such as cotton (including 100% organic cotton), modified natural fibers, semi-synthetic fibers (such as fibers spun from regenerated cellulose), synthetic fibers (such as fibers spun from polymer resins), or combinations thereof. Synthetic fibers can include fibers spun from a single polymer or a blend of polymers. Synthetic fibers can include single-component fibers, bicomponent fibers, or multicomponent fibers. (In this document, bicomponent or multicomponent fibers are fibers having a cross-section that is divided into clearly identifiable component parts, each of which is formed from a single polymer or a single homogeneous polymer blend, different from the other parts. Such fibers and methods for preparing them are known in the art. Examples of bicomponent fiber configurations having a substantially circular cross-section include side-by-side or "ribbon" configurations, eccentric sheath-core configurations, and concentric sheath-core configurations.

[0060] The nonwoven topsheet contemplated herein may include fibers having numerous combinations of constituent components. For example, the fibers may be spun from polymer materials such as polyethylene (PE) and / or polyethylene terephthalate (PET). The fibers may be spun in the form of bicomponent fibers. In some examples, the bicomponent fibers may have a combination of a core component of a first polymer (e.g., PET) and another polymer as the skin component, in a skin-core bicomponent configuration. In more specific examples, PE may be combined with the PET core component to form the skin component. Fibers including a PET component having relatively high stiffness and resiliency may be selected to help provide body and resiliency to the nonwoven web and the resulting cushioned feel. Additionally, fibers including a PET component having considerable resiliency help the web maintain the area and size of the holes (if included) formed therethrough.

[0061] Other polymer materials may be included. For example, fibers spun from polypropylene, polyethylene, copolyethylene terephthalate, copolypropylene, and other thermoplastic resins may be included. It may be desirable that when including skin-core bicomponent fibers, the polymer having a lower melting temperature forms the skin component. Additionally, without being bound by theory, it is believed that using polyethylene terephthalate as the core component may help impart resiliency to the topsheet.

[0062] Compared to other potentially useful polymers, polyethylene as a polymer component from which fibers may be spun has a relatively low melting temperature and exhibits a relatively smooth / silky surface feel. PET has a relatively high melting temperature and exhibits relatively high stiffness and resiliency. Thus, in some examples, it may be desirable for the topsheet nonwoven fibers to have a skin-core bicomponent configuration where the skin component is primarily polyethylene and the core component is primarily PET. Polyethylene may be used to impart a silky feel to the fibers and thus to the topsheet, and may be used to effect fiber-to-fiber bonding via heat treatment causing the skin of adjacent / contacting fibers to melt and fuse at the lower melting temperature of polyethylene, while PET may be used to impart resiliency and will not melt during a heat treatment process involving appropriately controlled temperatures due to its higher melting temperature. It is believed that a suitable weight ratio in such PE / PET skin-core bicomponent fibers may be from about 40:60 to about 60:40.

[0063] The constituent fibers may be staple fibers. The staple fibers may be carded and consolidated to produce a web having cohesiveness and tensile strength via a hydroentangling process or other suitable methods of integrating and / or entangling the fibers. In some examples, the web may be calender bonded to impart additional consolidation and tensile strength. However, in other examples, calender bonding may be preferably foregone as it may reduce web thickness and loft, reduce porosity, increase web stiffness, and adversely affect or reduce other softness attributes perceivable by the consumer.

[0064] Surface treatment (hydrophilic / hydrophobic)

[0065] Depending on its chemical composition, the surface of a fiber will inherently be hydrophilic or hydrophobic. For example, the surface of fibers spun or otherwise formed from some types of polymers such as polyethylene and polypropylene will inherently be hydrophobic. In contrast, the surface of other types of fibers such as those spun from regenerated cellulose (e.g., rayon, viscose, lyocell, etc.) is inherently hydrophilic. The surface of natural fibers may be inherently hydrophilic or hydrophobic, but this can depend on the treatments the fibers have undergone. For example, harvested cotton fibers carry a coating of natural wax and thus their surface is hydrophobic. However, after they have undergone processes including scouring and bleaching, the wax will be stripped, rendering the fiber surface hydrophilic.

[0066] Manufacturers and / or suppliers of spun synthetic staple fibers currently apply coatings in the form of surface finishes or processing aids to the fibers for the purpose of providing lubricity, for example, during the carding process. These surface finishes or processing aids can be formulated to be hydrophobic or hydrophilic and are substantially durable for the purposes herein as they will not dissolve in aqueous fluids during the normal wear duration of the pad. Thus, manufacturers or suppliers of spun synthetic staple fibers can provide fibers having a hydrophobic or hydrophilic surface finish, and currently, several manufacturers in the nonwoven materials industry do so.

[0067] Notably, spun synthetic staple fibers can be obtained with a surface that is inherently hydrophobic or hydrophilic, or with a surface finish that makes its surface hydrophilic or hydrophobic according to the purchaser's choice. It may be desirable to select fibers having a hydrophilic (“hydrophilic fibers”) or hydrophobic (“hydrophobic fibers”) surface, or a blend of these two types of fibers.

[0068] In some examples, it may be preferred that the fiber composition of the topsheet is predominantly, substantially, or completely hydrophobic, or rendered hydrophobic via the fiber surface finish. A topsheet formed from a nonwoven fibrous web having a predominantly hydrophobic fiber composition will resist backflow. On the other hand, if the size of the pores or inter-fiber voids within the fibrous structure of such a nonwoven fibrous web is not large enough, the topsheet may prevent fluid from passing through the surface facing the wearer to the absorbent core component of the pad thereunder, i.e., will not be prone to / rapidly collect fluid unless combined with other features as described herein.

[0069] In other examples, the fibers that make up part, most (by surface area), or all of the cross-section of the fibrous web material from which the topsheet is formed can be a blend of both hydrophobic and hydrophilic fibers. In such examples, the hydrophilic fibers can be used to assist in wicking fluid from the topsheet's wearer-facing surface downward to the underlying absorbent core component, while the hydrophobic fibers can be used to assist the topsheet in preventing backflow. It is believed that a successful balance can be achieved for such examples.

[0070] Accordingly, in some examples, the topsheet nonwoven can include a mixture of hydrophobic and hydrophilic fibers. For example, the nonwoven can include at least about 40 weight percent, more preferably at least about 50 weight percent, or most preferably at least about 60 weight percent hydrophilic fibers, by weight of the fibers, specifically including all values within these ranges and any ranges established thereby. In more specific examples, the nonwoven topsheet can include from about 40 weight percent to 70 weight percent, more preferably from about 45 weight percent to 68 weight percent, or most preferably from about 50 weight percent to 65 weight percent hydrophilic fibers, specifically listing all values within these ranges and any ranges established thereby. The topsheet nonwoven can include a blend of hydrophilic and hydrophobic fibers, with the weight ratio of hydrophilic fibers to hydrophobic fibers being from 30:70 to 70:30, more preferably from 35:65 to 65:35, and even more preferably from 40:60 to 60:40. As described above, the hydrophilicity of the hydrophilic fibers can be affected by applying a surface treatment composition.

[0071] Without being bound by theory, it is believed that in cases where most of the fibers are hydrophilic, the fluid collection rate can be improved by combining with other features described herein, without unduly affecting backflow in an adverse or unacceptable manner. In cases where the goal is less backflow, the opposite may be true. In such cases, a higher weight fraction of hydrophobic fibers may be desirable.

[0072] Linear density

[0073] Fibers are typically manufactured, selected, and purchased according to a linear density specification, expressed as denier or decitex. For fibers of a given polymer composition, the linear density is related to the fiber size / diameter.

[0074] In some examples, the fibers forming the topsheet may be selected to have an average linear density of from about 1.0 to 5.0 denier, more preferably from about 1.5 to 4.5 denier. All combinations of sub-ranges within these ranges are contemplated herein. Fibrous components of topsheet materials with denier numbers closer to the lower limit of these ranges are relatively finer and tend to impart relatively greater tactile softness to the topsheet material, but also impart smaller pore sizes (interstitial spaces) and thus lower fluid permeability. On the other hand, fibrous components with denier numbers closer to the upper limit of these ranges are relatively coarser and tend to impart relatively greater stiffness, but also impart larger pore sizes and thus greater fluid permeability. In the case of greater fluid permeability, the designer may have greater freedom to fabricate a topsheet with a greater proportion of hydrophobic fibers, which can provide greater resistance to rewetting. However, imparting larger pore sizes may also have the effect of imparting less opacity, which may be valuable otherwise to mask the staining of materials in the absorbent structure 302. The designer may wish to balance these characteristics when selecting the fiber denier. As described herein, this selection may also be influenced by the number and size of the pores created in the topsheet.

[0075] Without wishing to be bound by theory, it is believed that for nonwovens of a specific basis weight as contemplated herein, the inclusion of fibers having a linear density greater than about 5.0 denier may result in the topsheet lacking sufficient soft feel for some consumers, as such relatively large fibers will tend to be stiffer. Conversely, the selection of fibers having a linear density less than about 1.0 denier results in overly small interstitial spaces / voids between and within the fibers and makes fluid collection and movement through the topsheet unacceptably difficult, unless pores are included. In any case, a suitable pattern of pores may be imparted to the topsheet to increase fluid permeability and thereby offset the effects of including relatively small denier fibers.

[0076] Short fiber length

[0077] Suitable fibers may be staple fibers having lengths in the following ranges: at least about 30 mm, 40 mm, or 50 mm, up to about 55 mm or from about 30 mm to about 55 mm, or from about 35 mm to 52 mm, with each 1 mm increment within said ranges listed. In a specific example, the staple fibers may have a length of about 38 mm.

[0078] Pores

[0079] It is believed that in topsheet nonwovens formed of fibers of relatively small size / linear density and / or predominantly, substantially, or completely hydrophobic fibers, the collection rate can be appreciably increased by forming a pattern of pores through the fiber web. Generally, the preferred pores will have a size substantially greater than the average pore / void size (the size of the inter-fiber spaces) within the nonwoven fiber web.

[0080] An example of a cross-section of a topsheet nonwoven fibrous web material 20 with apertures having a pattern of holes 321 therethrough is depicted in Figure 11 FIG. Figure 11 . An enlarged image of an example of a hole through the nonwoven fibrous web material is depicted in Figure 12 FIG. Figure 12 . The holes can be distinguished from randomly arranged pores or voids through the nonwoven fibrous web material because they are created by an easily distinguishable displacement of fibers and / or fiber component materials in the x-y direction, creating a concentration of dense material and / or displaced fibers defining a perimeter 22 of a z-direction hole / aperture through the nonwoven web, which z-direction hole / aperture is relatively substantially larger than the randomly distributed pores or voids between and within the fibers making up the nonwoven material. The holes can be created through the web via any suitable process and equipment known in the art. However, in some examples, the holes can be created through the web via the processes and equipment described herein, and the holes are configured to impart an average x-y size hole area as specified in the examples listed herein. In the present document, the x-y size area of a hole is defined by the visually distinguishable inner edge of a dense zone 23 surrounding the perimeter 22 of the hole. Individual fibers that may have left the main structure and / or the dense zone around the perimeter and passed into or through the main opening area of the hole (by way of the exemplary illustration, the individual displaced fiber 16 shown in Figure 12 FIG. Figure 12 ) are not considered for the purposes herein to be subtracted from the hole area. Further, without intending to be bound by theory, it is believed that in cases where the shape of the hole is too long or too narrow, the fluid collection rate may be negatively affected. Thus, it is desirable for the holes to have a limited maximum average x-y direction aspect ratio (maximum dimension: minimum dimension in the x-y direction). Accordingly, it is desirable for the average aspect ratio of the holes to be from about 2.5:1 to 1:2.5; more preferably 2:1 to 1:2; even more preferably 1.5:1 to 1:1.5; still more preferably 1.3:1 to 1:1.3; and most preferably 1.2:1 to 1:1.2; all combinations of sub-ranges within these ranges are contemplated herein. Further, to maintain the structural integrity of the web and the shape integrity of the holes, it is preferred that the x-y plane shape of most or all of the holes, at least in the central region 305 (see Figure 1 FIG. Figure 1 ) (if not most or all of the topsheet), is substantially a circular shape (e.g., circular, oval, ovoid, elliptical, stadium-shaped, etc.), without defined sharp corners. Thus, when viewed in the radially inward direction toward the axis of the roller, it is desirable for the pins on the roller used to create the holes to have a radially outermost working surface that has a shape without defined sharp corners.

[0081] Central region hole arrangement

[0082] The amount of the X-Y plane area within the perimeters of all the holes in the region of interest of the topsheet totals to the total open x-y plane area (“open area”) in the topsheet nonwoven. In combination with the desired average hole size, the desired open area of the central region 305 has been determined in order to effectively mitigate potential barriers to fluid collection that may be caused by the composition of finer denier fibers and / or predominantly hydrophobic fibers. Thus, it may be desirable that the first arrangement of holes 322 within the central region 305 constitutes 1% to 12%, more preferably 2% to 10%, and even more preferably 3% to 8% of the open area percentage; all combinations of sub-ranges within these ranges are contemplated herein. It is preferred that such an amount of open area exists in the central region 305. The lower limits of these ranges are restricted by the need for efficacy / performance; the holes should provide at least a minimum amount of open area in order to function effectively as may be included for the purposes described herein. The upper limits of these ranges are restricted by the need for consumer acceptance; if the open area is too large, the consumer may perceive the topsheet as fragile or of poor quality; and furthermore, the topsheet becomes less effective in retaining fluid beneath it and is also less effective in reducing the visibility of the underlying absorbent component being contaminated by the absorbed fluid present therein.

[0083] Reference Figure 1 , for the purposes contemplated herein, the central region 305 is a rectangular cross-section of the topsheet that is 80 mm long in the longitudinal direction and 20 mm wide in the transverse direction. The central region is centered on the longitudinal axis 400. The central region spans the transverse axis 500 and may be centered on this transverse axis, or may be centered on a transverse line that is in front of the transverse axis (i.e., towards the front of the pad). The open area percentage of the central region 305 is the fraction (expressed as a percentage) of the x-y area therein that is opened in the z-direction by the co-presence of the holes passing through it. In other words, the open area percentage within the ROI is the total open x-y area of the holes within the central region divided by 1,600 mm 2 multiplied by 100%.

[0084] In some examples, the open area percentage fraction in the central region 305 may be obtained from the specifications given or provided by the manufacturer of the topsheet nonwoven fiber web material. In cases where this is not available, it may be measured via any suitable measurement technique applicable in a manner consistent with the above description of the x-y dimensional area of the hole area and the description of “open area”, which may include but is not limited to the “open area percentage measurement method” described below.

[0085] Furthermore, in combination with the above-described open area percentage and for similar reasons, it may be preferred that the first arrangement of holes 322 within the central region 305 has a size of 0.2 mm 2 to 0.75 mm 2, more preferably 0.4 mm 2 to 0.60 mm 2 in average size; all combinations of sub - ranges within these ranges are contemplated herein.

[0086] Outer hole arrangement

[0087] Lateral and / or longitudinal outside of the central region 305, the fluid discharged moving through the topsheet 301 is less of a concern because these regions are generally not as close to the source and location of fluid discharge when the pad is properly positioned for wear / use. However, it has been appreciated that one or more additional arrangements of the pore paths outside the central region as described herein may have beneficial effects. Referring Figure 1 , one or more second arrangements of the pores 323 may be created and located lateral and / or longitudinal outside of the central region 305 in the topsheet 301.

[0088] In some examples, it may be preferred that the average size of the pores 324b forming these second arrangements is less than that of the pores of the first arrangement 322. In some examples, it may be preferred that the pores 325b have an average size in the range of 0.2 mm 2 to 0.75 mm 2 ; all combinations of sub - ranges within this range are contemplated herein.

[0089] Alternatively or in addition, in some examples, it may be preferred that the pores 324b are arranged in one or more paths of pores as defined herein. The paths of such relatively small pores (preferably two or more paths arranged together as Figure 1 suggested) may create for the wearer both a barrier structure and a visual effect of a set of supplementary channels through the topsheet down to the underlying absorbent member below. The barrier structure can be used to prevent fluid from migrating across the topsheet to locations outside the paths, and the set of supplementary channels is for reducing the likelihood of fluid migrating across / along the wearer - facing surface of the topsheet in the x - y direction and escaping from the pad. Additionally, such paths may impart a pillow - like visual appearance to the pad and topsheet, which the wearer may perceive as enhancing softness.

[0090] From Figure 1 it can be noted that for each pad, the first arrangement 322 and the second arrangement 323 of the pores can be "tilted" (i.e., discrete and integral), rather than being part of a continuous and undifferentiated regular pattern between pads. This characteristic is incidental to the first and second arrangements as described above and is depicted in Figure 1 by non - limiting, illustrative examples.

[0091] Referring Figure 2B and Figure 15, in some examples, the holes 321 through the topsheet 301 material can be formed simultaneously and in a manner such that they are substantially aligned in the z-direction and have corresponding x-y dimensions with the holes through an immediately adjacent lower layer component (such as the fluid management layer 302a), for example, by simultaneously conveying these two materials through a pair of apertured rollers 100, 120 (e.g., Figure 3 ), as described herein. This can not only have the effect of creating and / or enhancing a pillow-like appearance in the vicinity of the location of such holes (e.g., in the central region and / or near the periphery of the absorbent structure 302), but also provide multiple direct paths for fluid to move downward in the z-direction to the storage layer 302b (see Figure 2B ). In the aperturing method, a certain degree of partial bonding can be achieved around the perimeter 22 of the hole 321 between the fibers of the topsheet nonwoven material and the fibers of the fluid management layer nonwoven material, thereby forming a generally funnel-shaped z-directional depression around the hole in the topsheet. This imparts a topography or surface profile along the topsheet, further enhancing the pillow-like visual appearance.

[0092] Bonding

[0093] In some examples, it may be desirable for the fibers forming the topsheet nonwoven to be bonded after the carding / laying process to impart a fabric-like structure and tensile strength (in both the MD and CD) to the web that is necessary for it to substantially maintain its structure during downstream / later processes and to be in the form of a topsheet during use by the user / wearer. As an alternative to other bonding methods such as mechanical compression point bonding (e.g., calendering bonding) (with or without the application of heat energy), adhesive bonding, etc., it has been found that bonding via through-air heating is effective for creating fiber-to-fiber bonds and imparting structural integrity to the web, while maintaining the fiber-to-fiber pore / void size and loft, and imparting resilience to the nonwoven. In an example of a suitable method, when the carded web is conveyed through an oven or heating chamber in the machine direction on a conveyor belt, air heated to a selected heating temperature is blown through and / or drawn through (via vacuum) the carded web. When the operating parameters including the heated air temperature and velocity and the exposure time are appropriately adjusted, multiple randomly distributed fiber-to-fiber bonds can be created within the web, which imparts structural integrity to the web. An example of such fiber-to-fiber bonds 17 can be seen in Figure 13 . When the constituent fibers are, for example, sheath-core bicomponent fibers, where the sheath component is a polymer having a melting temperature lower than that of the core component, the process can be configured such that a melt bond is formed between the sheaths of adjacent contacting fibers without complete melting and loss of the structure of the sheath, while the core remains in place and unmolten. In such a process, the bond can be formed without applying z-direction compression or its effects, and thus, there is no associated loss of web thickness and reduction in the fiber-to-fiber pore / void size.

[0094] Hole opening method, resulting characteristics and material selection

[0095] See Figures 3 to 6B , which schematically depicts a generally cylindrical aperturing roll operating on a portion of a nonwoven web material, including an aperturing roll 100 and a counter roll 120. The precursor web material 10 can be conveyed from an upstream supply source 200 in the machine direction MD into the nip 110 between the aperturing roll 100 and the counter roll 120, and one or both of the rolls are driven to rotate about axes that are parallel to each other and have a cross direction. The apertured nonwoven web material 20 exits the nip 110, in which an arrangement of holes 321 of a desired size, shape, and configuration is imparted (as exemplified in the non-limiting examples of Figure 11 ).

[0096] The aperturing roll 100 can form an arrangement of individual aperturing pins 101 thereon and around it, and the aperturing pins project radially outward from the base surface 106 of the roll 100. The aperturing pin 101 has a top surface 102, which has a surface area along a hypothetical cylindrical shape. The top surface 102 of the aperturing pin 101 is preferably smooth and polished, with substantially no macroscopic cavities or irregularities. The area of the top surface 102 is defined and bounded by the top surface peripheral edge 103. Preferably, at least after the manufacture of the roll and before the pins are worn due to their use, the top surface peripheral edge 103 is defined by an angled, non-circular transition away from the top surface 102. As shown in Figure 6A and Figure 6B , it can include a small chamfer 103a around the top surface peripheral edge 103 to reduce stress concentration at the edge and the chance of surrounding rupture. However, the top surface peripheral edge 103 is substantially not radiating or circular at the transition away from the top surface 102. (The reason is explained below.) For the purpose of the mechanical structural integrity of the pin 101, preferably, the pin base periphery 105 will define a surface area larger than the surface area of the top surface 102 at the pin base, and the pin walls 104 will taper inwardly towards each other from the pin base periphery 105 to the pin top surface periphery 103. In this regard, the angle α between the top surface 102 and the pin walls 104 is preferably greater than 90 degrees. The pins can be recessed radially or circularly around the base periphery 105 to reduce local stress at the pin base periphery during the use of the roll.

[0097] The top surface 102 of the aperturing pin 101 can be given any desired shape and size, generally corresponding to the desired x-y direction shape and size of the holes to be formed in the subject nonwoven web material. Similarly, the aperturing pins 101 can be arranged on the aperturing roll 100 in any desired pattern, generally corresponding to the desired x-y direction pattern of the holes to be formed in the subject nonwoven material.

[0098] For purposes of structural integrity, preferably, the perforating pins 101 and the portions of the perforating roll that form their base surfaces 106 are integral and formed from the same continuous block of material. If not the entire perforating roll, a major portion thereof may be integrally formed from the same continuous block of material. Preferably, the material forming the pins 101 and the base surfaces 106 will be relatively hard and rigid, such as a suitable steel or its alloy. In some examples, the pins 101 or at least the top surfaces 102 may be given a suitably selected non-stick or anti-stick coating to avoid or reduce the adhesion of the material to be melted and / or deformed in the nip.

[0099] In some examples, the perforating pins 101 may be formed by machining away or otherwise removing material from a solid cylinder, leaving the material that defines and constitutes the pins 101.

[0100] In some examples, as Figure 4 illustrated, the opposing roll 120 may have a simple cylindrical outer surface that will engage all of the top surfaces 102 of the perforating pins 101 in the nip 110 between the rolls 100, 120. In other examples, as Figure 5A illustrated, the opposing roll 120 may have opposing structures 122 formed thereon that effectively mirror and engage the top surfaces 102 of the perforating pins 101 on the perforating roll 100. In other examples, as Figure 5B illustrated, the opposing roll 120 may have opposing structures 122 formed and arranged thereon that are configured and arranged to engage a desired subgroup (one or more, but not all) of the top surfaces 102 of the perforating pins 101 in the nip 110. In these latter examples, flexibility in providing different configurations or patterns of holes offering various options can be provided by fabricating and selecting different opposing rolls to operate with the perforating roll 100. In cases where only selective regions of the nonwoven material are desired to be perforated, these latter configurations can also enable an extended service life of the perforating roll 100 since not all of the perforating pins 101 need to be used simultaneously.

[0101] As with the perforating roll 100 and the perforating pins 101, preferably, the material forming the surface of the opposing roll 120 and / or any of its opposing structures 122 is relatively hard and rigid. These surfaces may also be given a suitably selected non-stick or anti-stick coating.

[0102] When configured for operation, the perforating roll 100 and the opposing roll 120 are preferably arranged such that there is substantially no or virtually no (zero) specified gap in the nip 110 between the top surfaces 102 of the perforating pins 101 and the opposing surface of the opposing roll 120. See Figure 7 , in which case, the polymeric material of the constituent fibers forming the precursor nonwoven fibrous web material will plastically deform and asFigure 7 The double-headed arrow in indicates the area that is extruded from the nip region between the top surface 102 of the perforating pin and the opposing roller surface and that starts from the peripheral edge 103 of the top surface 102 of the pin 101 and extends in the x-y direction beyond this peripheral edge. See . Figures 7 to 10C As a result, a dense pore perimeter region 23 is obtained. Depending on the composition of the nonwoven fiber 15 components and the operating temperature of the roller, the dense region 23 may include a dense polymeric material of fiber components that have been melted and then fused, not melted but plastically deformed and extruded, or a combination thereof. The formation of the dense region 23 that defines the pore 321 stabilizes the size and shape of the pores in the open-cell nonwoven fiber web 20.

[0103] Either or both of the perforating roller 100 and the opposing roller 120 can be heated to a temperature at or above the melting temperature of one or more of the polymeric components of the web fiber composition to facilitate such deformation and / or melting and fusing.

[0104] Even when the rollers are configured to have a specified gap that is substantially zero or effectively zero in the nip 110, it may be difficult to extrude all of the fiber component material trapped in the nip region between the top surface 102 of the pin and the opposing roller surface 121. This can be the result of microscopic surface defects in the top surface 102 of the pin and / or the opposing roller surface 121 and / or some compliance intentionally provided in the respective roller structure or roller bearing and / or drive mechanism and structure, where a large amount of pressure that is not feasible in the nip would be required to extrude all of the material from the nip region between the top of the perforating pin and the opposing roller surface. The latter scenario would exist in examples where the fiber component is present in the subject nonwoven fiber web and the fiber component is brittle or substantially non-ductile and thus is crushed and flattened under the pin but not extruded. Such examples can include nonwoven fiber web materials that are partially composed of fibers made of non-thermoplastic materials (such as regenerated cellulose (e.g., rayon, viscose, lyocell, etc.)). In some examples, it may be desirable to include a feature in one or both of the rollers or in the roller bearing and / or drive mechanism and structure that provides limited compliance at a given pressure, i.e., allows the rollers to separate to a limited extent at the nip 110 at a given nip pressure to define the maximum pressure in the nip applied to the pin surface 102 to reduce the chance of roller wear and pin failure. As a result, when the open-cell fiber web 20 exits the nip 110, a very thin / low-thickness film 21a of unextruded polymer and / or other fiber component material (shown in one example in ) Figure 10BIt may remain within the hole 321. However, when the component materials of the fibers of the fibrous web are appropriately selected as described below, the film 21a will readily detach and leave the fibrous web, leaving the open hole 321. The resulting hole 321 may have a frayed edge 24 around its perimeter 22, which frayed edge will be the remainder of the film 21a after most of it has broken. When the peripheral edge 103 of the pin top surface 102 is clearly defined, as described above, the amount of the film forming the frayed edge 24 will be minimized, i.e., the film breakage will desirably occur very close to the compacted region 23 and the hole perimeter 22.

[0105] In some cases, when the nonwoven fibrous web 20 exits the nip 110, the unextruded film material may rupture away from the hole 321 and adhere to one or both of the pin top surface 102 and the opposing roller surface 106. To address this issue, the system can be provided with in-line roller cleaning devices 130a and / or 130b. Such roller cleaning devices can consist of or include: one or more scrapers, brushes (which can themselves be configured to operate on a reversely rotating roller), a system of one or more pressurized air knives, water sprayers, or any combination thereof, or any other suitable roller cleaning device.

[0106] If the component materials of the nonwoven constituent fibers are appropriately selected, the above methods and mechanisms can effectively impart holes to the nonwoven fibrous web at a relatively high production rate, thereby contributing to manufacturing efficiency.

[0107] As described herein, in some examples, the desired topsheet nonwoven fibrous web material can be partially or fully composed of bicomponent fibers having a first polymer component and a second polymer component. In such examples, it may be desirable for the respective polymer components to have different melting temperatures. When the melting temperatures of the respective components are sufficiently different, the above-described fibrous web hole-opening system can be operated, where one or both of the rollers 100, 120 are heated to a temperature sufficient to melt one of the polymer components but not the other. Doing so causes the polymer component with the lower melting temperature to melt and readily flow out from beneath the hole-opening pin top surface 102, past the peripheral edge 103 of the top surface. At the same time, the polymer component with the higher melting temperature will not melt, and when it is extruded from beneath the pin top surface 102 in the nip 110, it is forced not only to plastically deform but also to break. The film of unextruded material that may remain when the fibrous web exits the nip 110 will be mostly composed of the component with the higher melting temperature, which will desirably break into pieces that will readily fall out of or be pulled out of the holes.

[0108] To achieve or enhance this effect, it is desirable for the first polymer component and the second polymer component of the bicomponent fiber composition to have a melt temperature difference of at least about 44 °C, more preferably at least about 72 °C, and even more preferably at least about 100 °C. This provides the operator with a wide range of temperatures to which one or both of the apertured rolls can be heated to melt the first polymer component having the lower melt temperature while avoiding melting of the second polymer component having the higher melt temperature.

[0109] In some examples (such as those described herein), a suitable topsheet nonwoven fabric can be composed of sheath-core bicomponent fibers, where polyethylene terephthalate (PET) forms the core component and polyethylene (PE) forms the sheath component. PET has a melt temperature of about 264 °C, which is relatively high among potential thermoplastic polymer components considered suitable for spinning fibers for the purposes contemplated herein. This relatively high melt temperature leaves a fair amount of room for the selection of a second suitable polymer, since most currently known suitable thermoplastic polymers for spinning fibers for the purposes of the present invention have melt temperatures significantly lower than 264 °C. Additionally, PET is relatively brittle and tends to break more easily than other suitable polymers rather than plastically deforming in a ductile manner under heavy pressure, which is desirable for the reasons described above. In contrast, PE has a melt temperature of about 110 °C to 130 °C (depending on the specific form) and will flow easily above the melt temperature. This makes it suitable as a nonwoven constituent fiber component for the purposes described above, including forming a stable dense zone 23 around the apertures, which helps to stabilize the apertures and their configuration / pattern within the nonwoven material during downstream processing and conversion operations. As described above, PE also imparts other desirable properties to the nonwoven fabric.

[0110] It is contemplated that the above method can be applied to two different nonwoven web materials simultaneously together. As described above, the two different nonwoven web materials 10 can be conveyed together through the nip 110 between the perforated roll 101 and the opposing roll 120. When the materials exit the nip, they will each have holes 321 aligned in the z-direction. The corresponding nonwoven web materials will be bonded together to some extent at the densified regions 23 surrounding the corresponding aligned holes 321 by a thermoplastic fiber component material that has been melted and extruded from below the perforated pins 101 in the nip and then fused. For example, a topsheet nonwoven web material and a fluid management layer nonwoven material as described herein or in the references incorporated by reference herein can be placed together and perforated in the manner described above. The fluid management layer can be constructed as described, for example, in U.S. Provisional Application Serial No. 63 / 316,097. In some examples, the fluid management layer can include any combination of single-component fibers, hollow single-component fibers, bicomponent fibers, cellulose fibers, and regenerated cellulose fibers. The bicomponent fibers can be spun into a core-sheath structure including a PET core component. The sheath component can be PE. The hollow single-component fibers can be spun from PET.

[0111] As described, the perforated pins 101 can be formed with a top surface 102 having various surface areas and shapes corresponding to the area and shape of the holes desired to be imparted to the subject nonwoven web. It should be understood that substantially circular holes 321 in the web may be most effective per unit surface area for providing fluid passageways. Similarly, a shape having an aspect ratio (machine direction dimension to cross direction dimension aspect ratio) close to 1:1 is relatively effective compared to a shape having an aspect ratio where either dimension is significantly greater or less than the other dimension. The methods and apparatus described herein can be configured to effectively impart a hole pattern to the nonwoven web, wherein the holes in the pattern have an average aspect ratio of 2.5:1 to 1:2.5, more preferably 2:1 to 1:2, even more preferably 1.5:1 to 1:1.5, still more preferably 1.3:1 to 1:1.3, and most preferably 1.2:1 to 1:1.2.

[0112] The above method does not require the web to be stretched sufficiently in the machine direction or cross direction in a subsequent step to open the holes after it exits the nip.

[0113] Testing and measurement methods

[0114] Thickness

[0115] The thickness of the specimen is measured as the distance between the reference platform on which the specimen is placed and the pressure foot that applies a specified amount of pressure to the specimen over a specified amount of time. All measurements are made in a laboratory maintained at 23°C ± 2°C and 50% ± 2% relative humidity, and the specimen is conditioned in this environment for at least 2 hours prior to testing.

[0116] The thickness is measured using a manually operated micrometer equipped with a pressure foot capable of applying a steady pressure of 0.50 kPa ± 0.01 kPa to the specimen. The manually operated micrometer is a deadweight instrument with a reading accuracy of 0.01 mm. A suitable instrument is the Mitutoyo Series 543ID-C Digimatic, purchased from VWR International, or equivalent. The pressure foot is a flat circular movable surface with a diameter smaller than the specimen and capable of applying the required pressure. A suitable pressure foot has a diameter of 25.4 mm, but smaller or larger pressure feet can be used depending on the size of the specimen being measured. The specimen is supported by a horizontal flat reference platform that is larger than and parallel to the surface of the pressure foot. The system is calibrated and operated in accordance with the manufacturer's instructions.

[0117] If necessary, specimens are obtained by removing them from the pad. When cutting specimens from the pad, care is taken not to cause any contamination or deformation to the specimen layers during the process. Specimens are taken from areas without creases or wrinkles and must be larger than the pressure foot.

[0118] To measure the thickness, first zero the micrometer relative to the horizontal flat reference platform. Place the specimen on the platform with the test location centered under the pressure foot. Gently lower the pressure foot at a descent rate of 3.0 mm ± 1.0 mm per second until the full pressure is applied to the specimen. Wait 5 seconds, then record the thickness of the specimen to an accuracy of 0.001 mm. Repeat a total of ten replicate test specimens in a similar manner. Calculate the arithmetic mean of all thickness measurements and report as "thickness" to an accuracy of 0.001 mm.

[0119] Basis weight

[0120] The basis weight of a sample of sheet or web material is the mass (in grams) per unit area (in square meters) of a single layer of the material. If it is not otherwise known or available, the basis weight can be measured using the EDANA Pharmacopoeia method NWSP130.1. Cut the test sample to a known area and determine the mass of the test sample using an analytical balance accurate to 0.0001 grams. All measurements are made in a laboratory maintained at 23°C ± 2°C and 50% ± 2% relative humidity, and the test sample is conditioned in this environment for at least 2 hours prior to testing.

[0121] Measure the test samples taken from the raw material roll or sheet, or the test samples obtained from the material layer removed from the pad. When cutting the material layer from the pad, care should be taken not to cause any contamination or deformation to the layer during this process. The cut layer should be free of residual adhesive. To ensure the removal of all adhesives, soak the layer in a suitable solvent that will dissolve the adhesive without adversely affecting the material itself. One such solvent is THF (tetrahydrofuran, CAS 109-99-9, which is for general use and is purchased from any convenient source). After soaking in the solvent, allow the material layer to dry thoroughly in a manner that prevents excessive stretching or other deformation of the material. After the material has dried, obtain the test specimens. The test specimens must be as large as possible to account for any inherent material variability.

[0122] Use a calibrated steel metal ruler sourced from NIST or an equivalent to measure the dimensions of the single-layer test specimens. Calculate and record the area of the test specimens to an accuracy of 0.0001 square centimeters. Use an analytical balance to obtain the mass of the test specimens and record it to an accuracy of 0.0001 grams. Calculate the basis weight by dividing the mass (in grams) by the area (in square meters) and record it to an accuracy of 0.01 grams per square meter (gsm). Repeat for a total of ten replicate test specimens in a similar manner. Calculate the arithmetic mean of the basis weights and report it to an accuracy of 0.01 grams per square meter.

[0123] Material composition analysis

[0124] If the information cannot be obtained otherwise, use ISO 1833-1 to determine the quantitative chemical composition of the test specimens including the fiber type mixture. All measurements are carried out in a laboratory maintained at 23 °C ± 2 °C and 50% ± 2% relative humidity.

[0125] Analyze the test samples taken from the raw material roll or sheet, or the test samples obtained from the material layer removed from the pad. When cutting the material layer from the pad, care should be taken not to cause any contamination or deformation to the layer during this process. The cut layer should be free of residual adhesive. To ensure the removal of all adhesives, soak the layer in a suitable solvent that will dissolve the adhesive without adversely affecting the material itself. One such solvent is THF (tetrahydrofuran, CAS 109-99-9, which is for general use and is purchased from any convenient source). After soaking in the solvent, allow the material layer to dry thoroughly in a manner that prevents excessive stretching or other deformation of the material. After the material has dried, obtain the test specimens and test them according to ISO 1833-1 to quantitatively determine their chemical composition.

[0126] Average fiber decitex (dtex) or denier

[0127] A textile fiber web (e.g., a woven fiber web, a non-woven fiber web, an air-laid fiber web) is composed of individual material fibers. In one aspect, the fibers are characterized by their linear mass density, reported in denier or in decitex. The decitex value is the mass (in grams) of the fiber present in 10,000 meters of that fiber. The denier value is the mass (in grams) of the fiber present in 9,000 meters of that fiber. The average decitex value or denier value of the fibers within the fiber web of the material is often reported by the manufacturer as part of the specification. If the average decitex value or denier value of the fibers cannot be otherwise known or is not available, it can be calculated by measuring the cross-sectional area of the fiber via a suitable microscopy technique such as scanning electron microscopy (SEM), determining the composition of the fiber using suitable techniques such as FT-IR (Fourier transform infrared) spectroscopy and / or DSC (differential scanning calorimetry), and then using the literature value of the density of the composition to calculate the mass (in grams) of the fiber present in 10,000 meters of fiber (for decitex) or 9,000 meters of fiber (for denier).

[0128] All tests were conducted in a chamber maintained at a temperature of 23°C ± 2.0°C and a relative humidity of 50% ± 2%, and the samples were conditioned for at least 2 hours under the same environmental conditions before testing.

[0129] If desired, a representative sample of the fiber web material of interest can be excised from the pad. In this case, the fiber web material is removed in such a way that the sample is not stretched, deformed, or contaminated.

[0130] An SEM image was obtained and analyzed as follows to determine the cross-sectional area of the fibers. To analyze the cross-section of a sample of the fibrous web material, specimens were prepared as follows. A sample approximately 1.5 cm (height) × 2.5 cm (length) without creases or wrinkles was cut from the fibrous web. The sample was immersed in liquid nitrogen and the edge was fractured along the length of the sample using a razor blade (No. 9 VWR single-edge industrial razor blade, surgical carbon steel). The sample was coated with gold sputter and then adhered to an SEM mount using double-sided conductive tape (Cu, 3M, purchased from electron microscopy sciences). The sample was oriented such that the cross-section was as perpendicular as possible to the detector to minimize any tilt distortion of the measured cross-section. An SEM image was obtained at a resolution sufficient to clearly elucidate the cross-sections of the fibers present in the sample. The fiber cross-sections can vary in shape and some fibers can consist of multiple individual filaments. In any case, the area of each cross-section in the fiber cross-section was determined (e.g., using the diameter of circular fibers, the major and minor axes of elliptical fibers, and image analysis for more complex shapes). If the fiber cross-section indicates a non-uniform cross-sectional composition, the area of each recognizable component was recorded and the dtex contribution of each component was calculated and then summed. For example, if the fiber is a bicomponent, the cross-sectional areas of the core and the sheath were measured separately and the dtex contributions from the core and the sheath were calculated separately and summed. If the fiber is hollow, the cross-sectional area does not include the internal part of the fiber consisting of air, which makes no significant contribution to the fiber dtex. In summary, at least 100 such measurements of the cross-sectional area were made for each fiber type present in the sample and the cross-sectional area a 2 ) of each fiber was recorded in square micrometers (μm k ), and the arithmetic mean (accurate to 0.1 μm 2 ) was calculated.

[0131] Common characterization techniques such as FTIR spectroscopy were used to determine the fiber composition. For more complex fiber compositions (such as polypropylene core / polyethylene sheath bicomponent fibers), a combination of common techniques (e.g., FTIR spectroscopy and DSC) may be required to fully characterize the fiber composition. This process was repeated for each fiber type present in the fibrous web material.

[0132] The average dtex d k value of each fiber type in the fibrous web material was calculated as follows:

[0133] d k = 10000m × a k × ρ k × 10 -6

[0134] where d kIn grams (per 10,000 meters of length calculated), a k in μm 2 as the unit, and ρ k in grams per cubic centimeter (g / cm 3 ). Report the average decitex (accurate to 0.1 g (per 10,000 meters of length calculated)) and the fiber type (e.g., polypropylene (PP), PET, cellulose, PP / PET bicomponent). The average denier value of each fiber type in the fibrous web material is its decitex d k value × 0.9.

[0135] Method for measuring percentage of hole opening area

[0136] Measure the percentage of the opening area on an image of the apertured topsheet specimen collected using a flatbed scanner. The scanner is capable of scanning in reflection mode at a resolution of 2400 dpi and 8-bit grayscale. A suitable scanner is the Epson Perfection V750 Pro purchased from Epson America Inc. (Long Beach, California, USA), or one with substantially similar functionality. The scanner interacts with a computer running an image analysis program. A suitable program is ImageJ v.1.47 (National Institute of Health, USA), or a program with substantially similar functionality. Calibrate the distance of the sample image according to the image of a ruler calibrated by NIST. To achieve maximum contrast, back the sample with an opaque background sheet of uniform black color before collecting the image. All measurements are carried out in a conditioning chamber maintained at approximately 23 ± 2 °C and approximately 50 ± 2% relative humidity.

[0137] Measure the sample as prepared below:

[0138] Obtain samples of the desired number of pads of interest. To obtain measurement samples, first identify the longitudinal and transverse axes of the pad and lightly mark these axes on the topsheet with a fine-tip marker. Then tape the sample pad around its perimeter (i.e., tape on the area not under the fluid management layer), with the wearer-facing side up, and attach it to a horizontal flat working surface in a flat configuration. Any elastic materials included (e.g., in the leg cuffs), if present, can be cut to facilitate flat placement of the pad. Identify and mark the outer boundary of the topsheet area that covers the apertures of the absorbent structure of the pad. Now cut through the topsheet and any adhering underlying layers around and through this marked outer boundary with a new razor blade or other suitably new and sharp cutting tool. Then carefully separate the sample of the apertured topsheet from the underlying layer and remove it from the underlying layer such that its longitudinal and transverse dimensions do not change to avoid deformation of the apertures. If the topsheet is adhered to the underlying layer via an adhesive, apply any solvent that is suitable for dissolving the adhesive and allows the topsheet to be easily separated from the underlying layer without dissolving the polymeric materials of the fibers that make up the nonwoven fiber web material of the topsheet. (In many examples, tetrahydrofuran (THF) can be a suitable solvent for this purpose. As long as the solvent does not dissolve the polymer that makes up the fibers themselves, there is no need to worry about whether the solvent dissolves the surface finish coating applied to the fibers.) Once the cut portion of the topsheet that makes up the measurement sample has been removed, identify its wearer-facing side. Five replicate measurement samples obtained from five samples of the pad of interest are prepared for measurement. Prior to imaging, condition the samples at approximately 23 °C ± 2 °C and approximately 50% ± 2% relative humidity for 2 hours. If the topsheet is adhered by bonding around the perimeter of the aperture to the adjacent underlying fluid acquisition layer, keep the topsheet and the fluid acquisition layer bonded together.

[0139] Obtain images as follows.

[0140] Place a ruler on the scanning bed such that its orientation is parallel to the side of the scanner glass. Acquire an image of the ruler (calibration image) at a resolution of 2400 dpi (approximately 94 pixels / mm) and 8-bit grayscale in reflection mode. Save the calibration image as an uncompressed TIFF format file. After obtaining the calibration image, remove the ruler from the scanner glass and scan all samples under the scanning conditions described below.

[0141] Place the measurement sample flat on the center of the scanning bed with the body-facing surface of the sample facing the glass surface of the scanner. Fix the corners and edges of the sample so that its initial longitudinal and lateral dimensions (as on the pad before removal) are maintained. The sample is oriented such that its major and minor axes are aligned parallel and perpendicular, respectively, to the sides of the glass surface of the scanner. Place a black background on top of the sample, close the scanner lid, and acquire a scanned image of the entire sample with the same settings as those used for calibrating the image. Save the sample image as an uncompressed TIFF format file. Scan and save the remaining four replicate samples in a similar manner.

[0142] Analyze the sample images as follows. Open the calibration image file in the image analysis program and calibrate the image resolution using an imaging ruler to determine the number of pixels per millimeter. Now open the sample images in the image analysis program and set the distance scale using the image resolution determined from the calibration image. Now identify the central region 305 centered on the longitudinal and lateral axes of the pad, which has sides 80 mm long parallel to the longitudinal axis 400 and ends 30 mm wide parallel to the lateral axis, and visually inspect the images of the holes present within the central region. Now use the software tool to manually trace each hole (and any portions of it at the edges of the central region) within the holes in the central region. Draw an appropriate contour around the visually distinguishable inner edge of the concentration of displacement fibers 503 along the perimeter of the hole. Separate fibers that may have left the main structure and / or the concentration of displacement fibers around the perimeter and passed into or through the main opening area of the hole (by way of example, Figure 12 the separate displaced fiber 16 shown in 2 are not considered to be subtracted from the hole area for the purposes of this article.) Then use the software to measure the area within each discrete hole contour (whole and partial) in the central region and record each to the nearest 0.01 mm Figure 12 and calculate their sum. The area of each discrete hole is defined as the x-y surface area within the visually distinguishable contour of the opening region, which is created by the mechanical penetration of the fiber web and the x-y displacement of the fibers during the hole-opening process that creates the holes through the fiber web. (For example, refer to 2 where the discrete hole area 321 and the visually distinguishable boundary 22 are depicted. The dark area of the depicted hole is the image of the black construction paper used as the backing for the sample, and this particular image was made from this sample.) Record the sum of the areas of all the holes in the central region as the "hole area" to the nearest 0.01 mm 2 . Now divide the "hole area" by the central region area (1,600 mm

[0143] ), then multiply by 100 and record as the "opening area percentage" to the nearest 0.1%.In a similar manner, the entire procedure is repeated for the remaining four replicate sample images. The arithmetic mean of the "percent open area" is calculated across all five replicates and reported as the "average percent open area" accurate to 0.1%.

[0144] If desired, similar equipment and procedures can be employed to measure the size and open area of individual holes and / or groups of holes or hole paths, either inside or outside the central region. Those of ordinary skill in the art will readily understand how to adapt the method for such purposes.

[0145] However, it should be understood that the above methods and equipment are not necessarily the only possible methods and equipment that can be used to measure hole size and hole open area.

[0146] Non-limiting embodiments contemplated herein

[0147] In view of the foregoing description, the following non-limiting embodiments of combinations of features are contemplated herein: Other features described herein may also be included, where feasible.

[0148] 1. A feminine hygiene pad (300) having a longitudinal axis (400) oriented in the y-direction, a transverse axis (500) perpendicular to the longitudinal axis and oriented in the x-direction, and a pad thickness measured in the z-direction orthogonal to the longitudinal and transverse axes, and comprising a liquid-permeable topsheet (301), a backsheet (303) located beneath the topsheet, and an absorbent structure (302) disposed between the topsheet and the backsheet, the liquid-permeable topsheet comprising a first fibrous nonwoven web, wherein:

[0149] The first fibrous nonwoven web includes at least two arrangements (322, 323) of holes (324a, 324b) therethrough, including a first arrangement (322) having first holes (324a) of a first average size and a second arrangement (323) having second holes (324b) of a second average size, wherein the first average size is greater than the second average size;

[0150] wherein the first arrangement occupies a rectangular central region (305) that is 80 mm long × 20 mm wide, having a front side and a rear side and left and right sides, and is centered on the longitudinal axis (400) and located on both the front and rear sides of the transverse axis (500); the first average size is from 0.4 mm 2 to 0.6 mm 2 ; and the central region has an average percent open area of from 1% to 12%, more preferably from 2% to 9%, and even more preferably from 3% to 8%;

[0151] wherein the second arrangement occupies one or more regions laterally and / or longitudinally outside the central region, and the second average size is from 0.05 mm 2 to 0.2 mm 2 .

[0152] 2. The feminine hygiene pad according to embodiment 1, wherein the second arrangement (323) comprises one or more paths having holes of the second average size, the one or more paths being generally oriented along the longitudinal direction, laterally outside either side of the central region (305) and spanning the transverse axis (500).

[0153] 3. The feminine hygiene pad according to any one of the preceding embodiments, wherein the second arrangement (323) comprises a path having holes of the second average size, the path extending at least partially along the transverse direction, longitudinally outside either or both of the front end and the rear end of the central region (305) and spanning the longitudinal axis (400).

[0154] 4. The feminine hygiene pad according to any one of the preceding embodiments, wherein the holes in one or both of the first arrangement and the second arrangement have an average aspect ratio of from 2.5:1 to 1:2.5, more preferably from 2:1 to 1:2, even more preferably from 1.5:1 to 1:1.5, still more preferably from 1.3:1 to 1:1.3 and most preferably from 1.2:1 to 1:1.2.

[0155] 5. The feminine hygiene pad according to any one of the preceding embodiments, wherein the first nonwoven web comprises staple fibers, wherein some or all of the holes in one or both of the first arrangement and the second arrangement are surrounded by dense aggregates of the material (23) of the fibers constituting the first nonwoven web, the material having been plastically deformed and / or fused by the application of local z-direction compression and optionally by thermal application.

[0156] 6. The feminine hygiene pad according to embodiment 5, wherein the first nonwoven web includes within it a plurality of randomly distributed fiber-to-fiber bond sites (17) which do not exhibit the effect of z-direction compression in their formation.

[0157] 7. The feminine hygiene pad according to any one of the preceding embodiments, wherein the first nonwoven web comprises bicomponent fibers.

[0158] 8. The feminine hygiene pad according to embodiment 7, wherein the bicomponent fibers are of a core-sheath bicomponent configuration having a sheath component and a core component.

[0159] 9. The feminine hygiene pad according to embodiment 8, wherein the core component comprises a polymer selected from the group consisting of PET, PP, and PE and combinations thereof, and preferably PET.

[0160] 10. The feminine hygiene pad according to any one of embodiments 8 or 9, wherein the skin component comprises PE, preferably mainly PE.

[0161] 11. The feminine hygiene pad according to any one of the foregoing embodiments, wherein the constituent fibers of the first nonwoven fiber web comprise fibers that are mainly, substantially, or completely hydrophobic by weight ratio, or fibers rendered hydrophobic by fiber surface finishing.

[0162] 12. The feminine hygiene pad according to any one of the foregoing embodiments, wherein the first nonwoven fiber web comprises a first layer component having a first fiber constitution and a second layer component having a second fiber constitution different from the first fiber constitution.

[0163] 13. The feminine hygiene pad according to embodiment 12, wherein the first layer mainly comprises hydrophobic fibers and the second layer mainly comprises hydrophilic fibers.

[0164] 14. The feminine hygiene pad according to any one of embodiments 12 or 13, wherein the second fiber constitution comprises a combination of bicomponent fibers and hollow monocomponent fibers.

[0165] 15. The feminine hygiene pad according to embodiment 14, wherein the hollow monocomponent fiber comprises PET.

[0166] 16. The feminine hygiene pad according to any one of embodiments 12 to 15, wherein the second fiber constitution comprises cellulose fibers.

[0167] 17. The feminine hygiene pad according to embodiment 16, wherein the cellulose fibers comprise regenerated cellulose.

[0168] 18. The feminine hygiene pad according to any one of the foregoing embodiments, the feminine hygiene pad comprising a fluid management layer (302a) disposed below the topsheet (301), the fluid management layer comprising a second fibrous nonwoven fiber web, wherein the holes passing through the first nonwoven fiber web at least partially extend in the z-direction through the second fibrous nonwoven fiber web, wherein the first fibrous nonwoven fiber web and the second fibrous nonwoven fiber web are at least partially bonded together around the perimeter (22) of the holes extending through them, and wherein the material at the perimeter of the holes passing through the topsheet is recessed along the z-direction from the uppermost surface region of the topsheet.

[0169] 19. A method of producing a topsheet for a feminine sanitary pad, the pad and the topsheet having a defined length, width, longitudinal axis (400) and transverse axis (500), the method comprising the steps of:

[0170] Providing a nonwoven web (10) and conveying the nonwoven web along the machine direction (MD);

[0171] Providing a pair of apertured rolls (100, 120) having a nip (110) therebetween, the nip being oriented along the cross direction (CD);

[0172] Passing the nonwoven web through the nip along the machine direction and thereby sequentially and repeatedly imparting an inclined pattern of holes through the nonwoven web as the nonwoven web moves along the machine direction, the pattern comprising:

[0173] At least two arrangements (322, 323) of holes (324a, 324b) passing therethrough, including a first arrangement (322) having first holes (324a) of a first average size and a second arrangement (323) having second holes (324b) of a second average size, wherein the first average size is greater than the second average size, wherein:

[0174] The first arrangement occupies a rectangular central region (305) that is 80 mm long × 20 mm wide, having a front side and a rear side and a left side and a right side, and is centered on the longitudinal axis (400) and located on both the front and rear sides of the transverse axis (500); the first average size is 0.4 mm 2 to 0.6 mm 2 ; and the central region has an average opening area percentage of 1% to 12%, more preferably 2% to 9%, and even more preferably 3% to 8%;

[0175] The second arrangement occupies one or more regions outside the transverse and / or longitudinal sides of the central region, and the second average size is 0.05 mm 2 to 0.2 mm 2 .

[0176] ***

[0177] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, each such dimension is intended to represent the recited value and a range functionally equivalent around that value. For example, a dimension disclosed as "40 mm" is intended to represent "about 40 mm".

[0178] Each document cited herein, including any cross-referenced or related patent or patent application and any patent application or patent from which this application claims priority or benefits thereof, is hereby incorporated by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone or in any combination with any other reference teaches, suggests, or discloses any such invention. Further, when any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to the term in this invention shall govern.

[0179] While the specific embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is intended that all such changes and modifications that fall within the scope of the invention be covered by the appended claims.

Claims

1. A feminine sanitary pad (300) having a longitudinal axis (400) oriented in the y - direction, a transverse axis (500) perpendicular to the longitudinal axis and oriented in the x - direction, and a pad thickness measured in the z - direction orthogonal to the longitudinal and transverse axes, and comprising a liquid - permeable topsheet (301), a backsheet (303) located beneath the topsheet, and an absorbent structure (302) disposed between the topsheet and the backsheet, the liquid - permeable topsheet comprising a first fibrous non - woven web, wherein: the first fibrous non - woven web comprises at least two arrangements (322, 323) of holes (324a, 324b) therethrough, including a first arrangement (322) having first holes (324a) of a first average size and a second arrangement (323) having second holes (324b) of a second average size, wherein the first average size is greater than the second average size; wherein the first arrangement occupies a rectangular central region (305) that is 80 mm long × 20 mm wide, has a front side and a rear side, and a left side and a right side, and is centered on the longitudinal axis (400) and located on both the front side and the rear side of the transverse axis (500); the first average size is from 0.4 mm 2 to 0.6 mm 2 ; and the central region has an average opening area percentage of from 1% to 12%, more preferably from 2% to 9%, and even more preferably from 3% to 8%; wherein the second arrangement occupies one or more regions outside the lateral and / or longitudinal sides of the central region, and the second average size is from 0.05 mm 2 to 0.2 mm 2 .

2. The feminine sanitary pad according to claim 1, wherein the second arrangement (323) comprises one or more paths of holes of the second average size, the one or more paths being generally oriented along the longitudinal direction, laterally outside either side of the central region (305) and spanning the transverse axis (500).

3. The feminine sanitary pad according to any one of the preceding claims, wherein the second arrangement (323) comprises a path of holes of the second average size, the path extending at least partially along the transverse direction, longitudinally outside either or both of the front and rear ends of the central region (305) and spanning the longitudinal axis (400).

4. The feminine sanitary pad according to any one of the preceding claims, wherein the holes in one or both of the first and second arrangements have an average aspect ratio of from 2.5:1 to 1:2.5, more preferably from 2:1 to 1:2, even more preferably from 1.5:1 to 1:1.5, still more preferably from 1.3:1 to 1:1.3 and most preferably from 1.2:1 to 1:1.

2.

5. The feminine sanitary pad according to any one of the preceding claims, wherein the first non - woven web includes a plurality of randomly - distributed fiber - to - fiber bondings (17) therein, and the fiber - to - fiber bondings do not exhibit the effect of z - direction compression during their formation.

6. The feminine sanitary pad according to any one of the preceding claims, wherein the first non - woven web contains bicomponent fibers.

7. The feminine sanitary pad according to claim 6, wherein the bicomponent fibers are of a core - sheath bicomponent configuration having a skin component and a core component.

8. The feminine sanitary pad according to claim 7, wherein the core component comprises a polymer selected from the group consisting of PET, PP, and PE and combinations thereof, and is preferably PET.

9. The feminine sanitary pad according to any one of claims 7 or 8, wherein the skin component comprises PE, preferably mainly PE.

10. The feminine sanitary pad according to any one of the preceding claims, wherein the constituent fibers of the first nonwoven fiber web include fibers that are predominantly, substantially, or completely hydrophobic by weight ratio, or fibers rendered hydrophobic by fiber surface finishing.

11. The feminine sanitary pad according to any one of the preceding claims, wherein the first nonwoven fiber web includes a first layer component having a first fiber constitution and a second layer component having a second fiber constitution different from the first fiber constitution.

12. The feminine sanitary pad according to claim 11, wherein the first layer mainly includes hydrophobic fibers and the second layer mainly includes hydrophilic fibers.

13. The feminine sanitary pad according to any one of claims 11 or 12, wherein the second fiber constitution includes cellulose fibers.

14. The feminine sanitary pad according to any one of the preceding claims, the feminine sanitary pad including a fluid management layer (302a) disposed below the topsheet (301), the fluid management layer including a second fibrous nonwoven fiber web, wherein the holes passing through the first nonwoven fiber web extend at least partially in the z-direction through the second fibrous nonwoven fiber web, wherein the first fibrous nonwoven fiber web and the second fibrous nonwoven fiber web are at least partially bonded together around the perimeter (22) of the holes extending through each of them, and wherein the material at the perimeter of the holes passing through the topsheet is recessed along the z-direction from the uppermost surface region of the topsheet.

15. A method of manufacturing a topsheet for a feminine sanitary pad, the pad and the topsheet having a prescribed length, width, longitudinal axis (400), and transverse axis (500), the method comprising the steps of: providing a nonwoven fiber web (10) and conveying the nonwoven fiber web along the machine direction (MD); providing a pair of perforated rollers (100, 120) having a nip (110) therebetween, the nip being oriented along the cross direction (CD); passing the nonwoven fiber web through the nip along the machine direction, and thereby sequentially and repeatedly imparting an inclined pattern to the holes passing through the nonwoven fiber web as the nonwoven fiber web moves along the machine direction, the pattern including: at least two arrangements (322, 323) of holes (324a, 324b) passing through it, including a first arrangement (322) having a first hole (324a) with a first average size and a second arrangement (323) having a second hole (324b) with a second average size, wherein the first average size is greater than the second average size, wherein: The first arrangement occupies a rectangular central region (305) that is 80 mm long by 20 mm wide, has a front side and a rear side, and left and right sides, and is centered on the longitudinal axis (400) and located on both the front and rear sides of the transverse axis (500); the first average size is 0.4 mm 2 to 0.6 mm 2 ; and the central region has an average opening area percentage of 1% to 12%, more preferably 2% to 9%, and even more preferably 3% to 8%; The second arrangement occupies one or more regions laterally and / or longitudinally outside the central region, and the second average size is from 0.05 mm 2 to 0.2 mm 2 .

Images