Absorbent article with open-ported three-

Abstract

An absorbent article (10, 110) is provided. The absorbent article (10, 110) includes a non-woven liquid permeable topsheet (26, 114, 200), a liquid impermeable backsheet (28, 116), and an absorbent core (30, 118) disposed at least partially intermediate the topsheet (26, 114, 200) and the backsheet (28, 116). The topsheet (26, 114, 200) includes a fibrous layer and has a plurality of apertures (206) defined in the fibrous layer. According to a 2D X-ray CT scan test herein, at least some of the apertures (206) have sidewalls (212) having portions disposed at an angle in a range of about 55 degrees to about 90 degrees, in a range of about 60 degrees to about 80 degrees, and in a range of about 63 degrees to about 75 degrees.

Description

[0001] This application is a divisional application of the patent application with the application date of October 11, 2017, application number 201780095677.X (PCT / CN2017 / 105641), and the invention title of "Absorbent Article with Open-Celled Three-Dimensional Material and Method of Manufacturing the Same". Technical Field

[0002] The present disclosure relates to an absorbent article with open-celled three-dimensional material and a method of manufacturing the same. Background Art

[0003] Absorbent articles generally include a topsheet, a backsheet, and an absorbent core disposed at least partially between the topsheet and the backsheet. The absorbent article may further include a acquisition layer and an optional distribution layer, the acquisition layer temporarily storing liquid body exudates (e.g., loose stools, urine, menses) received from the topsheet, and the distribution layer transferring and distributing the liquid body exudates from the acquisition layer to the absorbent core.

[0004] Many absorbent articles, including diapers, rely on capillary action to effect liquid body exudate acquisition and wicking of the body exudates away from the skin of the wearer. The structure of the absorbent article typically results in a configuration in which there is a higher capillary pressure in the bottom layer and a lower capillary pressure in the top layer. Some absorbent articles also include a textured and / or open-celled topsheet to improve fluid handling characteristics.

[0005] Many topsheets are formed of hydrophilic materials to absorb liquids and transfer them away from the skin. However, such hydrophilic topsheets retain liquids and remain wet, which may not be preferred. A hydrophobic topsheet formed of a material that does not retain liquids is provided with openings that have large apertures on the surface facing the wearer so that liquids can effectively transfer from the surface facing the wearer to the absorbent core. However, the large apertures may come at the expense of reduced visual appeal and lower tactile softness. In addition, when forming large openings, long tails or sidewalls extend in a direction away from the surface facing the wearer. Further, it is believed that the angle at which the sidewalls are formed is not steep. During use of an absorbent article having an open-celled topsheet with long open-cell sidewalls, the compressive forces applied to the topsheet can cause the long sidewalls to collapse or fold inwardly toward the center of the opening, thereby reducing the amount of fluid that can flow through the opening.

[0006] Accordingly, current textured and / or open-celled topsheets have the disadvantages of softness, open cells that remain open under compression, and three-dimensionality. Such topsheets should be improved. Summary of the Invention

[0007] The present disclosure addresses the drawbacks of current textured and / or apertured topsheets by providing improved softness, three-dimensionality, and apertures that remain open under compression, which is advantageous for a hydrophobic topsheet. More specifically, the topsheet of the present disclosure is formed from at least some of the apertures having steeply sloped sidewalls. By forming at least some of the apertures having steeply sloped sidewalls, at least the following advantages can be achieved. First, a smaller wearer-facing opening area can be formed, resulting in fewer skin marks on the user, yet generating a similar body fluid flow through the apertures as apertures in the related art having a larger wearer-facing opening area. Additionally, the smaller wearer-facing opening area results in shorter tails or sidewalls, which are less likely to deform inwardly towards the center of the aperture and restrict or block the flow through the aperture. When the size of the opening area is small, the wearer-facing opening area is easily formed at a very steep angle because the length of the pins used to form the apertures with a smaller wearer-facing opening area is shorter. As further described below, it is believed that when the sidewalls of the apertures are formed at a steep angle, the sidewalls are less likely to fold inwardly towards the center of the aperture to partially or substantially completely close the aperture.

[0008] According to one aspect of the present disclosure, there is provided an absorbent article comprising: a nonwoven liquid-permeable topsheet, a liquid-impermeable backsheet, and an absorbent core disposed at least partially intermediate the topsheet and the backsheet. The topsheet includes a fibrous layer and a plurality of apertures defined in the fibrous layer. According to the basis weight tests herein, the basis weight of the topsheet is in the range of about 10 gsm to about 35 gsm, about 15 gsm to about 30 gsm, about 18 gsm to about 25 gsm, or about 20 gsm to about 24 gsm. According to the aperture tests herein, the topsheet has an effective opening area in the range of about 15% to about 30%, in the range of about 18% to about 25%, or in the range of about 20% to about 24%. The topsheet includes a wearer-facing surface and a garment-facing surface, wherein at least some of the apertures have a wearer-facing opening area and a garment-facing opening area, and wherein the wearer-facing opening area is greater than the garment-facing opening area. At least some of the apertures include sidewalls, wherein according to the 2D X-ray CT scan tests herein, at least a portion of the sidewalls has an angle in the range of about 55 degrees to about 90 degrees, in the range of about 60 degrees to about 80 degrees, or in the range of about 63 degrees to about 75 degrees. According to the 2D X-ray CT scan tests herein, the garment-facing opening area of at least some of the apertures is in the range of about 1.0 mm 2 to about 7.5 mm 2 and according to the 2D X-ray CT scan tests herein, the wearer-facing opening area of at least some of the apertures is in the range of about 2 mm 2 to about 12 mm 2within the range. At least some of the apertures have a central major axis dimension and a central minor axis dimension, wherein according to the 2D X-ray CT scan test herein, when measured at the opening area facing the garment, the central major axis dimension is greater than 1.5 mm.

[0009] According to another aspect of the present disclosure, there is provided an absorbent article comprising: a nonwoven liquid-permeable topsheet, a liquid-impermeable backsheet, and an absorbent core disposed at least partially between the topsheet and the backsheet. The topsheet includes a hydrophobic carded web fiber layer and a plurality of apertures defined in the carded web fiber layer. According to the basis weight test herein, the basis weight of the topsheet is in the range of about 10 gsm to about 35 gsm, about 15 gsm to about 30 gsm, about 18 gsm to about 25 gsm, or about 20 gsm to about 24 gsm. According to the aperture test herein, the topsheet has an effective opening area in the range of about 15% to about 30%, in the range of about 18% to about 25%, or in the range of about 20% to about 24%. The topsheet includes a surface facing the wearer and a surface facing the garment, wherein at least some of the apertures have an opening area facing the wearer and an opening area facing the garment, and wherein the opening area facing the wearer is greater than the opening area facing the garment. At least some of the apertures include sidewalls, wherein according to the 2D X-ray CT scan test herein, at least a portion of the sidewalls has an angle in the range of about 55 degrees to about 90 degrees, in the range of about 60 degrees to about 80 degrees, or in the range of about 63 degrees to about 75 degrees. According to the 2D X-ray CT scan test herein, the opening area facing the garment of at least some of the apertures is in the range of about 1.0 mm 2 to about 7.5 mm 2 and according to the 2D X-ray CT scan test herein, the opening area facing the wearer of at least some of the apertures is in the range of about 2 mm 2 to about 12 mm 2 and at least some of the apertures have a central major axis dimension and a central minor axis dimension, wherein according to the 2D X-ray CT scan test herein, when measured at the opening area facing the garment, the central major axis dimension is greater than 1.5 mm.

[0010] According to another aspect of the present disclosure, a method for forming a plurality of apertures in a nonwoven substrate for an absorbent article is provided, the substrate defining a first surface and a second surface. A plurality of tapered pins are inserted through the substrate from the first surface to the second surface to form a plurality of corresponding apertures in the substrate. Each of at least a portion of the pins includes: a first section having a first wall extending from a base portion of the first section to a distal portion of the first section, at least a portion of the first wall being disposed at a first angle greater than about 17.5 degrees, greater than about 20 degrees, or greater than about 25 degrees; and a second section having a second wall extending from a base portion of the second section, at least a portion of the second wall being disposed at a second angle less than about 20 degrees, less than about 18 degrees, or less than about 16 degrees. The pins are withdrawn from the topsheet, wherein each of at least some of the apertures defines: a wearer-facing opening area at the wearer-facing surface of the topsheet, which, according to the 2D X-ray CT scan test herein, is in the range of about 2 mm 2 to about 12 mm 2 ; a garment-facing opening area at the garment-facing surface of the topsheet, which, according to the 2D X-ray CT scan test herein, is less than the wearer-facing opening area and is in the range of about 1.0 mm 2 to about 7.5 mm 2 ; and sidewalls, which, according to the 2D X-ray CT scan test herein, have an angle of at least a portion of the sidewalls in the range of about 55 degrees to about 90 degrees, in the range of about 60 degrees to about 80 degrees, or in the range of about 63 degrees to about 75 degrees.

[0011] According to one aspect of the present disclosure, there is provided a method for forming a plurality of openings in a nonwoven liquid-permeable substrate for an absorbent article, the substrate defining a first surface and a second surface. The present invention provides a nonwoven liquid-permeable substrate and a forming device, the forming device including a plurality of tapered pins. Each of at least a portion of the pins includes: a first section having a first wall extending from a base portion of the first section to a distal portion of the first section, at least a portion of the first wall being disposed at a first angle greater than about 17.5 degrees, greater than about 20 degrees, or greater than about 25 degrees; and a second section having a second wall extending from a base portion of the second section, at least a portion of the second wall being disposed at a second angle less than about 20 degrees, less than about 18 degrees, or less than about 16 degrees. The substrate is conveyed through the forming device, wherein the pins penetrate the substrate and form openings therein. Each of at least some of the openings defines: a first opening area at the first surface of the substrate, which, according to the 2D X-ray CT scan test herein, is in the range of about 2 mm 2 to about 12 mm 2 ; a second opening area at the second surface of the substrate, which, according to the 2D X-ray CT scan test herein, is less than the first opening area and is in the range of about 1.0 mm 2 to about 7.5 mm 2 ; and a side wall, which, according to the 2D X-ray CT scan test herein, has an angle in the range of about 55 degrees to about 90 degrees, in the range of about 60 degrees to about 80 degrees, or in the range of about 63 degrees to about 75 degrees for at least a portion thereof.

[0012] According to another aspect of the present disclosure, there is provided a method for forming a plurality of openings in a nonwoven liquid-permeable substrate for an absorbent article, the device including: intermeshing members including a first member and a second member. The first member includes a body portion and a plurality of tapered pins. Each of at least a majority of the pins includes: a first section having a first wall extending from a base portion of the first section to a distal portion of the first section, at least a portion of the first wall being disposed at a first angle greater than about 17.5 degrees, greater than about 20 degrees, or greater than about 25 degrees; and a second section having a second wall extending from a base portion of the second section, the base portion of the second section extending from the first member body portion, at least a portion of the second wall being disposed at a second angle different from the first angle and less than about 20 degrees, less than about 18 degrees, or less than about 16 degrees.

[0013] The present invention also includes the following embodiments:

[0014] Embodiment 1. An absorbent article comprising:

[0015] A nonwoven liquid-permeable topsheet;

[0016] A liquid-impermeable backsheet;

[0017] An absorbent core, the absorbent core being disposed at least partially intermediate the topsheet and the backsheet;

[0018] Wherein the topsheet comprises:

[0019] A fibrous layer;

[0020] Wherein, according to the basis weight test herein, the basis weight of the topsheet is in the range of about 10 gsm to about 35 gsm, preferably about 15 gsm to about 30 gsm, more preferably about 18 gsm to about 25 gsm, and most preferably about 20 gsm to about 24 gsm;

[0021] A plurality of apertures defined in the fibrous layer;

[0022] Wherein, according to the aperture test herein, the topsheet has an effective opening area in the range of about 15% to about 30%, preferably in the range of about 18% to about 25%, more preferably in the range of about 20% to about 24%;

[0023] Wherein the topsheet includes a wearer-facing surface and a garment-facing surface;

[0024] Wherein at least some of the apertures have a wearer-facing opening area and a garment-facing opening area, and wherein the wearer-facing opening area is greater than the garment-facing opening area;

[0025] Wherein at least some of the apertures include sidewalls, and wherein, according to the 2D X-ray CT scan test herein, at least a portion of the sidewalls has an angle in the range of about 55 degrees to about 90 degrees, preferably in the range of about 60 degrees to about 80 degrees, more preferably in the range of about 63 degrees to about 75 degrees;

[0026] Wherein, according to the 2D X-ray CT scan test herein, the garment-facing opening area of at least some of the apertures is in the range of about 1.0 mm 2 to about 7.5 mm 2 ;

[0027] Wherein, according to the 2D X-ray CT scan test herein, the wearer-facing opening area of at least some of the apertures is in the range of about 2 mm 2 to about 12 mm 2 ; and

[0028] At least some of the apertures have a central major axis dimension and a central minor axis dimension, and wherein, according to the 2D X-ray CT scan test herein, when measured at the opening area facing the garment, the central major axis dimension is greater than 1.5 mm.

[0029] Embodiment 2. The absorbent article according to Embodiment 1, wherein at least some of the fibers comprise bicomponent fibers including a core and a sheath.

[0030] Embodiment 3. The absorbent article according to Embodiment 2, wherein the sheath comprises polyethylene and wherein the core comprises polyethylene terephthalate.

[0031] Embodiment 4. The absorbent article according to any one of the preceding embodiments, wherein, according to the 2D X-ray CT scan test herein, when measured at the opening area facing the garment, the ratio of the central major axis dimension to the central minor axis dimension is at least 1.3 but less than 4, preferably at least 1.5 but less than 3.

[0032] Embodiment 5. The absorbent article according to any one of the preceding embodiments, wherein at least some of the fibers have a denier per filament of from about 1 to about 3, preferably from about 1.5 to about 2.5, and more preferably about 2.

[0033] Embodiment 6. The absorbent article according to any one of the preceding embodiments, wherein, according to the 2D X-ray CT scan test herein, when measured at the opening area facing the garment, the central major axis dimension is in the range of from about 1.5 mm to about 3.5 mm, preferably in the range of from about 2 mm to about 3 mm, and more preferably in the range of from about 2.2 mm to about 2.8 mm.

[0034] Embodiment 7. The absorbent article according to any one of the preceding embodiments, wherein, according to the 2D X-ray CT scan test herein, when measured at the opening area facing the garment, the central minor axis dimension is in the range of from about 0.5 mm to about 2.5 mm, preferably in the range of from about 0.9 mm to about 1.5 mm, and more preferably in the range of from about 1 mm to about 1.4 mm.

[0035] Embodiment 8. The absorbent article according to any one of the preceding embodiments, wherein, according to the 2D X-ray CT scan test herein, at least some of the side walls of the apertures have a length in the range of from 0.2 mm to about 2.0 mm, preferably in the range of from 0.5 mm to about 1.5 mm.

[0036] Embodiment 9. The absorbent article according to any one of the preceding embodiments, wherein the fiber layer is hydrophobic.

[0037] Embodiment 10. The absorbent article according to any one of the preceding embodiments, wherein the fibrous layer comprises carded fibers.

[0038] Embodiment 11. The absorbent article according to any one of the preceding embodiments, wherein the fibrous layer comprises spunbonded fibers.

[0039] Embodiment 12. The absorbent article according to any one of the preceding embodiments, wherein the topsheet comprises cotton.

[0040] Embodiment 13. The absorbent article according to any one of the preceding embodiments, wherein the topsheet does not contain a film.

[0041] Embodiment 14. An absorbent article comprising:

[0042] A nonwoven liquid-permeable topsheet;

[0043] A liquid-impermeable backsheet;

[0044] An absorbent core, the absorbent core being at least partially disposed between the topsheet and the backsheet;

[0045] Wherein the topsheet comprises:

[0046] A hydrophobic carded fibrous layer;

[0047] Wherein according to the basis weight test herein, the basis weight of the topsheet is in the range of about 10 gsm to about 35 gsm, preferably about 15 gsm to about 30 gsm, more preferably about 18 gsm to about 25 gsm, and most preferably about 20 gsm to about 24 gsm;

[0048] A plurality of apertures defined in the carded fibrous layer;

[0049] Wherein according to the aperture test herein, the topsheet has an effective opening area in the range of about 15% to about 30%, preferably in the range of about 18% to about 25%, more preferably in the range of about 20% to about 24%;

[0050] Wherein the topsheet includes a surface facing the wearer and a surface facing the clothing;

[0051] Wherein at least some of the apertures have an opening area facing the wearer and an opening area facing the clothing, and wherein the opening area facing the wearer is greater than the opening area facing the clothing;

[0052] At least some of the apertures include sidewalls, and at least a portion of the sidewalls has an angle in the range of about 55 degrees to about 90 degrees, preferably in the range of about 60 degrees to about 80 degrees, and more preferably in the range of about 63 degrees to about 75 degrees according to the 2D X-ray CT scan tests herein;

[0053] wherein according to the 2D X-ray CT scan tests herein, the garment-facing opening area of at least some of the apertures is in the range of about 1.0 mm 2 to about 7.5 mm 2 ;

[0054] wherein according to the 2D X-ray CT scan tests herein, the wearer-facing opening area of at least some of the apertures is in the range of about 2 mm 2 to about 12 mm 2 ; and

[0055] wherein at least some of the apertures have a central major axis dimension and a central minor axis dimension, and wherein according to the 2D X-ray CT scan tests herein, when measured at the garment-facing opening area, the central major axis dimension is greater than 1.5 mm.

[0056] Embodiment 15. The absorbent article according to Embodiment 14, wherein the topsheet comprises a spunbonded fiber layer.

[0057] Embodiment 16. The absorbent article according to Embodiment 14 or 15, wherein the topsheet comprises cotton.

[0058] Embodiment 17. A method for forming a plurality of apertures in a nonwoven substrate for an absorbent article, the nonwoven substrate defining a first surface and a second surface, the method comprising:

[0059] Inserting a plurality of tapered pins from the first surface through the substrate into the second surface to form a plurality of corresponding apertures in the substrate, at least a portion of each of the pins comprising:

[0060] A first section having a first wall extending from a base portion of the first section to a distal portion of the first section, at least a portion of the first wall being disposed at a first angle greater than about 17.5 degrees, preferably greater than about 20 degrees, and more preferably greater than about 25 degrees; and

[0061] A second section having a second wall extending from a base portion of the second section, at least a portion of the second wall being disposed at a second angle less than about 20 degrees, preferably less than about 18 degrees, and more preferably less than about 16 degrees; and

[0062] Withdraw the pin from the topsheet, wherein each of at least some of the apertures defines:

[0063] A wearer-facing opening area at the wearer-facing surface of the topsheet, which, according to the 2D X-ray CT scan test herein, is in the range of about 2 mm 2 to about 12 mm 2 ;

[0064] A garment-facing opening area at the garment-facing surface of the topsheet, which, according to the 2D X-ray CT scan test herein, is less than the wearer-facing opening area and is in the range of about 1.0 mm 2 to about 7.5 mm 2 ; and

[0065] Sidewalls, which, according to the 2D X-ray CT scan test herein, have at least a portion with an angle in the range of about 55 degrees to about 90 degrees, preferably in the range of about 60 degrees to about 80 degrees, more preferably in the range of about 63 degrees to about 75 degrees.

[0066] Embodiment 18. The method according to Embodiment 17, wherein, according to the aperture test herein, the topsheet has an effective opening area in the range of about 15% to about 30%, preferably in the range of about 18% to about 25%, more preferably in the range of about 20% to about 24% after the pin is withdrawn.

[0067] Embodiment 19. The method according to Embodiment 17 or 18, wherein at least some of the apertures have a central major axis dimension and a central minor axis dimension, and wherein, according to the 2D X-ray CT scan test herein, the central major axis dimension is greater than 1.5 mm when measured at the garment-facing opening area.

[0068] Embodiment 20. The method according to any one of Embodiments 17 to 19, wherein, according to the basis weight test herein, the topsheet has a basis weight in the range of about 10 gsm to about 35 gsm, preferably about 15 gsm to about 30 gsm, more preferably about 18 gsm to about 25 gsm, and most preferably about 20 gsm to about 24 gsm.

[0069] Embodiment 21. The method according to any one of Embodiments 17 to 20, wherein the pin includes a third transition section extending between the first section and the second section.

[0070] Embodiment 22. The method according to any one of embodiments 17 to 21, wherein the second wall of the second section extends from the base portion of the second section to the base portion of the first section.

[0071] Embodiment 23. The method according to any one of embodiments 17 to 22, wherein:

[0072] A first portion of the first wall of the first section of the pin is set at a first direction angle, the first direction angle being greater than about 17.5 degrees and preferably greater than about 25 degrees:

[0073] A second portion of the first wall is set at a second direction angle, the second direction angle being greater than about 17.5 degrees and preferably greater than about 20 degrees; and

[0074] The second direction angle is less than the first direction angle.

[0075] Embodiment 24. A method for forming a plurality of openings in a nonwoven liquid-permeable substrate for an absorbent article, the substrate defining a first surface and a second surface, the method comprising:

[0076] Providing a nonwoven liquid-permeable substrate;

[0077] Providing a forming device, the forming device including a plurality of tapered pins, each of at least a portion of the pins including:

[0078] A first section having a first wall extending from a base portion of the first section to a distal portion of the first section, at least a portion of the first wall being set at a first angle, the first angle being greater than about 17.5 degrees, preferably greater than about 20 degrees, more preferably greater than about 25 degrees; and

[0079] A second section having a second wall extending from a base portion of the second section, at least a portion of the second wall being set at a second angle, the second angle being less than about 20 degrees, preferably less than about 18 degrees, more preferably less than about 16 degrees;

[0080] Passing the substrate through the forming device, wherein the pins penetrate the substrate and form openings therein;

[0081] Wherein each of at least some of the openings defines:

[0082] A first opening area at the first surface of the substrate, according to the 2D X-ray CT scan test herein, the first opening area being in the range of about 2 mm 2 to about 12 mm 2 ;

[0083] The second opening area at the second surface of the substrate, according to the 2D X-ray CT scan test herein, is less than the first opening area and is in the range of about 1.0 mm 2 to about 7.5 mm 2 ; and

[0084] Side walls, according to the 2D X-ray CT scan test herein, at least a portion of the side walls has an angle in the range of about 55 degrees to about 90 degrees, preferably in the range of about 60 degrees to about 80 degrees, more preferably in the range of about 63 degrees to about 75 degrees.

[0085] Embodiment 25. The method according to embodiment 24, wherein the pin includes a third transition section extending between the first section and the second section.

[0086] Embodiment 26. The method according to embodiment 24 or 25, wherein the second wall of the second section extends from the base portion of the second section to the base portion of the first section.

[0087] Embodiment 27. A forming device for forming a plurality of openings in a nonwoven liquid-permeable substrate for an absorbent article, the device comprising:

[0088] Intermeshing members, the intermeshing members including a first member and a second member, the first member comprising:

[0089] A body portion; and

[0090] A plurality of tapered pins, each of at least a majority of the pins comprising:

[0091] A first section having a first wall extending from a base portion of the first section to a distal portion of the first section, at least a portion of the first wall being set at a first angle greater than about 17.5 degrees, preferably greater than about 20 degrees, more preferably greater than about 25 degrees; and

[0092] A second section having a second wall extending from a base portion of the second section, the base portion of the second section extending from the body portion of the first member, at least a portion of the second wall being set at a second angle different from the first angle and less than about 20 degrees, preferably less than about 18 degrees, more preferably less than about 16 degrees.

[0093] Embodiment 28. The forming device according to embodiment 27, wherein the first member includes a first roll and the second member includes a second roll.

[0094] Embodiment 29. The shaping device according to Embodiment 27 or 28, wherein the pin includes a third transition section extending between the first section and the second section.

[0095] Embodiment 30. The shaping device according to any one of Embodiments 27 to 29, wherein the second wall of the second section extends from the base portion of the second section to the base portion of the first section.

[0096] Embodiment 31. The shaping device according to any one of Embodiments 27 to 30, wherein:

[0097] A first part of the first wall of the pin is arranged at a first direction angle, the first direction angle being greater than about 17.5 degrees and preferably greater than about 25 degrees:

[0098] A second part of the first wall is arranged at a second direction angle, the second direction angle being greater than about 17.5 degrees and preferably greater than about 20 degrees; and

[0099] The second direction angle is less than the first direction angle.

[0100] Embodiment 32. The shaping device according to any one of Embodiments 27 to 31, wherein each of at least most of the pins has a height defined by the first section and the second section of not more than about 5 mm, preferably not more than about 4.5 mm, and more preferably not more than about 4 mm. Description of the Drawings

[0101] Although the specification concludes with claims that particularly point out and clearly claim the subject matter forming the present invention, it is believed that the present invention can be better understood from the following description in conjunction with the drawings, in which reference numerals are used to indicate substantially identical elements, and in which:

[0102] Figure 1 Is a plan view of an exemplary absorbent article in the form of a diaper, in a flat, unfolded state, with the surface facing the wearer towards the observer;

[0103] Figure 2 Is Figure 1 A plan view of an exemplary absorbent article of, in a flat, unfolded state, with the surface facing the clothing towards the observer;

[0104] Figure 3 Is of Figure 1 And 2 A front perspective view of the absorbent article in a fastened state;

[0105] Figure 4 Is a front perspective view of an absorbent article in the form of pants;

[0106] Figure 5 Back perspective view of an absorbent article for Figure 4 ;

[0107] Figure 6 Plan view of an absorbent article for Figure 4 , in a flat, unfolded state, with the surface facing the garment towards the observer;

[0108] Figure 7 Cross-sectional view of the absorbent article taken along line Figure 6 7-7;

[0109] Figure 8 Cross-sectional view of the absorbent article taken along line Figure 6 8-8;

[0110] Figure 9 Plan view of an exemplary absorbent core of the absorbent article;

[0111] Figure 10 Cross-sectional view of the absorbent core taken along line Figure 9 10-10;

[0112] Figure 11 Cross-sectional view of the absorbent core taken along line 11-11 of Figure 10 ;

[0113] Figure 12 Plan view of an exemplary absorbent article of the present disclosure as a sanitary napkin;

[0114] Figure 13 Exemplary cross-sectional view taken in the front waist region of the absorbent article;

[0115] Figure 14 Exemplary cross-sectional view taken in the crotch region of the absorbent article;

[0116] Figure 15 Exemplary cross-sectional view taken in the back waist region of the absorbent article;

[0117] Figure 16 Plan view of an exemplary substrate, with the surface facing the wearer towards the observer;

[0118] Figure 16A Magnified view of an opening formed in the substrate for Figure 16 ;

[0119] Figure 17 Cross-sectional view taken along line Figure 16A 17-17;

[0120] Figure 17A Cross-sectional view similar to Figure 17 but with openings in the relevant art;

[0121] Figure 18 Similar to that of claim 17, but after the compressive force has been applied to the substrate;

[0122] Figure 19 Showing Figure 16 An enlarged view of a plurality of openings in the substrate of;

[0123] Figures 20 - 22 Similar to Figure 19 View showing a corresponding plurality of exemplary openings in the substrate;

[0124] Figure 23 A side view of a device for forming an opening in a substrate;

[0125] Figure 24 Is Figure 23 A perspective view of a plurality of pins of the device of;

[0126] Figure 25A And Figure 25B Are corresponding cross-sectional views of one of the pins of Figure 24 Taken longitudinally and transversely;

[0127] Figure 26A And Figure 26B Are corresponding front and side cross-sectional views of other exemplary pins for forming an opening in a substrate;

[0128] Figure 27 Images of a top sheet sample without external pressure applied and a top sheet sample with pressure applied are provided;

[0129] Figure 28 Is a view showing the measurement of the hole pattern distance according to the 2D X-ray CT scan test as disclosed herein; and

[0130] Figure 29 Is a view showing the measurement of the aperture and angle according to the 2D X-ray CT scan test as disclosed herein. Detailed Description

[0131] Various non-limiting forms of the present disclosure will now be described to provide an overall understanding of the structure, function, manufacture, and use principles of the absorbent article having an open-cell three-dimensional material disclosed herein and its manufacturing method. One or more examples of these non-limiting forms are shown in the drawings. Those of ordinary skill in the art will understand that the absorbent article having an open-cell three-dimensional material and its manufacturing method clearly described herein and shown in the drawings are non-limiting example forms, and the scope of the various non-limiting forms of the present disclosure is defined only by the claims. Features shown or described in connection with one non-limiting form may be combined with features of other non-limiting forms. Such modifications and variations are intended to be included within the scope of the present disclosure.

[0132] General description of the absorbent article

[0133] The exemplary absorbent article 10 shown in the form of a diaper according to the present disclosure is shown in Figures 1 - 3 below. Figure 1 is a plan view of the exemplary absorbent article 10 in a flat, unfolded state (i.e., without elastic contraction), with the garment-facing surface 2 facing the observer. Figure 2 is Figure 1 a plan view of the exemplary absorbent article 10 in a flat, unfolded state, with the wearer-facing surface 4 facing the observer. Figure 3 is a front perspective view of the absorbent article 10 in a fastened configuration of Figure 1 and 2 . Figures 1 - 3 The absorbent article 10 of

[0134] is shown for illustrative purposes only, as the present disclosure can be used to manufacture a variety of diapers, including, for example, adult incontinence products, pants, or other absorbent articles such as sanitary napkins and absorbent pads.

[0135] The absorbent article 10 may include a front waist region 12, a crotch region 14, and a back waist region 16. The crotch region 14 may extend between the front waist region 12 and the back waist region 16. The front waist region 12, the crotch region 14, and the back waist region 16 may each be one-third of the length of the absorbent article 10. The absorbent article 10 may include a front edge 18, a back edge 20 opposite the front edge 18, and longitudinally extending, laterally opposite side edges 22 and 24 defined by a base structure 52.

[0136] In other cases, the absorbent article may be in the form of pants having permanently or repeatedly fastenable side seams. Suitable repeatedly fastenable seams are disclosed in U.S. Patent Application Publication No. 2014 / 0005020 and U.S. Patent 9,421,137. See Figures 4 - 8 , which shows an exemplary absorbent article 10 in the form of pants. Figure 4 is a front perspective view of the absorbent article 10. Figure 5 is a rear perspective view of the absorbent article 10. Figure 6 is a plan view of the absorbent article 10 in a flat, unfolded state, with the surface facing the garment towards the observer. Figures 4 - 8 The elements having the same reference numerals as those described above with respect to Figures 1 - 3 may be the same elements (e.g., the absorbent core 30). Figure 7 is an exemplary cross-sectional view of the absorbent article taken along line 7-7 of Figure 6 . Figure 8 is an exemplary cross-sectional view of the absorbent article taken along line 8-8 of Figure 6 . Figure 7 and Figure 8 show exemplary forms of the front waistband 54 and the rear waistband 56. The absorbent article 10 may have a front waist region 12, a crotch region 14, and a rear waist region 16. Each of the regions 12, 14, and 16 may be one-third of the length of the absorbent article 10. The absorbent article 10 may have a base structure 52 (sometimes referred to as a central base structure or a central panel), which includes a topsheet 26, a backsheet 28, and an absorbent core 30 disposed at least partially between the topsheet 26 and the backsheet 28, and optionally acquisition materials 38 (similar to the acquisition materials described above with respect to Figures 1 - 3 ). The absorbent article 10 may include a front waistband 54 located in the front waist region 12 and a rear waistband 56 located in the rear waist region 16. The base structure 52 may be joined to the surface 4 of the front and rear waistbands 54 and 56 facing the wearer, or to the surface 2 of the waistbands 54, 56 facing the garment. The side edges 23 and 25 of the front waistband 54 may be joined to the side edges 27 and 29 of the rear waistband 56, respectively, to form two side seams 58. The side seams 58 may be any suitable seams known to those skilled in the art, such as, for example, adjacent seams or overlapping seams. When the side seams 58 are permanently formed or repeatedly fastened closed, the absorbent article 10 in the form of pants has two leg openings 60 and a waist opening perimeter 62. The side seams 58 may be permanently joined, for example, using an adhesive or bonding, or may be repeatedly fastened closed, for example, using a hook-and-loop fastener.

[0137] Girdle

[0138] See Figure 7 and Figure 8, the front tape 54 and the back tape 56 may include a front inner tape layer 66 and a back inner tape layer 67, as well as a front outer tape layer 64 and a back outer tape layer 65, which have an elastomeric material (e.g., strand 68 or film (which may be open-celled)) disposed at least partially between the inner tape layer and the outer tape layer. The elastomeric element 68 or film may be slack (including cut) to reduce the elastic strain on the absorbent core 30, or alternatively may be continuously distributed over the entire absorbent core 30. The elastic members 68 may have a uniform or variable spacing between them in any part of the tape. The elastic elements 68 may also be pre-strained by the same amount or different amounts. The front tape 54 and / or the back tape 56 may have one or more elastic element free regions 70, where the substrate 52 overlaps the front tape 54 and the back tape 56. In other cases, at least some of the elastic elements 68 may extend continuously over the substrate 52.

[0139] The front inner tape layer 66 and the back inner tape layer 67, as well as the front outer tape layer 64 and the back outer tape layer 65, may be joined using adhesives, heat bonding, pressure bonding, or thermoplastic bonding. Various suitable tape layer configurations can be seen in U.S. Patent Application Publication 2013 / 0211363.

[0140] The front tape edge 55 and the back tape edge 57 may longitudinally extend beyond the front substrate edge 19 and the back substrate edge 21 (as Figure 6 shown), or they may be co-terminus. The front tape side edges and the back tape side edges 23, 25, 27, and 29 may laterally extend beyond the substrate side edges 22 and 24. The front tape 54 and the back tape 56 may be continuous (i.e., having at least one continuous layer) from tape side edge to tape side edge (e.g., the lateral distance from 23 to 25 and from 27 to 29). Alternatively, the front tape 54 and the back tape 56 may be discontinuous from tape side edge to tape side edge (e.g., the lateral distance from 23 to 25 and from 27 to 29), such that they are discrete.

[0141] As disclosed in U.S. Patent 7,901,393, the longitudinal length of the back tape 56 (along the central longitudinal axis 50) may be greater than the longitudinal length of the front tape 54, and this may be particularly useful for increasing hip coverage when the back tape 56 has a greater longitudinal length than the front tape 54 adjacent to or immediately adjacent to the side seam 58.

[0142] The front outer tape layer 64 and the back outer tape layer 65 may be separated from each other such that these layers are discrete, or alternatively, these layers may be continuous such that the layer continuously extends from the front tape edge 55 to the back tape edge 57. The same may be true for the front and back inner tape layers 66 and 67 - i.e., they may also be longitudinally discrete or continuous. Furthermore, the front outer tape layer 64 and the back outer tape layer 65 may be longitudinally continuous, while the front inner tape layer 66 and the back inner tape layer 67 are longitudinally discrete, such that a gap is formed between them - the gap between the front and back inner and outer tape layers 64, 65, 66, and 67 is shown in Figure 7and the gap between the front inner belt layer 66 and the rear inner belt layer 67 is shown in Figure 8 .

[0143] The front belt 54 and the rear belt 56 may include slits, holes, and / or perforations that provide increased breathability, softness, and a clothing-like texture. The underwear-like appearance can be enhanced by substantially aligning the waist edge and the leg edge at the side seam 58 (see Figure 4 and 5 ).

[0144] The front belt 54 and the rear belt 56 may include graphics (see, for example Figure 1 78). The graphics may extend substantially around the entire circumference of the absorbent article 10 and may be disposed across the side seam 58 and / or across the proximal front belt seam 15 and the rear belt seam 17; or, in the manner shown in U.S. Patent No. 9,498,389, adjacent to the seams 58, 15, and 17 to form a more underwear-like article. The images may also be discontinuous.

[0145] Alternatively, discrete side panels may be attached to the side edges 22 and 24 of the infrastructure instead of attaching the belts 54 and 56 to the infrastructure 52 to form pants. Suitable forms of pants including discrete side panels are disclosed in U.S. Patent Nos. 6,645,190; 8,747,379; 8,372,052; 8,361,048; 6,761,711; 6,817,994; 8,007,485; 7,862,550; 6,969,377; 7,497,851; 6,849,067; 6,893,426; 6,953,452; 6,840,928; 8,579,876; 7,682,349; 7,156,833; and 7,201,744.

[0146] Top sheet

[0147] The topsheet 26 is the part of the absorbent article 10 that contacts the wearer's skin. As is well known to those of ordinary skill in the art, the topsheet 26 may be joined to the backsheet 28, the absorbent core 30, the barrier leg cuffs 32, and / or portions of any other layer. The topsheet 26 may be compliant, feel soft, and non-irritating to the wearer's skin. In addition, at least a portion or all of the topsheet may be liquid-permeable, allowing liquid body exudates to easily penetrate through its thickness. Suitable topsheets may be made from many different materials, such as porous foams, reticulated foams, open-cell plastic films, woven materials, non-woven materials, natural fibers (e.g., wood fibers or cotton fibers), synthetic fibers or filaments (e.g., polyester fibers or polypropylene fibers or PE / PP bicomponent fibers or mixtures thereof), or woven or non-woven materials that are a combination of natural fibers and synthetic fibers. The topsheet may have one or more layers. The topsheet may be open-celled (Figure 2 Component 27) can have any suitable three-dimensional feature structure and / or can have multiple embossings (e.g., bonding patterns). The topsheet can be apertured by overapplying an adhesive material and then rupturing the overapplied area by ring rolling, as disclosed, for example, in U.S. Patent No. 5,628,097, issued to Benson et al. on May 13, 1997, and in U.S. Patent Application Publication No. US 2016 / 0136014, issued to Arora et al. Any portion of the topsheet can be coated with a skin care composition, an antimicrobial agent, a surfactant, and / or other beneficial agents. The topsheet can be hydrophilic or hydrophobic or can have hydrophilic and / or hydrophobic portions or layers. If the topsheet is hydrophobic, there will typically be apertures such that body exudates can pass through the topsheet.

[0148] Back sheet

[0149] The backsheet 28 is generally that portion of the absorbent article 10 that is positioned adjacent the absorbent core 30 and facing the clothing. The backsheet 28 can be joined to portions of the topsheet 26, the outer cover material 40, the absorbent core 30, and / or any other layer by any attachment method known to those skilled in the art. The backsheet film 28 prevents or at least inhibits body exudates absorbed and contained by the absorbent core 10 from soiling articles such as sheets, undergarments, and / or clothing. The backsheet is generally liquid impermeable or at least substantially liquid impermeable. The backsheet can be, for example, or include a thin plastic film, such as a thermoplastic film, having a thickness of from about 0.012 mm to about 0.051 mm. Other suitable backsheet materials can include breathable materials that allow vapors to escape from the absorbent article while still preventing or at least inhibiting body exudates from passing through the backsheet.

[0150] Outer cover material

[0151] The outer cover material (sometimes referred to as the backsheet nonwoven material) 40 can comprise one or more nonwoven materials joined to and covering the backsheet 28. The outer cover material 40 forms at least a portion of the clothing-facing surface 2 of the absorbent article 10 and effectively "covers" the backsheet 28 such that the film is not present on the clothing-facing surface 2. The outer cover material 40 can comprise bonding patterns, apertures, and / or three-dimensional features.

[0152] Absorbent core

[0153] As used herein, the term "absorbent core" 30 refers to the component of the absorbent article 10 that has a maximum absorbent capacity and contains absorbent material. See Figures 9 - 11, in some cases, the absorbent material 72 may be positioned within a core pocket or core wrapper 74. Depending on the particular absorbent article, the absorbent material may or may not be shaped. The absorbent core 30 may comprise, consist essentially of, or consist of: a core wrapper, the absorbent material 72, and an adhesive encapsulated within the core wrapper. The absorbent material may comprise a superabsorbent polymer, a mixture of a superabsorbent polymer and a breathable mat, only a breathable mat, and / or a high internal phase emulsion foam. In some cases, the absorbent material may comprise at least 80%, at least 85%, at least 90%, at least 95%, at least 99%, or up to 100% of a superabsorbent polymer by weight of the absorbent material. In such cases, the absorbent material may be free of, or at least mostly free of, a breathable mat. The absorbent core perimeter (which may be the perimeter of the core wrapper) may define any suitable shape, such as, for example, a rectangular "T", "Y", "hourglass", or "dogbone" shape. An absorbent core perimeter having a generally "dogbone" shape or "hourglass" shape may taper along its width toward the crotch region 14 of the absorbent article 10.

[0154] Reference Figures 9 - 11 , the absorbent core 30 may have areas with little or no absorbent material 72, where the wearer-facing surface of the core pocket 74 may be joined to the garment-facing surface of the core pocket 74. These areas with little or no absorbent material may be referred to as "channels" 76. These channels may embody any suitable shape and may provide any suitable number of channels. In other cases, the absorbent core may be embossed to produce an imprint of the channels. Figures 9 - 11 The absorbent core in is only an exemplary absorbent core. Many other absorbent cores with or without channels are also within the scope of the present disclosure.

[0155] Barrier leg cuff / leg elastic member

[0156] See Figure 1 and Figure 2, for example, the absorbent article 10 may include one or more pairs of barrier leg cuffs 32 and one or more pairs of leg elastic members 34. The barrier leg cuffs 32 may be positioned laterally inward of the leg elastic members 34. Each barrier leg cuff 32 may be formed from a piece of material that is bonded to the absorbent article 10 such that it extends upwardly from the wearer-facing surface 4 of the absorbent article 10 and provides improved containment of body exudates near the juncture of the wearer's torso and legs. The barrier leg cuffs 32 are defined by their proximal edges and free end edges that are directly or indirectly joined to the topsheet and / or backsheet and are intended to contact the wearer's skin and form a seal. The barrier leg cuffs 32 extend at least partially between the front edge 18 and the rear edge 20 of the absorbent article 10 on opposite sides of the central longitudinal axis 50 and are present at least in the crotch region 14. The barrier leg cuffs 32 may each include one or more elastic members 33 (e.g., elastic strands or strips) near or at the free end edges. These elastic members 33 cause the barrier leg cuffs 32 to help form a seal around the wearer's legs and torso. The leg elastic members 34 extend at least partially between the front edge 18 and the rear edge 20. The leg elastic members 34 generally cause the portions of the absorbent article 10 near the side edges 22, 24 of the infrastructure to help form a seal around the wearer's legs. The leg elastic members 34 may extend at least within the crotch region 14.

[0157] Elastic waistband

[0158] Reference Figure 1 and Figure 2 , the absorbent article 10 may include one or more elastic waistbands 36. The elastic waistbands 36 may be positioned on the garment-facing surface 2 or on the wearer-facing surface 4. By way of example, a first elastic waistband 36 may be present in the front waist region 12 near the front band edge 18 and a second elastic waistband 36 may be present in the rear waist region 16 near the rear edge 20. The elastic waistbands 36 may help to seal the absorbent article 10 around the wearer's waist and at least inhibit body exudates from escaping the absorbent article 10 through the perimeter of the waist opening. In some cases, the elastic waistband may completely surround the waist opening of the absorbent article.

[0159] Collection material

[0160] See Figure 1 , Figure 2 , Figure 7 and Figure 8, one or more acquisition materials 38 may be at least partially present between the topsheet 26 and the absorbent core 30. The acquisition materials 38 are typically hydrophilic materials that provide significant capillary action for body exudates. These materials can dehydrate the topsheet 26 and quickly move body exudates into the absorbent core 30. The acquisition materials 38 can include, for example, one or more nonwoven materials, foams, cellulose materials, crosslinked cellulose materials, airlaid cellulose nonwovens, spunlace materials, or combinations thereof. In some cases, portions of the acquisition material 38 may extend through portions of the topsheet 26, portions of the topsheet 26 may extend through portions of the acquisition material 38, and / or the topsheet 26 may be nested with the acquisition material 38. Generally, the acquisition material 38 may have a width and length that are less than the width and length of the topsheet 26. The acquisition material can be a second topsheet in the context of a feminine pad. The acquisition material can have one or more channels (including embossed patterns) as described above with respect to the absorbent core 30. The channels in the acquisition material may or may not be aligned with the channels in the absorbent core 30. In one example, the first acquisition material can include a nonwoven material and the second acquisition material can include a crosslinked cellulose material.

[0161] Landing zone

[0162] See Figure 1 and Figure 2 , the absorbent article 10 may have a landing zone area 44 formed in a portion of the garment-facing surface 2 of the outer cover material 40. If the absorbent article 10 is fastened from front to back, the landing zone area 44 may be located in the rear waist region 16; or if the absorbent article 10 is fastened from back to front, the landing zone area may be located in the front waist region 12. In some cases, the landing zone 44 can be or can include one or more discrete nonwoven materials that are attached to a portion of the outer cover material 40 in the front waist region 12 or the rear waist region 16, depending on whether the absorbent article is fastened in the front or the back. Substantially, the landing zone 44 is configured to receive the fastener 46 and can include, for example, a plurality of loops configured to engage a plurality of hooks on the fastener 46, or vice versa.

[0163] Wetting indicator mark / graphical pattern

[0164] See Figure 1, the absorbent article 10 of the present disclosure may include a graphic 78 and / or a wetness indicating marker 80 visible from the garment-facing surface 2. The graphic 78 may be printed on the landing zone 40, the backsheet 28, and / or other locations. The wetness indicating markers 80 are typically applied to the absorbent core side of the backsheet 28 such that they can be contacted by body exudates within the absorbent core 30. In some cases, the wetness indicating markers 80 may form part of the graphic 78. For example, the wetness indicating markers may appear or disappear and create / remove characters within some graphics. In other cases, the wetness indicating markers 80 may be coordinated (e.g., the same design, the same pattern, the same color) or uncoordinated with the graphic 78.

[0165] Front ear tab and rear ear tab

[0166] See the above-mentioned Figure 1 and Figure 2 , the absorbent article 10 may have front tabs 47 and / or rear tabs 42 in an adhesive diaper. In most adhesive diapers, only one set of tabs is required. The single set of tabs may include fasteners 46 configured to engage the landing zone or landing area 44. If two sets of tabs are provided, in most cases, only one set of tabs may have fasteners 46 while the other set of tabs does not have fasteners. The tabs or portions thereof may be elastic or may have elastic sheets. In one example, an elastic film or elastic strands may be positioned between a first nonwoven material and a second nonwoven material. The elastic film may be open-celled or may be non-open-celled. The tabs may be formed. The tabs may be integral (e.g., an extension of the outer cover material 40, the backsheet 28, and / or the topsheet 26), or may be discrete components attached to the underlying structure 52 of the absorbent article on the wearer-facing surface 4, on the garment-facing surface 2, or between the two surfaces 2, 4.

[0167] Sensor

[0168] See again Figure 1, the absorbent article of the present disclosure may include a sensor system 82 for monitoring changes within the absorbent article 10. The sensor system 82 may be separate from or integral with the absorbent article 10. The absorbent article 10 may include sensors that can sense various aspects of the absorbent article 10 associated with the invasion of body exudates such as urine and / or BM (e.g., the sensor system 82 can sense temperature changes, humidity, the presence of ammonia or urea, various vapor components of the exudates (urine and feces), changes in the wet vapor transmission through the garment-facing layer of the absorbent article, changes in the translucency of the garment-facing layer, and / or color changes through the garment-facing layer). Additionally, the sensor system 82 can also sense the components of urine such as ammonia or urea, and / or the by-products generated due to the reaction of these components with the absorbent article 10. The sensor system 82 can sense the by-products generated when urine is mixed with other components of the absorbent article 10 (e.g., adhesives, agm). The sensed components or by-products may exist in the form of vapors that can pass through the garment-facing layer. It may also be desirable to place a reactant in the absorbent article that changes state (e.g., color, temperature) or produces a measurable by-product when mixed with urine or BM. The sensor system 82 can also sense changes in pH, pressure, odor, the presence of gases, blood, chemical markers or biomarkers, or combinations thereof. The sensor system 82 may have components on or near the absorbent article that transmit signals to a receiver further distal to the absorbent article such as an iPhone. The receiver can output the results to convey the condition of the absorbent article 10 to a caregiver. In other cases, a receiver may not be provided. Instead, the condition of the absorbent article 10 may be visually or audibly evident from the sensors on the absorbent article.

[0169] Package

[0170] The absorbent article of the present disclosure can be placed into a package. The package may comprise a polymer film and / or other materials. Graphics and / or markings related to the characteristics of the absorbent article may be formed on, printed on, positioned on, and / or placed on the outer portion of the package. Each package may include a plurality of absorbent articles. The absorbent articles may be stacked under compression to reduce the size of the package while still providing a sufficient quantity of absorbent articles for each package. By encapsulating the absorbent articles under compression, caregivers can easily handle and store the packages, and at the same time, it also provides savings in distribution for the manufacturer due to the size of the packages.

[0171] Sanitary napkin

[0172] See Figure 12, the absorbent article of the present disclosure can be a sanitary napkin 110. The sanitary napkin 110 can include a liquid-permeable topsheet 114, a liquid-impermeable or substantially liquid-impermeable backsheet 116, and an absorbent core 118. The liquid-impermeable backsheet 116 can be vapor-permeable or can be vapor-impermeable. The absorbent core 118 can have any or all of the characteristic structures described herein with respect to the absorbent core 30, and in some forms, can have a second topsheet 119 (STS) instead of the acquisition material disclosed above. The STS 119 can include one or more channels (including embossed patterns) as described above. In some forms, the channels in the STS 119 can be aligned with the channels in the absorbent core 118. The sanitary napkin 110 can also include wings 120 that extend outwardly relative to the longitudinal axis 180 of the sanitary napkin 110. The sanitary napkin 110 can also include a lateral axis 190. The wings 120 can be joined to the topsheet 114, the backsheet 116, and / or the absorbent core 118. The sanitary napkin 110 can further include a front edge 122, a rear edge 124 longitudinally opposite the front edge 122, a first side edge 126, and a second side edge 128 longitudinally opposite the first side edge 126. The longitudinal axis 180 can extend from the midpoint of the front edge 122 to the midpoint of the rear edge 124. The lateral axis 190 can extend from the midpoint of the first side edge 128 to the midpoint of the second side edge 128. The sanitary napkin 110 can also have additional characteristic structures that are commonly present in sanitary napkins as known in the art.

[0173] Exemplary cross - section of the absorbent article

[0174] Figures 13 to 15 Exemplary cross-sectional views of absorbent articles within the scope of the present disclosure are shown. Figure 13 Is an exemplary cross-sectional view taken within the front waist region 12 of the absorbent article. Figure 14 Is an exemplary cross-sectional view taken within the crotch region 14 of the absorbent article. Figure 15 Is an exemplary cross-sectional view taken within the rear waist region 16 of the absorbent article. In Figures 13 to 15 , the outer cover material is element 40, the liquid-permeable topsheet is element 26, the opaque patch is element 84, the liquid-impermeable backsheet is element 28, the absorbent core is element 30, the core pocket is element 74, the absorbent material is element 72, and the distribution material is element 86. The distribution material 86 can include a crosslinked cellulose material and can be optional. The acquisition material is element 88. The liquid-permeable topsheet is element 26. The barrier leg cuffs are element 90. The elastic member in the barrier leg cuffs is element 92. The rear ear tabs are element 42. The fasteners on the rear ear tabs 42 are element 46. For clarity, the structural adhesives and / or bonds between the layers and / or components have been removed. Other cross-sectional configurations known to those skilled in the art are also within the scope of the present disclosure.

[0175] General structure and properties of the substrate

[0176] The substrate of the present disclosure can be used as a component or part of a component of an absorbent article such as a diaper, pants, or sanitary napkin. Some examples of such uses can be, for example, a topsheet, an outer cover nonwoven material, and / or a portion of an ear tab. Although the topsheet is referred to herein as an example, it should be understood that the substrate can be used as any component of an absorbent article. Figure 16 Is a plan view of a portion of an exemplary substrate for an absorbent article according to the present disclosure, such as topsheet 200, wherein a first surface of topsheet 200 facing the wearer surface 202 of topsheet 200 faces the observer. A second surface of topsheet 200 including the surface facing the clothing 204 is shown in Figure 17 and 18 wherein Figure 17 Is a cross-sectional view of topsheet 200 taken along view line 17-17 before a compressive force F C Is applied to topsheet 200, and Figure 16A Is a cross-sectional view of topsheet 200 taken along view line 17-17 after a compressive force F Figure 18 Is applied to topsheet 200. C Is a cross-sectional view of topsheet 200 taken along view line 17-17 after a compressive force F Figure 19 Is an enlarged view of a plurality of apertures 206 formed in topsheet 200. Topsheet 200 shown in Figures 16 - 19 Herein (excluding Figure 17A , which shows related art apertures) can form part of any absorbent article described herein, or can be used in other types of absorbent articles as will be understood by those of ordinary skill in the art.

[0177] Topsheet 200 can be formed of any suitable nonwoven material and includes a single layer or multiple layers, such as two or more layers. If multiple layers are used, they can be composed of the same type of nonwoven material, or different types of nonwoven materials. In some cases, topsheet 200 can be free of a film. The thickness T of topsheet 200 can be in the range of about 0.2 mm to about 3 mm, in the range of about 0.5 mm to about 2 mm, or in the range of about 0.7 mm to about 1.5 mm, see Figure 17 .

[0178] The topsheet 200 may include a fibrous layer, such as a hydrophobic fibrous layer. The fibrous layer may be made of any suitable material, including but not limited to natural materials, synthetic materials, and combinations thereof. Suitable natural materials may include but are not limited to cellulose, cotton linter, bagasse, wool fibers, silk fibers, etc. Cellulose fibers may be provided in any suitable form, including but not limited to single fibers, fluff pulp, dry cloth boards, liner boards, etc. Suitable synthetic materials may include but are not limited to nylon, rayon, and polymeric materials. Suitable polymeric materials may include but are not limited to: polyethylene (PE), polyester, polyethylene terephthalate (PET), polypropylene (PP), polylactic acid (PLA), and copolyesters. However, in some forms, the topsheet 200 may be substantially or completely free of one or more of these materials. For example, in some forms, the topsheet 200 may be substantially free of cellulose and / or not include paper materials. In some forms, one or more layers of the topsheet 200 may contain up to 100% thermoplastic fibers. Thus, in some cases, the fibers are substantially non-absorbent. The fibrous layer may be 100% carded web fibers, 100% spunbond fibers, or one or more carded web fiber layers and one or more spunbond fiber layers. One or more layers of the topsheet 200 may contain cotton fibers.

[0179] At least some of the fibers may include bicomponent fibers having a core and a sheath. The core may comprise polyethylene terephthalate (PET), and the sheath may comprise polyethylene (PE). As an alternative, the core may comprise polypropylene (PP) or polylactic acid (PLA). The fibers may be composed of about 30% to about 60% core (e.g., PET), about 70% to about 40% sheath (e.g., PE), and optionally up to about 4% titanium dioxide (TiO2), i.e., 0% to about 4% TiO2. According to one example, the PET and PP portions may each constitute about 49% of the fiber composition, e.g., PET and PE constitute about 98% of the fiber composition, and the other 2% is TiO2.

[0180] In addition, at least some of the fibers may have a denier per filament of about 1 to about 3, about 1.5 to about 2.5, or about 2.

[0181] The basis weight of nonwoven materials is typically expressed in grams per square meter (gsm). Depending on the end use of the material, the basis weight of a single-layer nonwoven material may range from about 8 gsm to about 100 gsm. For example, the topsheet 200 may have a basis weight of about 10 gsm to about 35 gsm, about 15 gsm to about 30 gsm, about 18 gsm to about 25 gsm, or about 20 gsm to about 24 gsm. All basis weights are calculated according to the basis weight tests described herein.

[0182] Openings formed through the top sheet

[0183] An exemplary opening 206 formed through the fibrous layer of the topsheet 200 as shown in Figure 16A will now be described. It should be understood that the topsheet 200 may include one or more of the openings 206, but not all of the openings in the topsheet 200 need to be as described above, i.e., one or more conventional openings or one or more other types of openings as described herein may also be formed through the topsheet 200.

[0184] In the exemplary topsheet 200 shown in Figures 16 - 19 (including Figure 16A , but not including Figure 17A which shows an opening of the related art), the opening 206 is formed in the topsheet 200 and includes a wearer-facing opening area 208 at the wearer-facing surface 202 and a garment-facing opening area 210 defined in the displaced topsheet material including a tail 206A. The opening 206 allows liquid body exudates such as loose stools, urine, menses, etc. to pass through the topsheet 200 and thus makes the topsheet 200 a liquid-permeable substrate even though the fibers of the topsheet 200 may be hydrophobic. As shown in Figure 16A , 17 and 18, the wearer-facing opening area 208 is larger than the garment-facing opening area 210, wherein the wearer-facing opening area 208 and the garment-facing opening area 210 are measured according to the 2D X-ray CT scan test herein. The wearer-facing opening area 208 of the opening 206 is in the range of about 2 mm 2 to about 12 mm 2 , or in the range of about 3 mm 2 to about 8 mm 2 . The garment-facing opening area 210 of the opening 206 is in the range of about 1.0 mm 2 to about 7.5 mm 2 , or in the range of about 1.7 mm 2 to about 4 mm 2 .

[0185] The sidewall 212 defined by the tail 206A extends from the wearer-facing opening area 208 to the garment-facing opening area 210 and has an inward taper. In the example shown, the taper of the sidewall 212 is continuous from the wearer-facing opening area 208 to the garment-facing opening area 204, but may be discontinuous therebetween without departing from the scope and substance of the present disclosure. According to the present disclosure and as shown in Figure 17 , the sidewall 212 is set at an angle θ A measured with respect to a plane P1 that is substantially parallel to the wearer-facing surface 202. The angle θ Acan be greater than 55 degrees, within a range of about 55 degrees to about 90 degrees, within a range of about 60 degrees to about 80 degrees, or within a range of about 63 degrees to about 75 degrees.

[0186] According to the present disclosure, the angle θ A is defined such that the sidewall 212 extends from the opening area 208 facing the wearer to the opening area 210 facing the garment at a steep angle, e.g., the angle θ measured relative to a plane P1 substantially parallel to the surface 202 facing the wearer A can be within a range of about 55 degrees to about 90 degrees, or within a range of about 60 degrees to about 80 degrees, or within a range of about 63 degrees to about 75 degrees. It is believed that in the relevant art, the angle defined by the sidewall extending from the opening area 208 facing the wearer to the opening area 210 facing the garment is less steep. By forming the sidewall 212 with a steep angle, it is believed that two advantages can be achieved. First, a smaller opening area 208 facing the wearer can be used, thereby causing fewer skin imprints on the user, yet generating a body fluid flow through the opening 206 similar to that of an opening in the relevant art having a substantially larger opening area 208 facing the wearer and a similarly sized opening area 210 facing the garment. Additionally, a larger opening area facing the wearer results in a longer tail or sidewall, which is more likely to deform inwardly towards the center of the opening and restrict or block the flow through the opening. A smaller opening area facing the wearer is easier to form at a very steep angle because the length of the pin used to form the opening with a smaller opening area facing the wearer is shorter. Second, as will be discussed further below, it is believed that when the sidewall 212 is steep, it is less likely to fold back into the opening 206 to partially or substantially completely close the opening 206.

[0187] In the illustrated form, the opening 206 has a generally oval - like shape, see Figure 16A the opening 206 shown in Figure 16A As shown in A1 the oval - like shaped opening 206 has a center major axis dimension C A2 and a center major axis dimension C A2 which is measured at the opening area 210 facing the garment in the illustrated form. The center minor axis dimension C A1 has a length from one side of the opening 206 to the opposite side, which is shorter than the length of the center major axis dimension C A1 In one example, when measured at the opening area 210 facing the garment, the center major axis dimension CA2 Greater than 0.5 mm and in the range of about 0.5 mm to about 2.5 mm, in the range of about 0.9 mm to about 1.5 mm, or in the range of about 1 mm to about 1.4 mm. The central major axis dimension C A1 The ratio to the central minor axis dimension C A2 Can be at least 1.3 but less than 4, or at least 1.5 but less than 3.

[0188] The opening 206 can be arranged in the top sheet 200 such that the top sheet 200 has an effective opening area in the range of about 15% to about 30%, in the range of about 18% to about 25%, or in the range of about 20% to about 24% according to the opening test herein, as measured at the clothing-facing surface 204. Such an effective opening area can be achieved by a first spacing S1 of about 3.0 mm between adjacent openings 206 in a first direction (such as the side-to-side direction as shown in Figure 19 and a second spacing S2 of about 2.5 mm between adjacent openings 206 in a second direction (such as the up-down direction as shown in Figure 19 ), as measured at the wearer-facing surface 202, wherein the central major axis dimension C of the opening 206 A1 Is about 2.5 mm and the central minor axis dimension C of the opening 206 A2 Is about 1.2 mm.

[0189] In some aspects, all of the openings 206 can have similar dimensions and / or shapes, and in other aspects, the openings 206 can have one or more different dimensions and / or shapes.

[0190] Now referring to Figure 17 and 18 , the compressive force F C will now be described in terms of its effect on the top sheet 200, wherein the compressive force F C can be applied to the top sheet 200 including the component in a direction generally perpendicular to the wearer-facing surface 202. For example, such a compressive force F can occur when the wearer of the absorbent article including the top sheet 200 sits on a surface such as a chair, the floor, etc. C .

[0191] Due to Figure 18 the compressive force F shown in C , instead of folding inwards towards the center of the opening 206, as in the case of the opening 206' in the related art shown in Figure 17A (in Figure 17A , corresponding to Figure 17 and 18The structure shown (including the same reference numerals followed by basic signs) is believed to have the side walls 212 of the openings 206 at the opening area 210 facing the garment folded outwardly, i.e., away from the center of the opening 206, or curved as shown by the dashed lines on the left or right side portions of the side walls in Figure 18 . Since Figure 18 the side walls 212 of the openings 206 shown in C are folded outwardly or bent generally along their own axes at the opening area 210 facing the garment, the opening area 210 of the opening 206 facing the garment is not reduced (or only very slightly reduced) by the compressive force F C , thereby avoiding (or minimizing) a reduction in the amount of fluid that can flow through the opening 206 when the top sheet 206 is undergoing or has undergone the compressive force F Figure 17A . This is in contrast to the situation in Figure 17A where the side walls 212' of the opening 206' at the opening area 210' facing the garment are folded inwardly as shown by the dashed lines, and since the side walls 212' have a smaller steepness angle θ A' , the inward folding of the side walls 212' at the opening area 210' facing the garment can result in a reduction in the opening area 210' of the opening 206' facing the garment. When the top sheet 200' is undergoing or has undergone the compressive force F C , this reduction will decrease the amount of fluid that can flow through the opening 206'.

[0192] When forming the opening 206 of a generally oval shape, the top sheet material is displaced inwardly, i.e., in a direction away from the surface 202 facing the wearer, thereby forming the side walls 212. The side walls 212 have a length L A， See Figure 17 , Figure 17 which is a cross-sectional view corresponding to the longitudinal direction taken along view line 17-17 in Figure 16A . Since the opening 206 has an oval shape, the side wall length L A is smaller compared to an opening 206 that is generally circular but has a substantially similar area. The shorter side walls 212 are advantageous because when a compressive force is applied to the top sheet 206, it is believed to be less likely to bend or, in other words, fold inwardly towards the center of the opening 206. According to the 2D X-ray CT scan tests herein, the side walls 212 of the opening can have a length L A in the range of from 0.2 mm to about 2 mm, or in the range of from 0.5 mm to about 1.5 mm.

[0193] Additional exemplary openings

[0194] Figures 20 - 22 is similar to Figure 19view and shows additional exemplary apertures 206 formed in the respective top sheet 200. Unless otherwise specified, Figures 20 - 22 the material and configuration of the top sheet 200 shown in Figures 20 - 22 may be substantially similar to the top sheet 200 described above, and like reference numerals identify like elements.

[0195] In Figure 20 Figure 20 , the apertures 206 may be arranged in the top sheet 200 such that the top sheet 200 has an effective opening area of about 31% as measured by the aperture test herein, such as at the clothing-facing surface 204. Such effective opening area may be achieved by a first spacing S1 of about 3.0 mm between adjacent apertures 206 as measured at the wearer-facing surface 202 in a first direction (such as the side-to-side direction as shown in Figure 20 Figure 20 ) and a second spacing S2 of about 3.0 mm between adjacent apertures 206 as measured at the wearer-facing surface 202 in a second direction (such as the up-and-down direction as shown in Figure 20 Figure 20 ), wherein the center major axis dimension C of the aperture 206 A1 is about 3.0 mm and the center minor axis dimension C of the aperture 206 A2 is about 2.0 mm.

[0196] In Figure 21 Figure 21 , the apertures 206 may be arranged in the top sheet 200 such that the top sheet 200 has an effective opening area of about 23% as measured by the aperture test herein, such as at the clothing-facing surface 204. Such effective opening area may be achieved by a first spacing S1 of about 2.5 mm between adjacent apertures 206 as measured at the wearer-facing surface 202 in a first direction (such as the side-to-side direction as shown in Figure 21 Figure 21 ) and a second spacing S2 of about 8.5 mm between adjacent apertures 206 as measured at the wearer-facing surface 202 in a second direction (such as the up-and-down direction as shown in Figure 21 Figure 21 ), wherein the center major axis dimension C of the aperture 206 A1 is about 3.4 mm and the center minor axis dimension C of the aperture 206 A2 is about 2.8 mm.

[0197] In Figure 22 Figure 22 , the apertures 206 may be arranged in the top sheet 200 such that the top sheet 200 has an effective opening area of about 22% as measured by the aperture test herein, such as at the clothing-facing opening area 210. Such effective opening area may be achieved by a first spacing S1 of about 3.2 mm between adjacent apertures 206 as measured at the wearer-facing surface 202 in a first direction (such as Figure 22The first spacing S1 in the side-to-side direction (as shown) and the second spacing S2 between adjacent apertures 206, which is measured at the surface 202 facing the wearer and is about 2.6 mm in the second direction (as Figure 22 shown in the up-down direction), are achieved, where the center major axis dimension C of the aperture 206 A1 is about 2.5 mm and the center minor axis dimension C of the aperture 206 A2 is about 1.2 mm.

[0198] Equipment for opening formation and shaping

[0199] Any suitable apparatus and method for forming the apertures 206 can be utilized. For example, the apertures 206 in the materials of the present disclosure can be formed by hydroforming a web of fibers, laser cutting, perforating with a patterned roller, die cutting, using a hot melt method, overbonding, and loop-rolling apertures, as disclosed in U.S. Patent Application Publication No. US 2016 / 0136014 and U.S. Patent No. 5,628,097, or other suitable methods. The materials can also be manually apertured using, for example, a pin punch. Other exemplary aperture methods can be used, such as those described in U.S. Patents 9,023,261, 8,158,043, 8,241,543, and 8,679,391.

[0200] As an example, referring to Figures 23 - 25B , a nonwoven liquid-permeable substrate 300 including a first surface 300A (facing downward in Figure 23 ), and a second surface 300B (facing upward in Figure 23 ) is provided to an aperture forming apparatus 310. The first surface 300A of the substrate can correspond to the surface of the substrate 300 facing the wearer, and the second surface 300B of the substrate can correspond to the surface of the substrate 300 facing the garment.

[0201] The substrate 300 can be preheated by methods known in the art, such as by radiant heating, forced air heating, convection heating, or by heating on oil-heated rollers before entering the device 310. In addition or as an alternative, the pins and / or rollers (described below) of the device 310 can be heated so as to heat the substrate 300 while forming the openings therein. The heat is used to heat-set the formed openings in the substrate 300. The substrate 300 can also be pre-printed with marks, designs, logos, or other visible or invisible printed patterns. For example, the design and color can be printed by methods known in the art, such as by inkjet printing, gravure printing, flexographic printing, or offset printing to change the color of at least part of the substrate 300. In addition to printing, the substrate 300 can also be treated with a coating, such as with a surfactant, a lotion, an adhesive, etc. Treatment of the substrate 300 can be achieved by methods known in the art, such as by spraying, slot coating, extrusion, or in other words, applying a coating to one or two surfaces.

[0202] Exemplary apparatus 310 includes a Figure 23 A supply device (not shown) moves the substrate 300 in the direction shown and a pair of reversely intermeshing first ( Figure 23 the lower part of the middle) and the second ( Figure 23 The upper portion of the substrate includes a roller 312, 314 that rotates around an axis that is parallel and in the same plane. The rollers 312, 314 can be made of corrosion-resistant and wear-resistant materials such as steel or aluminum and are used to form openings in the substrate, such as the openings 206 disclosed herein.

[0203] The supply device moves the substrate 300 into the nip 316 formed by rollers 312, 314 by methods known in the art, including over or around any of various idler rollers, tension control rollers, etc. (none of which is shown).

[0204] Figure 23 The first roller 312 shown in the figure includes a plurality of exemplary pins 320, which are provided to penetrate the substrate 300 from the first surface 300A to the second surface 300B to form the openings 206 therein. The pins 320 may have a tapered shape or any other suitable shape for forming correspondingly shaped openings 206 in the substrate 300. The tapered pins 320 may also have an elongated direction in the machine direction MD, the cross direction CD, or a direction between MD and CD (such as 45 degrees relative to MD and CD). Figures 23 - 25B In the exemplary pin 320 shown in FIG. 1 , the direction of elongation is in the machine direction MD. The “machine direction” or “MD” is a direction parallel to the direction of travel of the substrate 300 as it moves through the manufacturing process. The “cross direction” or “CD” is a direction substantially perpendicular to the MD and in a plane generally defined by the substrate 300.

[0205] See Figure 25A and 25B , the pin 320 may include a first section 322 extending outwardly from a second section 324 that extends outwardly from a body portion 312A of the first roller 312. Figure 25A is a cross-sectional view of the pin 320 taken longitudinally, and Figure 25B is a cross-sectional view of the pin 320 taken transversely.

[0206] The first section 322 includes a first wall 326 extending from a base portion 328 of the first section 322 to a distal portion 330 of the first section 322, the distal portion 330 defining an outer / top end of the pin 320. In Figure 25A , a first portion 326A of the first wall 326 is disposed at a first longitudinal angle θ A relative to a central axis C of the pin 320 1A such that the first direction angle θ 1A is greater than about 17.5 degrees, greater than about 20 degrees, or greater than about 25 degrees. More specifically, referring to Figure 25A , the first portion 326A of the first wall 326 of the first section of the pin is disposed at a first longitudinal angle θ equal to 26.5 degrees 1A such that. Referring to Figure 25B , a second portion 326B of the first wall 326 of the first section of the pin is disposed at a second transverse angle θ 1B such that the second direction angle θ 1B is greater than about 17.5 degrees, greater than about 20 degrees, and less than or equal to the first direction angle θ 1A . In the form shown, the second transverse angle θ 1B is equal to 20.5 degrees.

[0207] The second section 324 includes a second wall 336 extending from a base portion 338 of the second section 324 to the base portion 328 of the first section 322, the base portion 338 of the second section extending outwardly from the body portion 312A of the first roller 312. A first portion 336A of the second wall 336 is disposed at a third longitudinal angle θ A relative to a central axis C of the pin 320 2A such that the third angle θ 2A is less than about 20 degrees, less than about 18 degrees, or less than about 16 degrees. In the form shown, the third longitudinal angle θ 2A is equal to 14 degrees. A second portion 336B of the second wall 336 is disposed at a fourth transverse angle θ A relative to a central axis C of the pin 320 2B such that the fourth angle θ 2BLess than about 20 degrees, less than about 18 degrees, or less than about 16 degrees. In the illustrated form, the fourth longitudinal angle θ 2B is equal to 14 degrees. Figure 25A and 25B the pin 320 shown in may be at an angle θ 1A 、θ 2A 、θ 1B 、θ 2B drawn that is different from the angle values discussed herein for convenience of illustration.

[0208] When the substrate 300 is conveyed through the device 302, the pin 320 is inserted through the substrate 300 and received in a female notch 350 formed in a body portion 314A of the second roller 314. Thus, the pin 320 penetrates the substrate 300 from the first surface 300A to the second surface 300B to form an opening 206 therein according to the size and shape of the second section 324 of the pin 320. For example, the second section 324 of the pin 320 may define the shape of the opening 206, while the first section 322 of the pin 320 is provided to penetrate the substrate 300. A transition in the angle of the pin 320 from the first section 322 to the second section 324 is provided to avoid the pin being significantly longer than the illustrated pin. More specifically, Figure 25A and 25B the pin 320 shown in has a height H defined by the first section 322 and the second section 324 that does not exceed about 5 mm, does not exceed about 4.5 mm, or does not exceed about 4 mm. In the absence of a transition in the angle of the pin 320 from the first section 322 to the second section 324, in order to obtain sidewalls of the opening having the desired dimensions (i.e., as set by the angles θ 2A and θ 2B of the second section 324 of the pin), the height H of the pin 320 would have to be much longer, which would be undesirable since longer pins tend to be less durable and difficult to release from the corresponding female notch 350 in the second roller 314.

[0209] A pin 420 formed according to another aspect is shown in Figure 26A and 26B . The pin 420 can be used in place of the pin 320 on the first roller to form an opening 206 in the substrate 300. The pin 420 includes a first section 422, a second section 424, and a third transition section 425 extending between the first section 422 and the second section 424. Figure 26A is a cross-sectional view of the pin 420 taken longitudinally, and Figure 26B is a cross-sectional view of the pin 420 taken transversely.

[0210] The pin first section 422 includes a first wall 426 extending from a base portion 428 of the first section 422 to a distal portion 430 of the first section 422, the distal portion 430 defining the outer / top end of the pin 420. In Figure 26A a first portion 426A of the first wall 326 is disposed at a first longitudinal angle θ A relative to the central axis C 3A of the pin 420, the first angle θ 3A being greater than about 17.5 degrees, greater than about 20 degrees, or greater than about 25 degrees. More specifically, referring to Figure 26A a first portion 426A of the first wall 426 of the pin first section is disposed at a first longitudinal angle θ equal to 26.5 degrees 3A relative to the central axis C of the pin 420. Referring to Figure 26B a second portion 426B of the first wall 426 of the pin first section is disposed at a second transverse angle θ 3B relative to the central axis C of the pin 420, the second direction angle θ 3B being greater than about 17.5 degrees, or greater than about 20 degrees, and less than or equal to the first direction angle θ 3A . In the form shown, the second transverse angle θ 3B is equal to 20.5 degrees.

[0211] The second section 424 includes a second wall 436 extending from a base portion 438 of the second section 424 to the base portion 428 of the first section 422, the base portion 438 of the second section extending outwardly from the body portion 412A of the first roll. A first portion 436A of the second wall 436 is disposed at a third longitudinal angle θ A relative to the central axis C 4A of the pin 420, the third angle θ 4A being less than about 20 degrees, less than about 18 degrees, or less than about 16 degrees. In the form shown, the third longitudinal angle θ 4A is equal to 14 degrees. A second portion 436B of the second wall 436 is disposed at a fourth transverse angle θ A relative to the central axis C 4B of the pin 420, the fourth angle θ 4B being less than about 20 degrees, less than about 18 degrees, or less than about 16 degrees. In the form shown, the fourth longitudinal angle θ 4B is equal to 14 degrees.

[0212] According to another aspect of the present disclosure, the first wall of the pin first section may define a curved surface extending from the distal portion toward the base portion of the first section, as shown by the dashed lines in Figure 26A and 26B .

[0213] Example

[0214] A set of topsheet samples formed in accordance with the present disclosure is tested without applying pressure to the sample, and a pressure of 689 Pa is applied to the sample using a GE phoenix v|tome|×m X-ray microfocus CT system. The material tested is a carded airlaid nonwoven material of 22 gsm, having 2 dpf PE / PET sheath / core hydrophobic bicomponent fibers and a thickness of 0.71 mm. 2D X-ray slices are measured in both the MD and CD directions. The data collected for each sample includes the opening diameter, the sidewall angle, the opening surface area, and the remaining opening surface area. The surface area is calculated using the following formula:

[0215] Opening surface area = π (a / 2) (b / 2), where a and b are the long diameter and short diameter of the opening, respectively.

[0216] The average of the data collected for the first set of topsheet samples without pressure applied is labeled "sample_1_pore_average" and is shown below. The average of the data collected for the first set of topsheet samples with a pressure of 689 Pa applied is labeled "sample_1_pore_under_pressure_average" and is shown below.

[0217]

[0218]

[0219]

[0220] It is apparent from the data listed above that for the set of topsheet samples formed in accordance with the present disclosure, when pressure is applied to the sample, the opening areas facing the garment and the wearer (i.e., the dorsal region and the skin-side region) change only slightly, decreasing slightly to 93.9% of the initial uncompressed dorsal opening area (dorsal area retention percentage in the chart above) and slightly decreasing to 92.6% of the initial uncompressed skin-side opening area (skin-side area retention percentage in the chart above).

[0221] Additionally, as shown in the 2D X-ray slice along Figure 27 the MD of topsheet sample 1 formed in accordance with the present disclosure has very little, if any, pore closure when the sample is subjected to pressure.

[0222] Test method

[0223] Unless otherwise specified, all tests described herein are performed on samples conditioned at 23°C ± 2°C and 50% ± 10% relative humidity (RH) for at least 24 hours.

[0224] Basis weight test

[0225] The basis weight of the materials disclosed herein can be determined by several available techniques, but a simple representative technique involves obtaining an absorbent article or other consumer product, removing any elastic components that may be present, and stretching the absorbent article or other consumer product to its full length. Then, a die having an area of 45.6 cm 2 is used to cut out a patterned apertured fibrous web (e.g., topsheet, outer cover) from an approximate center of the absorbent article or other consumer product at a location that maximally avoids any adhesives that may be present, which may be used to fasten the patterned apertured fibrous web to any other layers that may be present; and the patterned apertured fibrous web is removed from the other layers (if necessary, using a cryogenic spray such as Cyto-Freeze, Control Company (Houston, Texas)). The sample is then weighed and divided by the area of the die to obtain the basis weight of the patterned apertured fibrous web. The results are reported as the average of 5 samples, accurate to 0.1 cm 2 .

[0226] Opening test

[0227] In addition to other measurements, the pore size, effective pore area, and percentage of effective opening area are obtained from sample images acquired using a flatbed scanner. The scanner is capable of scanning in reflection mode at a resolution of 6400 dpi and 8-bit gray scale (a suitable scanner is the Epson Perfection V750 Pro from Epson America Inc. (Long Beach, CA) or equivalent). The scanner is connected to a computer running an image analysis program (a suitable program is ImageJ v. 1.47 or equivalent, National Institute of Health, USA) via an interface. The sample images are distance calibrated based on the image of a NIST-certified ruler acquired. Before acquiring the sample images, the sample is mounted using a steel frame and then backlit with a black glass ceramic tile (P / N 11-0050-30, purchased from HunterLab (Reston, VA)). The resulting images are then thresholded to separate the open pore regions from the sample material regions and analyzed using the image analysis program. All tests are conducted in a conditioning chamber maintained at approximately 23 ± 2 °C and approximately 50 ± 2% relative humidity.

[0228] Sample preparation :

[0229] To obtain a sample, the absorbent article is secured to a rigid flat surface with tape in a planar configuration. Any leg elastic members may be cut to facilitate laying the article flat. A sample is mounted using a straight steel frame (100 square millimeters, 1.5 mm thick, with a 60 square millimeter opening). The steel frame is obtained and a double-sided adhesive tape is placed on the bottom surface around the inner opening. The release paper of the tape is removed and the steel frame is attached to the apertured layer of the article. The frame is aligned such that it is parallel and perpendicular to the longitudinal (MD) and cross-directional (CD) of the apertured layer. The apertured layer is cut from the underlying layer of the article around the outer perimeter of the frame using a razor blade. The sample is carefully removed such that its longitudinal and lateral extensions are maintained to avoid distortion of the apertures. If necessary, a cryogenic spray (such as Cyto-Freeze, Control Company (Houston TX)) may be used to remove the sample from the underlying layer. Five replicates obtained from five substantially similar articles are prepared for analysis. If the apertured layer of interest is too small to accommodate the steel frame, the frame dimensions are reduced accordingly to achieve the purpose of removing the sample without aperture distortion while leaving an opening of sufficient size to allow scanning of a significant portion of the apertured layer. The apertured or patterned apertured substrate raw material is prepared for testing by extending or activating it to the same extent as it will be used in the absorbent article under the same process and then attaching it to the steel frame for testing as described above in its extended state. Before testing, the samples are conditioned at about 23°C ± 2°C and about 50% ± 2% relative humidity for 2 hours.

[0230] Image acquisition :

[0231] The ruler is placed on the scanning bed, oriented parallel to the edge of the scanner glass, and the cover is closed. A calibration image of the ruler is acquired in reflection mode at a resolution of 6400 dpi (about 252 pixels / mm) and 8-bit grayscale, where the field of view corresponds to the dimensions inside the steel frame. The calibration image is saved as an uncompressed TIFF format file. The cover is lifted and the ruler is removed. After obtaining the calibration image, all samples are scanned under the same conditions and measurements are made based on the same calibration file. Next, the sample on the upper frame is placed flat at the center of the scanning bed, laid flat, with the outer-facing surface of the sample facing the glass surface of the scanner. The sample is oriented such that the edges of the frame are aligned parallel and perpendicular to the edges of the scanner glass surface such that the resulting sample image will have an MD extending vertically from top to bottom. A black glass tile is placed on top of the frame, covering the sample, the cover is closed and a scanned image is acquired. The remaining four parallel samples are scanned in the same manner. If necessary, all images are cropped to a rectangular field of view circumscribing the apertured area and the files are re-saved.

[0232] Calculation of percentage of effective opening area :

[0233] Open the calibration image file in an image analysis program and perform linear distance calibration using an imaging ruler. Before analysis, this distance calibration scale will be applied to all subsequent sample images. Open the sample image in the image analysis program and set the distance scale. Observe the 8-bit histogram (0 to 255, a binary value / GL), and identify the gray level (GL) value of the smallest population located between the dark pixel peak of the open hole and the brighter pixel peak of the sample material. Set the threshold of the image to the minimum gray level value to generate a binary image. In the binary image, the open hole appears black with a GL value of 255; and the sample appears white with a GL value of 0.

[0234] Using an image analysis program, analyze each of the discrete open hole regions. Measure and record all of the individual open hole regions, accurate to 0.01 mm 2 , including partial open holes along the image edge. Discard any open holes with an area less than 0.3 mm 2 . Accumulate the remaining open hole area (including full and partial open holes), divide by the total area included in the image, and multiply by 100. Record this value as the percentage of effective opening area, accurate to 0.01%.

[0235] Analyze the remaining four sample images in a similar manner. For the five replicates, calculate and record the average percentage value of the effective opening area, accurate to 0.01%.

[0236] 2D X - ray CT scan test

[0237] Collect the CT data provided herein on a top sheet sample with or without pressure (about 289 Pa). Mount the sample parallel to the X-ray beam direction on a plastic sample holder with a foam surface (low X-ray absorption). Prepare a sample from the product in the same manner as measured for the open hole test above, and the sample is approximately 2.0 cm × 2.0 cm. Then fix the sample holder on a rotating table (integrated in the chamber), and scan using a GE Phoenix v|tome|x m CT scanner (GE Sensing & Inspection Technologies GmbH Niels-Bohr-Str. 7 31515 Wunstorf, Germany) with the following image acquisition parameters to ensure good image quality: microtube; voltage: 30 kV; current: 500 µA; tube mode: 1; timing: 1000 milliseconds; average: 2; skip frame: 1; number of images: 1500. Each reconstructed data set consists of a large number of 2D images, each pixel being 2014 In 2014, the isotropic resolution was 11.48 µm / pixel. 3D reconstruction was performed using the software attached to the GE CT instrument.

[0238] Visualization, image analysis, and quantification of the micro-CT data were completed using the software VG Studio MAX 3.0 (Volume Graphics GmbH, Germany), Avizo 9.1.1 (Visualization Services Group / FEI Company, Burlington, Massachusetts, U.S.A.), and image J for the micro-CT data. The steps included are as follows:

[0239] 1. Read the reconstructed micro-CT data into VG studio MAX 3.0.

[0240] 2. Export the 3D CT data set to a 16-bit tif image stack using VG Studio MAX 3.0.

[0241] 3. Then read the 16-bit tif image stack into Avizo 9.1.1.

[0242] 4. Use a thresholding method based on the image gray level to segment the top sheet from the background.

[0243] 5. After thresholding, use the Generate Surface module with a smoothing parameter of 3 to generate the 3D surface of the top sheet sample.

[0244] The image analysis and quantification of the Micro-CT data consisted of the following steps:

[0245] 1. Import the image stack generated by VG studio MAX 3.0 into image J.

[0246] 2. Perform pore pattern distance measurements on the X-ray CT slices parallel to the MD and CD axes, as Figure 28 shown. For each sample, measure the distance between the pore centers along both the MD and CD directions (indicated by the lines in Figure 28 ) as a reflection of their pattern.

[0247] 3. Then re-slice the image stack into 2D X-ray CT slices along the MD and CD axes in image J (the Excision module) for pore diameter and angle measurements.

[0248] 4. Then measure the pore diameters in both the skin side and the dorsal side on the X-ray CT slices at the center of each pore along the MD and CD axes, as Figure 29As shown. The angle between the line parallel to the top sheet fibers of the hole and the line parallel to the MD and CD planes is measured as an indication of the hole surface angle, as Figure 29 shown by the dashed line in

[0249] The dimensions and values disclosed herein should not 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 functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to represent "about 40 mm".

[0250] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or application, is incorporated herein by reference in its entirety. The citation of any document is not an admission that it is prior art with respect to any aspect disclosed herein or claimed herein, or that it independently or in any combination with any other one or more references teaches, suggests, or discloses any such aspect. 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.

[0251] Although specific aspects of the disclosure 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 disclosure. Accordingly, it is intended that all such changes and modifications that fall within the scope of the disclosure be covered by the appended claims.

Claims

1. An absorbent article comprising: A nonwoven liquid-permeable topsheet; A liquid-impermeable backsheet; An absorbent core, at least partially disposed between the topsheet and the backsheet; Wherein the topsheet comprises: A fibrous layer; Wherein, according to the basis weight test herein, the basis weight of the topsheet is in the range of 10 gsm to 35 gsm; A plurality of apertures defined in the fibrous layer; Wherein, according to the aperture test herein, the topsheet has an effective opening area in the range of 15% to 25%; Wherein the topsheet comprises a wearer-facing surface and a garment-facing surface; Wherein the apertures have a wearer-facing opening area and a garment-facing opening area, and wherein the wearer-facing opening area is greater than the garment-facing opening area; Wherein the cross-sectional shape of the apertures is elliptical, wherein the apertures comprise sidewalls, and wherein, according to the 2D X-ray CT scan test herein, the sidewalls have an angle in the range of 60 degrees to 80 degrees; wherein when a compressive force is applied to the sidewalls in a direction perpendicular to the apertures, the garment-facing opening area folds outward; Among them, according to the 2D X-ray CT scan test of this article, the opening area of the opening facing the clothes of the opening is within the range of 1.0 mm 2 to 7.5 mm 2 ; Among them, according to the 2D X-ray CT scan test of this article, the opening area of the opening facing the wearer of the opening is within 2 mm 2 to 12 mm 2 ; and Wherein the apertures have a central major axis dimension and a central minor axis dimension, and wherein, according to the 2D X-ray CT scan test herein, when measured at the garment-facing opening area, the central major axis dimension is greater than 1.5 mm; Wherein, according to the 2D X-ray CT scan test herein, when measured at the garment-facing opening area, the ratio of the central major axis dimension to the central minor axis dimension is at least 1.3 but less than 4.

2. The absorbent article according to claim 1, wherein at least some of the fibers comprise bicomponent fibers comprising a core and a sheath, wherein the sheath comprises polyethylene, and wherein the core of the bicomponent fibers comprises polyethylene terephthalate.

3. The absorbent article according to claim 1 or 2, wherein the fibers have a monofilament denier of 1 to 3.

4. The absorbent article according to claim 1 or 2, wherein, according to the 2D X-ray CT scan test herein, when measured at the garment-facing opening area, the central major axis dimension is in the range of 1.5 mm to 3.5 mm.

5. The absorbent article according to claim 1 or 2, wherein, according to the 2D X-ray CT scan test herein, when measured at the garment-facing opening area, the central minor axis dimension is in the range of 0.5 mm to 2.5 mm.

6. The absorbent article according to claim 1 or 2, wherein, according to the 2D X-ray CT scan test herein, the sidewalls of the apertures have a length in the range of 0.2 mm to 2.0 mm.

7. The absorbent article according to claim 1 or 2, wherein the fibrous layer is hydrophobic.

8. The absorbent article according to claim 1 or 2, wherein the fibrous layer comprises carded fibers.

9. The absorbent article according to claim 1 or 2, wherein the fibrous layer comprises spunbond fibers.

10. The absorbent article according to claim 1 or 2, wherein the topsheet comprises cotton.

11. The absorbent article according to claim 1 or 2, wherein the topsheet is free of film.

12. The absorbent article according to claim 1 or 2, wherein the apertures are formed by the following methods: hydroforming a carded web, laser cutting, perforating with a patterned roll, die cutting, using a hot melt method, over-bonding and / or loop punching; wherein, as measured by 2D X-ray CT scanning herein, when measured at the opening area facing the garment, the ratio of the central major axis dimension to the central minor axis dimension is at least 1.3 but less than 4.

13. A method for forming a plurality of apertures in a nonwoven substrate for an absorbent article according to any one of claims 1-12, the nonwoven substrate defining a first surface and a second surface, the method comprising: Inserting a plurality of tapered pins through the substrate from the first surface into the second surface to form a plurality of corresponding apertures in the substrate, each of the pins comprising: A first section having a first wall extending from a base portion of the first section to a distal portion of the first section, at least a portion of the first wall being disposed at a first angle greater than 17.5 degrees; and A second section having a second wall extending from a base portion of the second section, at least a portion of the second wall being disposed at a second angle less than 20 degrees; and Withdrawing the pins from the nonwoven substrate.

14. The method according to claim 13, wherein the pins include a third transition section extending between the first section and the second section.

15. The method according to claim 13, wherein the second wall of the second section extends from the base portion of the second section to the base portion of the first section.

16. The method according to claim 13, wherein: A first portion of the first wall of the pin is disposed at a first direction angle greater than 17.5 degrees: A second portion of the first wall is disposed at a second direction angle greater than 17.5 degrees; and The second direction angle is less than the first direction angle.

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