Absorbent article with mechanically integrated core wrap top layer

Abstract

A personal hygiene absorbent article, such as an adult incontinence pant, employing a mechanically integrated nonwoven, particularly a spunlace, as a core wrap top layer is provided. The article optionally includes a fluff-free pulp absorbent core and a lateral stenosis stabilizing element.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to personal hygiene absorbent articles. These articles can be adult incontinence ("AI") products, such as light incontinence adult pants, in particular. BACKGROUND

[0002] In recent years, the population structure in many countries has shifted towards an aging population. This population represents a relatively increased demand for products and services aimed at solving problems associated with aging. One such problem is adult urinary incontinence ("AI"). Urinary incontinence can be caused or exacerbated by a variety of health conditions or even normal experiences such as childbirth.

[0003] Disposable absorbent pants for incontinent patients have been on the market for many years. Traditionally, these products have been a scaled-up version of disposable baby training pants. One design type is referred to as a "belted" or "balloon" style pant, which is formed from a wide belt that encircles the waist and lower torso of the wearer, and connects the front and back portions of the belt by an absorbent pad assembly that forms a bridge across the crotch region of the wearer. The crotch absorbent pad assembly includes an absorbent core designed to receive, contain, and store urine until the pant is changed. The belt is typically formed from a stretch laminate.

[0004] The absorbent material in the absorbent core is typically a mixture of cellulosic fibers and superabsorbent polymer (SAP) particles, which are prone to accordion folding due to the wet collapse effect of the pulp fibers when a small amount of urine load is present. This problem is particularly acute for AI, as the product is in a low load state for most of the wear period (as opposed to a high load product, which is changed immediately). Typically, the absorbent material is contained in a core wrap, which is often a low basis weight SMS nonwoven.

[0005] Behavioral studies of AI consumers have shown that comfort and fit during use are the primary factors influencing consumer preference, with leakage protection being a secondary consideration. It is believed that this is because consumers, at least non-institutional users, view the purchase of adult incontinence products as an insurance measure against a sudden, large urine loss ("UUL"). However, due in part to preventative measures such as frequent toileting, consumers who use AI products rarely experience a severe urine loss (UUL). Instead, the more common occurrence is a minor urine loss. Thus, unlike baby diapers, adult wearers mostly wear AI products in a dry or substantially dry state. Adult wearers will typically also change the product as soon as possible if it becomes too heavily loaded. Since incontinence products are worn for long periods of time and do not or only rarely result in a UUL, consumers focus more on achieving an underwear-like wearing experience (comfort and fit) rather than a long-lasting dryness and high absorbency as with baby diapers.

[0006] This analysis leads to the counterintuitive conclusion that the ideal core design for an AI product should focus more on flexibility and prioritize the ability to absorb frequent small loads over sudden large loads compared to other absorbent articles. However, it was found that thin and flexible products are also more prone to bunching or bunching into the wearer's crotch. It is believed that this bunching exacerbation is due to product design: to ensure sufficient absorbent capacity, the width of the absorbent pad assembly is often greater than the width of the wearer's crotch. While increasing the core thickness can prevent bunching, it can also cause wearer discomfort. In addition, it is desirable to avoid urine accumulation only in the area under the urethral opening to prevent the article from overexpanding in one area. SUMMARY

[0007] The present invention relates to a personal hygiene absorbent article. The article is virtually divided into a left half and a right half by a longitudinally extending longitudinal centerline, and into a front half and a back half by a transversely extending transversal centerline. The absorbent article comprises a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core disposed between the topsheet and the backsheet. The absorbent core comprises an absorbent material layer and a core wrap. The core wrap comprises a top layer and a bottom layer, the absorbent material layer being sandwiched between the two layers. The top layer substantially forms the wearer-facing side of the absorbent core, and the bottom layer substantially forms the garment-facing side of the absorbent core. The top layer and the bottom layer are independent layers, wherein the top layer comprises or consists of a mechanically integrated nonwoven, and the top layer has a basis weight of at least 20 g / m 2 . The mechanically integrated nonwoven can in particular have a basis weight in the range of about 20 g / m 2 to about 200 g / m 2 , more in particular in the range of 25 g / m 2 to 70 g / m 2 . The mechanically integrated nonwoven can in particular consist of a spunlace nonwoven.

[0008] The core wrap bottom layer can be wider than the core wrap top layer, such that the bottom layer can be folded on both sides to form a C-wrap structure around the absorbent material layer and the core wrap top layer. The core wrap bottom layer can be a low basis weight nonwoven (less than 20 g / m 2 , such as an SMS nonwoven.

[0009] According to the present invention, it was found that the use of a vertically integrated nonwoven, such as a spunlace, as a core wrap top layer not only improves core utilization, but also improves the wearer comfort experience for the consumer. This finding is particularly useful in the case of an absorbent material layer that does not contain cellulose fibers. The absorbent material can in particular substantially consist of superabsorbent polymers that do not contain cellulose fibers (also known as fluffless pulp cores).

[0010] The absorbent article can be a belted adult incontinence pant, but the present application can also be used in other product forms, such as taped diapers. Exemplary dimensions, materials, and properties of the present article will be further disclosed below and in the appended claims, while other aspects of the present application are set forth. The absorbent article can also comprise any of the following elements, alone or in combination, and without limitation.

[0011] The absorbent article can also comprise a stabilizing element at least in the crotch region of the absorbent article, which design has been found to contribute to further reducing the most visible and tactile wrinkling phenomena in this area. The stabilizing element can be present at least at point C, which is laterally aligned with the layer of absorbent material, and disposed at a distance of about 40 mm from the lateral centerline in the direction of the front end of the absorbent article. Preferably, the stabilizing element has a relatively narrow width at point C, which is not more than 50 mm in lateral width, measured according to the "Width and Thickness Measurement Method" described below.

[0012] The stabilizing element can generally have a width in the range of about 20 mm to about 50 mm, or 25 mm to 45 mm, or 30 mm to 40 mm, which has been found to enhance the stability of the article while still being narrow enough to avoid compression of the inner thighs during walking or other activities. The absorbent core is generally wider than the stabilizing element, such that the absorbent core extends laterally beyond the stabilizing element. Preferably, the layer of absorbent material extends laterally at least 5 mm outward beyond point R and 5 mm outward beyond point L, where points R and L are disposed 30 mm laterally right and left, respectively, of point C. On the other hand, preferably, the stabilizing element does not extend laterally to either of points L and R.

[0013] The absorbent article can have a first thickness CI at point C, a second thickness C2 at point R, and a third thickness C3 at point L (where these thicknesses are each measured according to the "Width and Thickness Measurement Method" disclosed herein). The ratio CI / (C2+C3) can have a value of at least 0.6.

[0014] The ratio CI / (C2+C3) can particularly be in the range of 0.6 to 3.0, more particularly in the range of 0.65 to 1.0.

[0015] The thickness CI can be less than 5.0 mm.

[0016] The average value (C2+C3) / 2 can be less than 4.5 mm. BRIEF DESCRIPTION OF DRAWINGS

[0017] While the specification concludes with claims particularly pointing out and distinctly claiming the application, it is believed the application will be better understood from the following description when read in conjunction with the accompanying drawings, in which:

[0018] Figure 1 Perspective view of an exemplary adult incontinence pant;

[0019] Figure 2 Perspective view of an exemplary adult incontinence pant; Figure 1 Perspective view of an exemplary adult incontinence pant;

[0020] Figure 3 Perspective view of an exemplary adult incontinence pant;

[0021] Figure 4 Perspective view of an exemplary adult incontinence pant;

[0022] Figure 5 Perspective view of an exemplary adult incontinence pant;

[0023] Figure 6 and Figure 7 Perspective view of an exemplary adult incontinence pant; DETAILED DESCRIPTION

[0024] Definitions

[0025] As used herein, the terms "nonwoven," "nonwoven web," and "nonwoven layer" are used interchangeably. Nonwovens are broadly defined as engineered fibrous assemblies that are predominantly planar, which have been imparted with a designed level of structural integrity by physical and / or chemical means, excluding weaving, knitting, or papermaking.

[0026] Nonwovens can be formed by a number of processes, such as meltblowing, spunbonding, solvent spinning, electrospinning, and carding, and the fibers can be consolidated, for example, by hydroentanglement (in hydroentangled nonwovens), thermal-bonding (using hot air blown through the fibrous layer in the thickness direction), needlepunching, one or more bonding patterns and bonding indentations created by localized pressurization and / or application of heat or ultrasonic energy, or combinations of these processes. Alternatively or additionally, the fibers can be consolidated by the use of a binder. The binder can be provided in the form of binder fibers that are subsequently melted, or it can be provided in liquid form, such as a styrene butadiene binder. The liquid binder is applied to the fibers (for example, by spraying, printing, or foam coating), and subsequent curing treatment effects setting. The basis weight of a nonwoven fabric is typically expressed in grams per square meter (g / m 2 ).

[0027] The nonwoven material can be formed from a variety of fibrous materials (PP, PE, PET, coPET, bicomponent fibers, natural fibers, and mixtures thereof). Synthetic fibers can be selected from the group consisting of polyolefins such as polyethylene, polypropylene, or combinations and mixtures thereof, polyethylene terephthalate (PET), coPET, polylactic acid (PLA), polyhydroxyalkanoate (PHA), or mixtures or combinations thereof. Natural fibers are, for example, cotton or bamboo fibers, or of man-made origin. The fibers can be staple fibers (e.g., in a carded nonwoven web / layer) or long fibers (e.g., in a spunbond or meltblown nonwoven web / layer). In some cases, the fibers or nonwovens can be treated to enhance particular fluid handling properties, such as fluid permeability or fluid barrier properties.

[0028] The term "hydroentangled" or "hydroentangled nonwoven" means a nonwoven in which the entanglement of fibers with one another is consolidated by means of multiple high-pressure water jets penetrating a moving batt or fabric, which water jets, like needles, penetrate the batt or fabric, causing the fibers to interweave three-dimensionally. The definition of these hydroentangled nonwovens is essentially due to the fact that their consolidation is caused by hydroentanglement. The hydroentangled nonwovens can be a single-layer structure (homogeneous), but can also be formed from two or more layered structures having different fiber mix compositions, which are combined with one another by the hydroentanglement process. These two or more layered structures can have been subjected to a bonding process, such as by heat and / or pressure bonding using, for example, patterned calender rolls and anvil rolls, to impart a bond pattern, prior to being compounded by hydroentanglement into a single nonwoven. However, the two or more layered structures are combined with one another by hydroentanglement only.

[0029] As used herein, the term "decitex" refers to a unit used to indicate the fineness of a filament / fiber. The unit represents the mass of the filament / fiber per 10,000 meters length in grams.

[0030] "Wettability" describes the property of a substrate surface that can be wetted by an aqueous fluid (e.g., a 0.9% NaCI physiological saline solution) deposited on the substrate. Wettability and wetability are generally defined in terms of the contact angle of the fluid, e.g., through a nonwoven fabric, and the wet-out time. This is discussed in detail in a publication of the American Chemical Society entitled "Contact angle, Wettability and Adhesion" by Robert F. Gould, copyright 1964. A substrate surface is said to be wetted by a fluid (i.e., hydrophilic) when the contact angle between the fluid and the surface is less than 90°, or when the fluid tends to spontaneously spread along the substrate surface, both conditions generally coexisting. Conversely, a substrate is said to be "hydrophobic" if the contact angle is greater than 90° and the fluid cannot spontaneously spread along the fiber surface.

[0031] "Longitudinal" refers to a direction running perpendicular to a direction from a middle of a waist edge to an opposite waist edge, nominally defined as a longitudinal centerline. The absorbent article is constructed symmetrically about this longitudinal centerline such that the longitudinal centerline divides the article into a left half and a right half. "Lateral" refers to a direction perpendicular to the longitudinal direction, while a lateral centerline is an imaginary line perpendicular to the longitudinal centerline that equally divides the article into a front half and a back half of equal length. As used herein, "longitudinally extending" refers to a feature of the article that extends in the longitudinal direction at least twice as long as it extends in the lateral direction.

[0032] "Body-facing" and "garment-facing" refer to the relative location of an element or the relative location of a surface of an element or group of elements. "Body-facing" refers to an element or surface that is closer to the wearer during wear than is another element of the same assembly. "Garment-facing" refers to an element or surface that is further from the wearer during wear than is another element of the same assembly. A garment-facing surface can face another garment of the wearer, or other article, such as bedding or the atmosphere.

[0033] "Including" or "containing" are open-ended terms, each specifying the presence of a feature, e.g., a component, after the term, but not excluding the presence of other features, e.g., elements, steps, components, known in the art or disclosed herein. These verb forms based on the term "comprising" encompass the narrower term "consisting essentially of, which excludes any element, step, or ingredient not specified, which materially affects the function of the feature; and the term "consisting of, which excludes any element, step, or ingredient not specified.

[0034] Absorbent article

[0035] As used herein, the term "absorbent article" refers to personal care absorbent articles that are placed on the crotch region of a wearer to absorb body exudates, particularly urine. The absorbent articles of the present invention can be particularly placed around the lower torso of a wearer so as to encircle the waist and legs of the wearer. The absorbent articles of the present invention can be particularly pant-type articles whose waist and leg openings are preformed by left and right seams at the edges of the pant-type article. The pant-type articles can be preformed by any applicable technique, including but not limited to joining portions of the absorbent article together using refastenable and / or non-refastenable bonds (e.g., stitching, fusion, adhesive, cohesive bonding, fasteners, etc.). The pant-type articles can be preformed at any location around the circumference of the article (e.g., side edge fastened, front waist fastened). The present invention can also be used in other types of absorbent articles, such as taped or sanitary napkins. In taped articles, the back half of the article can be releasably attached to the front half by a tape system. While the present invention is generally applicable to any type of absorbent article, including baby or infant diapers, it is particularly suited for adult incontinence pant-type articles.

[0036] Brief description of incontinence pants 10

[0037] Figure 1 An example of a belt-type or balloon-type disposable absorbent pant 10 is depicted. The pant 10 has a waist opening defined by a front waist edge 11 and a back waist edge 12, and a pair of leg openings defined by respective leg opening edges 14. The pant 10 includes a belt structure having a front panel 20 and a back panel 30 joined at side seam regions 13. Typically, the side seams are formed by fusion / hot bonding, in which the polymer materials at the edges of the front and back panels are fused together by the application of a combination of heat and pressure. The pant 10 can also include an absorbent pad assembly 50 that extends between the front and back panels through the crotch region of the pant. The absorbent pad assembly 50 can be adhesively bonded to the inner surfaces of the front and back panels, typically by applying a hot melt adhesive during the manufacturing process. The front and back belts 20, 30 typically include an elasticated laminate material, such as a plurality of elastic strands 40 extending in the cross direction and sandwiched between two layers of nonwoven substrate.

[0038] Figure 2 A pant-type article of the present invention is shown Figure 1 with its side seams 13a,b unfastened so that the article can be presented in an unfastened laid-flat condition, and showing its wearer-facing side. As Figure 2As shown, the article extends in a longitudinal direction as indicated by longitudinal centerline 2 and in a transverse direction as indicated by transverse centerline 4. The longitudinal centerline extends from the midpoint of the front belt edge to the midpoint of the back belt edge and virtually divides the article into left and right halves, which are substantially symmetrical. The transverse centerline 2 is disposed in the crotch portion of the article and divides the article into front and back halves of equal length as measured along longitudinal centerline 2. The intersection of the longitudinal centerline 2 and the transverse centerline 4 is defined herein as the midpoint M.

[0039] Further referring to Figure 2 Pant 10 includes a belt structure that includes a front panel 20 and a back panel 30. In the example depicted, the outer layer of the front and back panels includes a continuous layer 32 that is common to both. The continuous layer 32 also wraps around the outer side of the pant through the crotch region; this configuration is sometimes referred to as a "single panel" configuration. The outer layer 32 is typically a nonwoven layer. In another possible configuration (not shown), the front panel 20 and the back panel 30 can have independent, separate outer layers, with no common layer, and are joined with the absorbent pad assembly only by the side seams 13. This alternative configuration is sometimes referred to as a "multi-panel" configuration.

[0040] The front and back panels can each include one or more elastic members, specifically a plurality of laterally-extending strands 40 of elastomeric material, such as spandex yarn (e.g., LYCRA HYFIT fiber, which is a product of Invista Corporation, Wichita, Kansas), laminated between an inner belt layer (not shown) and an outer belt layer 32. The inner and outer belt layers can be joined together around the elastic strands 40 by means of adhesive deposited between the layers, thermal bonding, pressure bonding, or a combination thereof. In other examples, the one or more elastic members can be a strip or a segment of film formed of elastomeric material. However, elastic strands rather than a film can be preferred because they provide flexibility by enabling the level of pre-strain to be personalized set, the uniform or varying longitudinal spacing between strands to be selected and set, and a high level of vapor transmission (breathability) through the belt laminate to be maintained, for the purpose of coolness, comfort, and skin health. This flexibility helps manufacturers achieve enhanced fit of the pant structure around different contours and sizes of the body structure of different wearers, and imparts a garment-like appearance to the belt laminate. For purposes herein, a "strand" is a member that, in an unstrained state, has a cross-section perpendicular to the direction of the longest dimension, and the ratio of the largest dimension to the smallest dimension of that cross-section (aspect ratio) is no more than 2.

[0041] The elastic belt may also or alternatively comprise an elastomeric nonwoven material. Other typical features of incontinence pants articles, in particular the belt / panel structure, can be found, for example, in WO 2018 / 09417 A1 (Minoguchi et al.), WO 2017 / 192992 A1 (Desai et al.) and WO 2016 / 115421 A1 (Seitz et al.).

[0042] Absorbent pad assembly 50

[0043] like Figures 3-4 As shown in cross-section in FIG, the absorbent pad assembly 50 may include: a liquid-permeable topsheet 60 located on the wearer-facing side, a liquid-impermeable backsheet 66 located on the garment-facing side, a multicomponent absorbent structure 65 including an absorbent core 26 disposed between the topsheet and the backsheet, and elasticized barrier leg cuffs 80. Other features and combinations thereof may also be included, as described herein. Examples and descriptions of components and configurations of such absorbent pad assemblies may be found in WO 2013 / 122936 A1, where the central chassis described includes components and features that may be included.

[0044] The top sheet 60 can be formed by a nonwoven web material, which is suitably selected to accommodate the components of the absorbent structure 65 while allowing urine to pass freely from the surface facing the wearer to the absorbent structure. The back sheet 66 can include a polymer film material, or at least partially formed by a polymer film material, which is suitably selected to accommodate the components of the absorbent structure, and is also selected to accommodate urine under normal use conditions and prevent urine from seeping through the absorbent structure to the surface facing the clothes. In some examples, the back sheet 66 can also include an outer layer formed by a nonwoven web material to enhance strength and impart a more excellent cloth-like texture. In some examples, the back sheet film can be formed into a breathable structure so that it can allow water vapor to pass through while still preventing aqueous liquid (urine) from penetrating, and this characteristic can contribute to improving the wearer's trouser comfort. The materials used for suitable top sheet and back sheet materials are well known in the art. The materials of the topsheet and backsheet may be joined and bonded together around their peripheries to form an enclosed structure containing the absorbent structure 65 by any suitable bonding mechanism, such as a hot melt adhesive.

[0045] Figure 3For illustrative purposes, the depicted absorbent pad assembly is shown in schematic exploded view, with the components separated from one another. Some adhesive layers are shown in dashed lines, although it will be appreciated that the depicted materials can be bonded together to form the pant assembly by any suitable mechanism, for example by heat bonding or by a hot melt adhesive deposited between the respective components to be bonded. For example, the topsheet 60 and the backsheet 66 can be bonded together around their perimeters to form an enclosure that houses the absorbent structure 65. Similarly, the proximal portions 82 of the barrier leg cuffs 80 can be bonded to the topsheet or other portions of the assembly by any suitable mechanism, such as a hot melt leg cuff adhesive 69.

[0046] The absorbent article of the present application can optionally include a relatively narrow stabilizing element 100. The stabilizing element 100 is preferably disposed between the absorbent core 26 and the topsheet 60, but it is not excluded that it can also be disposed between the absorbent core 26 and the backsheet 66, or within the absorbent core 26.

[0047] The absorbent core 26 comprises a layer of absorbent material 72 (referred to herein as "absorbent material layer") sandwiched between a core wrap top layer 91 and a core wrap bottom layer 92. The transversal stabilizing portion 100 is narrower in the crotch region relative to the rest of the article. The absorbent material layer 72 has a width Wl and the transversal stabilizing element 100 has a width W2, both measured in the transversal direction at point C disposed at about 40 mm from the transversal centerline in the direction of the front end of the article. Advantageously, W2 can be equal to or less than about 50 mm, and preferably, W2 is in the range of about 20 mm to about 50 mm, more particularly in the range of 25 mm to 45 mm, most preferably in the range of about 30 mm to 40 mm. On the other hand, the width Wl of the absorbent material layer 72 of the absorbent core 26 can typically have a value in the range of 70 mm to 150 mm. The ratio of Wl divided by W2 can be at least about 1.5 (75 / 50). The ratio of Wl divided by W2 can particularly be in the range of about 2.0 to about 4.0. The widths are measured in the transversal direction (parallel to the transversal centerline), as shown in the "width and thickness measurement method" further detailed below and indicated hereafter. Figures 3-5

[0048] The benefits of the present application will be further described in the "Experimental Section" hereafter, while the main components of the present application will be described in more detail hereafter.

[0049] Absorbent core 26

[0050] The absorbent core 26 can be a unitary component comprising an absorbent material layer 72 that provides the absorbent capacity to the absorbent article and is disposed between the core wrap bottom layer 92 and the core wrap top layer 91.

[0051] ​The layer of absorbent material 72 can comprise, or consist of, superabsorbent polymer (SAP) particles. SAP is a polymer that is insoluble in water but swellable in water, capable of absorbing large amounts of fluid. The term "superabsorbent polymer" refers herein to an absorbent material that is capable of absorbing at least 10 times its weight of a 0.9% saline solution, the absorbency capacity being measured by the Centrifuge Retention Capacity (CRC) test as specified in EDANA method WSP 241.2.R2 (19). The SAP can specifically have a CRC value of more than 20 g / g, or more than 24 g / g, or from 20 g / g to 50 g / g, or from 20 g / g to 40 g / g, or from 24 g / g to 35 g / g. The SAP can be a cross-linked polyacrylate, or other types of polymers known in the art.

[0052] The absorbent material can comprise superabsorbent polymer particles mixed with cellulose fibers (as known in fluff-containing core bodies), or can be free of cellulose fibers (as known in fluff-free core bodies). The absorbent material can advantageously comprise a high proportion of SAP. The absorbent material can specifically comprise at least 70%, in particular at least 80%, or at least 90% up to 100% by weight of the absorbent material of SAP. The resulting high-SAP-proportion absorbent core is typically thinner in the dry state compared to conventional absorbent cores comprising cellulose fibers as absorbent material. The reduced thickness helps to improve fit and wearing comfort of the absorbent article. The absorbent material of the absorbent core used in the present invention can be free of cellulose fibers. The absorbent core can comprise at least one layer of SAP that is not mixed with cellulose fibers.

[0053] The layer of absorbent material can optionally comprise at least one channel-forming zone (not shown). The channel-forming zone is a region within the layer of absorbent material that is deliberately left empty, i.e. free of absorbent material, except for particles that can have been deposited there by accident during core body manufacturing. The channel-forming zone is preferably not extending to either side of the layer of absorbent material, so as to be completely surrounded by absorbent material. The channel-forming zone is typically elongated in the longitudinal direction, with a longitudinal length of 20% to 80%, or 20% to 70%, or 30% to 60% of the longitudinal length of the layer of absorbent material (the longitudinal length meaning the length as measured projected on the longitudinal centerline). The absorbent core can comprise a pair of channel-forming zones disposed symmetrically on either side of the longitudinal centerline 2, wherein these channel-forming zones can be straight, curved, or a combination of both. Such a pair of channel-forming zones can be a discontinuous structure, but alternatively, the channel-forming zones can also be connected, e.g. at one or both of their ends, to form a U-shaped or O-shaped structure. Examples of channel-forming zones are disclosed in more detail in, e.g., WO2012170778A1, WO2012170781 (Kreuzer et al.).

[0054] The absorbent material layer 72 can advantageously comprise a high proportion of SAP. Various absorbent core designs comprising a high proportion of SAP as absorbent material have been proposed, see for example US 5,599,335 (Goldman), EP 1,447,066 (Busam), WO 95 / 11652 (Tanzer), US 2008 / 0312622 Al (Hundorf), WO 2012 / 052172 (Van Malderen). In particular, SAP printing techniques as disclosed in US 2006 / 024433 (Blessing), US 2008 / 0312617 and US 2010 / 0051166 Al (both to Hundorf et al.) can be used.

[0055] The absorbent material layer is typically deposited on a substrate that is part of the absorbent core, such as the core wrap bottom layer 92 or the core wrap top layer 91. In a SAP printing method as described in US 2008 / 312,622 Al (Hundorf), a continuous layer of SAP is obtained by depositing the SAP on each core wrap layer in a pattern such that the absorbent material landing areas are separated by joint areas that do not contain absorbent material. The absorbent material landing areas of the first layer substantially correspond to the joint areas that do not contain absorbent material of the second layer, or vice versa, such that a continuous layer of SAP is obtained when the two discontinuous layers are combined.

[0056] The total amount of SAP present in the absorbent core is adapted to the needs of the intended wearer of the article. For adult incontinence products, the amount of SAP in the absorbent core can for example be from about 2 g to 50 g, in particular from 5 g to 40 g, and from 10 g to 20 g, for example for a typical adult incontinence article. The average SAP basis weight within the absorbent core can be at least 50 g / m2, 100 g / m2, 200 g / m2, 300 g / m2, 400 g / m2, 500 g / m2, or more, and typically in the range of 200 g / m2to 600 g / m2, in particular 400 g / m2to 525 g / m2, as calculated by dividing the total amount of SAP by the surface area of the absorbent core. 2 2 2 2 2 2 2 2 2 2

[0057] Core wrap 91, 92

[0058] ​​​​​​​​​​The absorbent core includes a core wrap top layer 91 and a core wrap bottom layer 92, with a layer of absorbent material 72 sandwiched therebetween. The core wrap top and bottom layers are constructed of a material capable of containing and providing support to the absorbent material. These core wrap layers are each made from a separate web of material, such as Figure 3 and Figure 4 are illustratively shown. These separate layers are typically longitudinally bonded by one or more longitudinal core wrap bond lines 93. The core wrap bottom layer 92 can be wider than the top layer, and the bottom layer can form a C-wrap configuration around the absorbent material layer and top layer, as shown in these figures. The use of different materials for the core wrap top and bottom layers can be used to impart different properties to the top and bottom surfaces of the core wrap, in particular, the top layer 91 can be more hydrophilic than the bottom layer 92.

[0059] The basis weight of these nonwovens is typically macroscopically uniform across the length and width of the core wrap layer (i.e., each layer is uniform in both the longitudinal and transverse directions). The basis weight value of the material is typically provided by the supplier or calculated by dividing the weight of the layer by its surface area.

[0060] Typical core wrap layers used in the art have a low basis weight (typically less than 20 gsm, particularly in the range of 8 gsm to 14 gsm). The core wrap bottom layer 92 can be a conventional nonwoven typically used in the art to which this application pertains. The nonwoven layer can be a spunbond or meltblown nonwoven web (made from long fibers), or a nonwoven having a spunbond layer and a meltblown layer (e.g., SMS, SMMS, SMSS, etc.), particularly an SMS nonwoven (spunbond-meltblown-spunbond laminate). Carded nonwovens (made from short fibers) are also equally suitable. As is known in the art, carded nonwovens can be processed using hydroentanglement (spunlace), thermal calender bonding, or through-air bonding processes.

[0061] In another aspect, the core wrap top layer 91 comprises or consists of a mechanically integrated nonwoven, and has a basis weight of at least 20 g / m 2 The core wrap top layer can be particularly a spunlace, as disclosed in further detail in the following sections.

[0062] The core wrap top and bottom layers are preferably longitudinally bonded by one or more longitudinal core wrap bond lines 93 to prevent lateral escape of the absorbent material from the absorbent core. These core wrap layers can also be optionally transversely bonded by one or more transverse core wrap bond lines on the front and back of the absorbent core. These core wrap layers can be face-to-face bonded, at least as shown longitudinally bonded, or in a C-wrap configuration. The core wrap bottom layer 92 can be wider than the core wrap top layer 91, such that flaps formed by the core wrap bottom layer can be Figures 3-4The absorbent material is shown folded around and attached to the core wrap layers. While the reverse configuration is possible, as Figure 4 As shown, when the core wrap top layer basis weight is higher than the core wrap bottom layer, the use of a C-wrap with the core wrap bottom layer 92 is advantageous to reduce the amount of higher basis weight material, and thus the amount of more expensive core wrap top layer material 91'.

[0063] The core wrap top layer 91 and the core wrap bottom layer 92 generally at least partially or completely enclose the absorbent material layer 72, thereby providing containment of the absorbent material in both dry and wet states.

[0064] The absorbent core can include one or more glue layers, specifically a secondary glue layer 94 applied between the inner surface of one or both of the core wrap layers and the SAP layer, which secures the SAP within the core wrap by adhesive means. Additionally, the SAP layer can be at least partially secured to the core wrap top layer and / or the core wrap bottom layer by a network of thermoplastic fibers applied on the SAP layer. For simplicity, these adhesives are not shown in the drawings.

[0065] When a channel forming zone is present in the absorbent core (not shown in the drawings), the core wrap top layer 91 and the core wrap bottom layer 92 are preferably bonded to each other through at least a portion of the length of the absorbent core channel forming zone. This channel bond provides structural integrity to the channel in both dry and wet states. Any known bonding technique known in the art can be used to provide this bond, particularly a technique selected from the group consisting of adhesive bonding, thermal bonding, mechanical bonding, ultrasonic bonding, or any combination thereof. An adhesive can be applied, for example, on the inside of the top side and / or the inside of the bottom side of the core wrap in the channel region, typically by slot die application or any other method, followed by the application of pressure in the channel region to provide good adhesive bonding in these regions. Exemplary patent disclosures of such adhesive bonding processes can be found in WO2012 / 170798A1 (Jackels et al.), EP2,905,000 (Jackels et al.), and EP2,905,001 (Armstrong-Ostle et al.) for airfelt-containing or airfelt-free absorbent cores.

[0066] Other bonds such as thermal bonds, mechanical bonds, ultrasonic bonds can also be used as additional bonds or as alternative bonds. For example, the adhesive bond can be reinforced by a thermal bond, a mechanical bond, or an ultrasonic bond. Such thermal, mechanical, or ultrasonic bonds can be applied across the channel on the outside of the core wrap layers.

[0067] Optional acquisition layer 70

[0068] The absorbent article 10 can optionally include an acquisition layer 70 disposed directly below the topsheet in order to quickly conduct fluid away from the topsheet, asFigure 3 As shown. In the case of a pant-type article comprising an absorbent pad assembly 50, the acquisition layer 70 is part of the absorbent pad assembly. Any typical acquisition layer known in the art may be used, such as a surfactant-treated nonwoven acquisition layer. Such an acquisition layer typically has a basis weight of 20 g / m 2 Up to 70g / m 2 range, especially 30g / m 2 Up to 60g / m 2 The acquisition layer may be a latex bonded nonwoven, an air-through bonded nonwoven, or any other conventional acquisition layer known in the art.

[0069] Although in Figure 3 In the first embodiment shown, the absorbent structure 65 includes an acquisition layer 70 disposed between the absorbent core and the topsheet to enhance the liquid handling properties of the product, but a second embodiment is also possible in which the acquisition layer 70 is removed, as shown in FIG. Figure 4 This design may be particularly useful when a stabilizing element 100 with liquid handling properties is present and / or when the core wrap top layer 91 itself has sufficient fluid acquisition and distribution properties. This design may be particularly useful for light adult incontinence products, which need to handle relatively small amounts of urine per gush, such as compared to baby diapers.

[0070] The core wrap top layer 91 of the present invention preferably has high fluid absorption properties, which can compensate for the lack of selectivity of the acquisition layer or the lack of a stenosis stabilization element that also acts as a distribution layer. For example, when a stenosis stabilization element 100 is used, even if the element contains absorbent fibers, it cannot provide a buffering effect for the spread of fluid in the lateral direction of the stabilization element 100.

[0071] Core wrap top layer 91

[0072] In order for the core wrap top layer 91 to act as a temporary storage layer, the basis weight of the core wrap top layer can be relatively high relative to typical prior art core designs. The core wrap top layer 91 in the present invention is a core wrap having a thickness of at least 20 g / m 2 In particular, the core wrap top layer 91 may have a basis weight of about 20 g / m 2 About 200g / m 2 , or 25g / m 2 Up to 70g / m 2 Hydroentangled nonwovens or other mechanically vertically integrated nonwovens can be advantageously used as the core wrap top layer 91, 91' in the article, whether or not an acquisition layer is provided. The core wrap top layer 91 can in particular consist of a hydroentangled material, which is a material that generally has good fluid absorption properties.

[0073] Fiber integration of the nonwoven can occur by any suitable process that entangles the fibers primarily in the Z direction (positive or negative). Mechanical integration processes include needle punching and hydroentanglement, and do not require chemical integration or adhesive integration.

[0074] Needle punching involves mechanical interlocking of the fibers of a spunbond and / or carded fiber web. In a needle punching process, multiple barbed needles repeatedly pass into and out of the nonwoven fiber web and push the fibers of the nonwoven fiber web in the positive and / or negative Z direction. In contrast, hydroentanglement processes use high velocity water jets to cause interlocking of the fibers of the nonwoven fiber web. The high velocity water jets push the fibers of the nonwoven fiber web in the positive or negative Z direction. With the aid of a microscope, needle punched nonwovens include multiple discrete Z-direction fiber integrations in both the MD and CD directions, while hydroentangled nonwovens typically include integrations that are much more continuous along the MD direction but discrete in the CD direction.

[0075] Such integrated nonwovens do not require adhesive or latex binders for stability due to the integration of the fibers. Additionally, carded staple fiber nonwovens can be made from a wide variety of suitable fiber types that produce the desired performance characteristics. Mechanically integrated stable elements, such as hydroentangled fabrics, can include combinations of absorbent fibers, strengthening fibers, and elastic fibers, as further detailed below (the disclosed percentages apply to hydroentangled fabrics, but can also apply to other vertically integrated nonwovens).

[0076] Any suitable absorbent fiber can be utilized. Some conventional absorbent fibers include cotton, rayon, or regenerated cellulose, or combinations thereof. In one example, the absorbent fibers can include viscose cellulose fibers. The absorbent fibers can include staple length fibers. The staple length of the absorbent fibers can range from about 20 mm to about 100 mm, or from about 30 mm to about 50 mm, or from about 35 mm to about 45 mm, including all values within these ranges and any ranges created thereby.

[0077] The absorbent fibers can have any suitable shape. Some examples include trilobal, “H” shaped, “Y” shaped, “X” shaped, “T” shaped, or round. Additionally, the absorbent fibers can be solid, hollow, or multi-hollow. Other examples of suitable multi-lobed absorbent fibers for the carded staple fiber nonwovens detailed herein are disclosed in US6333108, US5634914, and US5458835 (all to Wilkes et al.). The trilobal shape can improve wicking and improve masking. Suitable trilobal rayon fibers are purchased from Kelheim Fibres and sold under the trade name Galaxy. While each ply can include absorbent fibers of different shapes (much like described above), not all carding equipment can be suitable to handle such variation between two / two plus plies. In one specific example, the fluid management layer includes round absorbent fibers.

[0078] Generally, the core wrap top layer 91 of the present application can comprise absorbent fibers in the range of from about 20 wt% to about 75 wt%, or from about 25 wt% to about 60 wt%, or from about 30 wt% to about 50 wt%, specifically including any values and any ranges created thereby. In one specific example, the core wrap top layer 91 can comprise about 50 wt% absorbent fibers.

[0079] The core wrap top layer, in addition to comprising absorbent fibers, can also comprise stiffening fibers. Stiffening fibers can be utilized to help provide structural integrity to the nonwoven. Stiffening fibers can help increase the structural integrity of the nonwoven in the machine direction and the cross direction, which can be beneficial for web handling during nonwoven processing to incorporate it into a disposable absorbent article. Any suitable stiffening fiber can be utilized. Some examples of suitable stiffening fibers include bicomponent fibers comprising polyethylene and polyethylene terephthalate components or polyethylene terephthalate and co-polyethylene terephthalate components. The components of the bicomponent fibers can be arranged in a core-sheath structure, side-by-side structure, eccentric core-sheath structure, trilobal structure, or the like. In one specific example, the stiffening fibers can comprise bicomponent fibers arranged in a concentric core-sheath structure having a polyethylene / polyethylene terephthalate component, wherein the polyethylene is the sheath. In another example, monocomponent fibers can be utilized, and the constituent material of the monocomponent can comprise polypropylene or poly lactic acid (PLA). Notably, these components (e.g., polypropylene and poly lactic acid) can also be utilized in bicomponent fibers.

[0080] The reinforcing fibers can be polyethylene terephthalate (PET) fibers or other suitable non-cellulosic fibers known in the art. The reinforcing fibers can have a staple length in the range of about 28 mm to about 100 mm, or in the range of about 37 mm to about 50 mm. Some carded staple nonwovens include reinforcing fibers having a staple length of about 38 mm to 42 mm. The PET fibers can have any suitable structure or shape. For example, the PET fibers can be round or have other shapes such as helical, notched oval, trilobal, notched ribbon, and the like. Further, the PET fibers can also be solid, hollow, or multi-hollow. In some embodiments of the carded staple nonwoven, the reinforcing fibers can be fibers made from hollow / helical PET. Optionally, the reinforcing fibers can be spiral crimped or flat crimped. The reinforcing fibers can have a crimp value of between about 4 and about 12 crimps per inch (cpi), or between about 4 and about 8 cpi, or between about 5 and about 7 cpi, or between about 9 and about 10 cpi. Particular non-limiting examples of reinforcing fibers are available from Wellman, Inc. Ireland under the trade names H1311 and T5974. Other examples of reinforcing fibers suitable for use in the carded staple nonwovens detailed herein are disclosed in US7767598 (Schneider et al.).

[0081] Other suitable examples of reinforcing fibers include polyester / co-extruded polyester fibers. The reinforcing fibers can be so-called bicomponent fibers, in which a single fiber is provided from different materials (typically a first polymeric material and a second polymeric material). The two materials can be chemically different (so the fiber is chemically heterogeneous), or they can differ only in their physical properties while being chemically the same (so the fiber is chemically homogeneous). For example, there can be a difference in the intrinsic viscosity of the two materials, which has been found to affect the crimping properties of the bicomponent fiber. Suitable bicomponent fibers for use as reinforcing fibers are side-by-side bicomponent fibers, as disclosed in, for example, WO 99 / 00098. The reinforcing fibers can also be a blend of bicomponent fibers with polyester fibers.

[0082] In general, the core wrap top layer 91 of the present application can comprise reinforcing fibers in the range of about 1% to about 50%, or about 10% to about 40%, or about 20% to about 30%, including specifically all values within these ranges and any ranges created thereby. In one particular example, the nonwoven can include about 20% by weight reinforcing fibers.

[0083] As previously mentioned, the core wrap top layer of the present disclosure can additionally comprise elastic fibers. The elastic fibers help the nonwoven maintain its permeability and cushioning properties. Suitable fibers that can be utilized specifically include hollow fibers, spiral fibers, and / or hollow spiral fibers. For example, the elastic fibers can have a linear density in the range of from about 4 denier to about 12 denier, from about 6 denier to about 11 denier, or from about 8 denier to about 10 denier, specifically including all values within these ranges and any ranges created thereby. In one specific example, the elastic fibers can comprise hollow spiral polyethylene terephthalate fibers having a linear density of about 10 denier. In another specific example, the elastic fibers can comprise 6.7 denier round polyethylene terephthalate fibers.

[0084] The elastic fibers can be any suitable thermoplastic fiber such as polypropylene (PP), polyethylene terephthalate, or other suitable thermoplastic fiber known in the art. The staple length of the elastic fibers can range from about 20 mm to about 100 mm, or from about 30 mm to about 50 mm, or from about 35 mm to about 45 mm. The elastic fibers can have a round cross-section with a hollow space having a spiral crimp in the center. It is preferred that 10-15% of the cross-sectional area is hollow, more preferably 20-30% of the cross-sectional area is hollow. Without wishing to be bound by theory, it is believed that the spiral crimp of the fibers benefits their liquid acquisition and distribution properties. It is hypothesized that the spiral crimp increases the void space in an acquisition member formed from such fibers.

[0085] Generally, absorbent articles are exposed to a certain pressure applied by the wearer when being worn, which can decrease the void space in the acquisition member. Having good permeability and sufficient available void space is important for good liquid distribution and transport. It is also believed that the dual component spiral crimped fibers as described above are suitable to maintain sufficient void volume even when the acquisition member is exposed to pressure. Additionally, it is also believed that the spiral crimped fibers provide good permeability for a given fiber denier value, the hollow fiber cross-section allows the fiber to have a larger outer diameter than a compact cross-section. The outer diameter of the fiber appears to determine the permeability properties of an acquisition member formed from such fibers.

[0086] Generally, the core wrap top layer 91 of the present disclosure can comprise elastic fibers in the range of from about 10 wt% to about 50 wt%, or from about 13 wt% to about 40 wt%, or from about 20 wt% to about 35 wt%, or from about 25 wt% to about 30 wt%, specifically including all values within these ranges and any ranges created thereby. In one specific example, the nonwoven of the present disclosure can comprise about 30 wt% elastic fibers.

[0087] To enhance the stabilizing effect of the integration, one or more of the fibers can be crimped prior to the integration. For example, in the case of synthetic fibers, the fibers can be mechanically crimped by intermeshing teeth. Also for the absorbent fibers, the fibers can be mechanically crimped and / or can have a chemically induced crimp due to the variable surface layer thickness formed during the production of the absorbent fibers.

[0088] The core wrap top layer 91 can comprise a hydrophilic agent, especially when the core wrap top layer comprises inherently hydrophobic synthetic fibers or consists entirely of such fibers. Any conventional hydrophilic treatment can be used to provide the hydrophilic agent. Typically, the fiber web such as a nonwoven can be externally coated with a surfactant, either directly or via an oil / emulsion. Alternatively, a hydrophilic melt additive can be added to the polymer melt used to make the fibers, as is known in the art. The hydrophilic melt additive is an amphiphilic molecule having a hydrophilic head and a hydrophobic tail. The hydrophilic head orients towards the surface of the adhesive, thereby providing the hydrophilic properties of the adhesive, while the hydrophobic tail remains in the polymer matrix. However, hydroentangled fabrics comprising absorbent fibers (cellulose fibers) typically do not need additional hydrophilic treatment.

[0089] Generally, the fiber denier (related to the diameter of the fiber) directly influences the pore size of the material and thus, among others, the capillary pressure and the permeability / imbibition and the moisture vapor transmission of the material. At a given basis weight, the lower the denier, the lower the permeability and the higher the capillary pressure. The core wrap top layer 91 can comprise at least 50 wt%, at least 70 wt% or at least 80 wt% or even up to 100 wt% of fibers having a denier value of less than 10 denier.

[0090] Stabilizing element 100

[0091] The absorbent article can optionally comprise a narrow stabilizing element 100, which can resist excessive lateral compression in the crotch region of the article. The stabilizing element can be disposed between the topsheet and the absorbent core, as Figures 3-4 shown, however other positioning is possible, for example between the absorbent core and the backsheet.

[0092] Various materials can be used for the stabilizing element. The stabilizing element can comprise or consist of synthetic fibers or cellulose fibers. The stabilizing element can be a layer of fibers comprising un-bonded or loosely bonded hydrophilic fibers, in particular crosslinked cellulose fibers. The stabilizing element can also be a nonwoven such as a hydroentangled fabric or an air-laid material. The stabilizing element can have fluid acquisition or distribution properties in addition to stabilizing the absorbent article.

[0093] The stabilizing element can for example consist of crosslinked cellulose fibers. The stabilizing element can comprise at least 50 wt.% of crosslinked cellulose fibers, optionally consist of 100 wt.% of crosslinked cellulose fibers. The crosslinked cellulose fibers can be crimped, twisted, or curled, or a combination thereof (including crimped, twisted, and curled). This type of material has been previously applied as part of the acquisition system in disposable paper diapers (e.g. US 2008 / 0312622 Al (Hundorf)), but in a different manner than the present application. Crosslinked cellulose fibers provide higher elasticity, thereby enhancing the compression resistance of the product in the packaged state or under use conditions (e.g. when the wearer's thighs are squeezed).

[0094] The stabilizing element can also be a mechanically integrated nonwoven, such as a hydroentangled fabric, similar to the integrated material disclosed herein as the core wrap top layer. The fiber integration of the nonwoven can occur via any suitable process that entangles the staple fibers predominantly in the Z direction (positive or negative). The mechanical integration processes include needle punching and hydroentanglement, and do not require chemical integration or adhesive integration.

[0095] The stabilizing element can generally have an average basis weight of at least 50 g / m2 2 , preferably from about 50 g / m2 2 to about 400 g / m2 2 , in particular from 80 g / m2 2 to 240 g / m2 2 . The average basis weight is calculated by dividing the weight of the stabilizing element by its surface area. The stabilizing element can have a uniform basis weight, which is a typical feature of nonwoven materials. The basis weight of the stabilizing element can also vary locally along the length of the article, for example the front and middle portions of the layer can have a higher basis weight than the back portion. This can be particularly the case when the stabilizing element is composed of loose-bonded fibers, such as crosslinked cellulose fibers. For example, such a stabilizing element can be produced in-line by depositing the fibers (e.g. crosslinked cellulose fibers) onto a forming surface within a deposition chamber having a variable depth, such that the locally deposited basis weight can be varied. The forming surface of the deposition chamber can be provided with a series of small holes that are connected to a source of negative pressure vacuum, such that the suction force pulls the fibers to the desired location to form a fiber layer having the desired morphology and shape. The fiber layer can be formed on a carrier sheet or transferred, so the carrier sheet should be at least as large as the fiber stabilizing element. The carrier sheet can for example be a topsheet, another liquid management layer such as a nonwoven acquisition layer 70, or any other layer of the article (e.g. the core wrap top layer 91).

[0096] The stabilizing element 100 is generally present at least in the middle of the article, as embodied by the midpoint M as defined above. The stabilizing element also extends at least along the longitudinal centerline towards the front end of the absorbent article, and at least 40 mm from the transverse centerline; preferably, the element also extends an equal distance towards the back end of the absorbent article as well. Here, at the C-point, the width of the stabilizing element in the transverse direction does not extend more than 50 mm. The width of the stabilizing element, measured at the C-point, is generally in the range of about 20 mm to about 50 mm, and preferably, the same width range is maintained at the midpoint M as well. It has been found that a stabilizing element with a narrower width avoids compression of the inner thigh during walking or other activities, while the width is sufficient to reduce the occurrence of wrinkles at least in the crotch region of the absorbent article, both visually and tactilely. The stabilizing element 100 can generally have a generally rectangular shape, as this shape allows for the most efficient use of the material provided in a roll, such as a nonwoven. Other shapes are possible, such as an hourglass shape, dog bone shape, trapezoidal shape, etc. When the stabilizing element comprises air-laid fibers, the fibers can be air-laid in a mold having the desired shape. The stabilizing element 100 has a longitudinal dimension, measured along the longitudinal centerline, in the range of 100 mm to 500 mm. For adult incontinence pant applications, the length of the stabilizing element can in particular be in the range of 200 mm to 400 mm.

[0097] While the stabilizing element can be a single layer component to simplify construction (this also includes integrated layers comprising two or more layered structures, such as a hydroentangled layer), the stabilizing element can also be a multi-layer component comprising at least two sub-layers. The sub-layers can be separate layers that are stacked, or the sub-layers can be formed by folding a layer of material, the folds forming the sub-layers. The sub-layers can be arranged such that the stabilizing element has a higher basis weight in a central region extending in the longitudinal direction relative to lateral regions disposed laterally outward of the central region. In this way, the stabilizing element provides increased stability within the central region of the article, where stability is most needed. This can be achieved by stacking at least two sub-layers having different widths. Two vertically adjacent sub-layers forming the stabilizing element can be uniformly attached to each other at their interface, or attached in a particular attachment pattern - the pattern comprising a longitudinally extending central attachment zone, but no attachment treatment in lateral non-attachment zones disposed laterally outward of the central attachment zone. When the stabilizing element is composed of two or more layers, the width of each layer is preferably no more than 50 mm. In addition, the combined total basis weight of the two or more layers is preferably greater than 50 gsm, and each individual layer can have a lower basis weight.

[0098] Other components

[0099] The absorbent pad assembly 50 generally includes a pair of longitudinally extending barrier leg cuffs 80, each disposed on a longitudinal side of the absorbent pad assembly. The barrier leg cuffs 80 each include a proximal portion 82 attached to the absorbent pad assembly, for example via adhesive 69, and a respective free edge 84 that can extend away from the assembly toward the wearer. The barrier leg cuffs advantageously include elastic members 86 disposed along the free edges 84. The barrier cuff edge elastic members 86 cause the free edges 84 to be longitudinally taut when the absorbent pad assembly is flexed to the body along the crotch region of the wearer, as is known in the art. The barrier cuff edge elastic members 86 can be incorporated into the cuff structure in a pre-strained state, which causes the free edges to be taut and tend to gather in the longitudinal direction when under stress, so that the free edges extend away from the assembly when the pants are worn, and conform to the body curves of the wearer.

[0100] The barrier leg cuffs can be formed of a material that is highly efficient at preventing the transmission of liquids, such as a film material or a breathable but highly efficient liquid-impervious nonwoven web material, and can be used to barrier urine within the pant body before it is absorbed by the absorbent structure. The absorbent article can also optionally include an outer cuff, also known as a gasketing cuff, provided by elastic strands disposed on the longitudinal sides of the absorbent assembly while in a pre-strained state (this dual cuff construction is not shown in the drawings). The outer cuff can cause the longitudinal edges on both sides of the assembly to gather toward the crotch region along the wearer's legs, thereby reinforcing the leakage prevention function and improving the fit. The longitudinal edge elastic members can be disposed between the material of the barrier cuffs 80 and the material of the topsheet 60, or alternatively, these members can be disposed between the topsheet and the backsheet, or the outer side of the backsheet. However, the outer barrier cuffs generally increase the width of the absorbent assembly. In the present invention, it has been found that the outer barrier cuffs can be omitted. Thus, the articles of the present invention can be free of outer barrier cuffs. In particular, the absorbent assembly can include barrier leg cuffs 80 (inner cuffs) as described above, but can be free of outer barrier cuffs.

[0101] The barrier cuff elastic members 86 are generally elastic strands, which can have the same or different material as the elastic strands 40 in the panels 20, 30. One, two or more such elastic strands 86 can be disposed at the fold of the cuff material. The barrier cuffs and associated longitudinal edge structures and elastic members can also be formed of materials and configured as described in any of, for example: US 8,939,957; US 2016 / 270978; US 2016 / 270971; US 2016 / 270980; US 2016 / 270985; US 2016 / 270983; US 2016 / 270979; US 2016 / 270975; US 2016 / 270981; and US 2016 / 270973.

[0102] Relationship between layers and manufacturing method

[0103] The components can be converted into absorbent articles according to processes known in the art. Typically, adjacent layers will be joined together using conventional bonding methods, such as adhesive coatings applied across the surface or a portion of the surface of the layers via slot coating or spraying, or thermal bonding, or pressure bonding, or combinations thereof. For clarity and readability of the illustration, not all bonding structures between components are shown in the drawings. Bonding between the layers of the article should be considered to be present unless specifically excluded. Adhesives can typically be used to improve adhesion between different layers, for example between the backsheet and the core wrap. The adhesives used can be any standard hot melt glue as known in the art. For example, as shown in Figure 3 A construction adhesive 96, 97 can be applied between the topsheet 60 and the acquisition layer 70, and between the acquisition layer 70 and the stabilization element 100, respectively, for example by slot coating, as shown. In case no separate acquisition layer 70 is provided between the topsheet and the absorbent core, the stabilization element 100' can be attached directly to the topsheet by slot coating an adhesive 98, as shown. The stabilization element 100, 100' can also be adhered to the core wrap top layer 91 by an adhesive 99. Typically, an adhesive 95 is applied on the inside facing side of the backsheet 66, for example by spiral coating, to secure the components (absorbent core, topsheet and barrier leg cuffs) directly to the backsheet. Figure 4

[0104] Packaging The articles according to the present application will typically be packaged together for transport and sale. The articles can be folded and packaged as is known in the art. The package can be, for example, a plastic bag or a cardboard box. Disposable absorbent pants can typically be folded along the transverse centerline and packaged with the side panels folded inward. The absorbent articles can be packed under compression in order to reduce the size of the package while still providing a sufficient number of absorbent articles per package. By packing the absorbent articles under compression, the caregiver can easily handle and store the packages, while the size of the packages also provides savings in distribution and inventory for the manufacturer. A standard package can contain from 8 to 40 articles, although other quantity specifications are of course possible, for example individually packaged articles can also be provided.

[0105]

[0106] Recycle-friendly and bio-based absorbent articles

[0107] ​The components of the absorbent articles described herein can be recycled for other uses, whether or not they are (at least partially) formed from recyclable materials. Examples of absorbent article materials that can be recycled are nonwovens, films, fluff pulp, and superabsorbent polymers. The recycling process can sterilize the absorbent articles using an autoclave, then the absorbent articles can be shredded and separated into different byproduct streams. Example byproduct streams can include plastics, superabsorbent polymers, and cellulosic fibers such as pulp. These byproduct streams can be used to produce fertilizer, to manufacture plastic articles, paper articles, viscose, construction materials, absorbent pads for pets or hospital beds, and / or other uses. Further details regarding the design of absorbent articles that facilitate recycling, the design of recycling-friendly diapers, and the design of recycling-friendly and biobased component diapers are disclosed in US2019 / 0192723, published June 27, 2019.

[0108] Examples

[0109] First class of examples

[0110] Example 1 (Code GD) is an adult incontinence pant according to the present application, which is generally as shown in Figures 1-3 The sizes are indicated in a width x length format. This Example 1 comprises a latex bonded acquisition layer (70) of 90 mm x 305 mm, and a stabilizing element (100) of 40 mm x 305 mm, which is composed of crosslinked cellulosic fibers, and has a basis weight of 144 g / m 2 The core is a fluff pulp free absorbent core, containing 16.3 g SAP (absorbent layer size of 120 mm x 400 mm). The core wrap top layer is 130 mm wide, a spunlace of 55 g / m 2 The spunlace is of homogenized composition, containing by weight: 20% viscose fibers (1.3 dtex), 30% hollow spiral PET fibers (10 dtex), and 50% PE / PET fibers (core-sheath composite fibers, 2.2 dtex). The core wrap bottom layer is 165 mm wide, an SMS of 10 g / m 2 The core pocket overall size is 120 mm x 430 mm.

[0111] Example 2 (comparative, code JD) is Always ® Discreet Underwear Max S / M, which is a cross-linked fiber Elementary layer width of 55 mm .

[0112] Example 3 (comparative, code H) is Depend ® Fit Flex Maxi small size .

[0113] The thickness measurements of the articles listed above were performed according to the "Width and Thickness Measurement Method" disclosed herein, and the results are reported in Table 1 below.

[0114] Table 1: Thickness measurements

[0115]

[0116] The panelists were asked to test 10 incontinence briefs per panel under CDA conditions. The incontinence briefs were randomized via a rotating generator. Each panelist filled out a diary card for each product, weighed the used product, and completed an online questionnaire for each code. Results are summarized in Tables 2-3 below.

[0117] Table 2: Diary card data

[0118]

[0119] Table 3: Questionnaire data

[0120] Scored scale 1-5 (poor, fair, good, very good, excellent)

[0121]

[0122] From the diary cards, it was found that Example 1 of the present application, which has a reduced basis weight and width of the crosslinked cellulose layer, did not negatively impact the leakage performance compared to a commercially available control product (Example 2, Code JD).

[0123] It was found that the product of the present application had significantly less sag in the crotch region and better fit in the crotch region than the commercially available product, and that the product of the present application had significantly less bunching between the legs than the control product.

[0124] Second class of examples

[0125] Example 4 (Code T) was a hand-made absorbent brief substantially as shown in Figure 4 The absorbent core (26) was a fluffless pulp absorbent core including a 40 g / m 2 spunlace core wrap top layer.

[0126] The stabilization element (100) was 135 g / m 2 spunlace, 40 mm wide, including two integrated layered structures:

[0127] Layer 1 (top layer structure)

[0128] 50% hollow spiral PET fiber (10 dtex)

[0129] 50% PE / PET fiber (sheath-core composite fiber, 5.8 dtex)

[0130] Layer 2 (bottom layer structure)

[0131] 50% viscose fiber (1.3 dtex)

[0132] ​​50% PE / PET fiber (sheath-core fiber, 5.8 dtex)

[0133] No other acquisition or distribution layers were used in this example. The chassis was a single cuff chassis (no outer barrier cuff).

[0134] Example 5 (Code L) had approximately the same construction as Example 4, except that a 90 mm wide hydroentangled layer was used as the stabilization element (versus 40 mm wide), and the core wrap top layer was a 10 gsm SMS nonwoven.

[0135] Example 6 (Code C) was a commercially available Always ® Discreet Adult Incontinence product with a fluff pulp core, a double acquisition-distribution layer (composed of a 70 mm wide, 43 gsm acquisition layer and a 200 gsm crosslinked cellulose layer), and a double cuff system. This is the same product as Code JD used in the first series of examples above.

[0136] The differences between the test products in this series are summarized in Table 4 below:

[0137] Table 4: Test product description

[0138]

[0139] The thickness measurements for the products listed in the above examples were performed according to the "Width and Thickness Measurement Method" disclosed herein, and the results are reported below.

[0140] Table 5: Thickness measurements

[0141]

[0142] Forty-five panelists evaluated nine of each of the three Code products under CDA conditions. The order of product use was randomized as evenly as possible across the six rotation combinations assigned to each panelist. Panelists filled out diary cards for each product and completed an online questionnaire for each Code. The results are summarized in Tables 6-7 below.

[0143] Table 6: Questionnaire data

[0144] Scoring scale 1-5 (poor, fair, good, very good, excellent)

[0145]

[0146] Table 7: Diary card data

[0147] (Percentage of positive responses)

[0148]

[0149] Code T exhibited a significant advantage over Code L and Code C (control) in terms of comfort, concealment, and fit associated with the problem. Code L also exhibited an advantage over the control in these same metrics, but to a relatively limited extent.

[0150] Commercial product thickness measurements

[0151] The thickness measurements of the commercial products were performed according to the "Width and Thickness Measurement Method" disclosed below. The results are recorded in Table 8 below.

[0152] Table 8

[0153]

[0154] Test methods

[0155] Width and thickness measurement methods

[0156] Equipment :

[0157] • Ono-Sokki GS-503 linear caliper with Ono-Sokki DG-3610 digital gauge, or equivalent precision equipment.

[0158] • Flat presser foot with a diameter of 10.1 mm.

[0159] • The resulting pressure is equivalent to 0.45 psi (3.103 kPa) without applying additional load to the mechanism.

[0160] Sample preparation and width measurement :

[0161] • Ten parallel samples were prepared for each product variant and measured according to the following procedure.

[0162] • For pant-type products, the side seams (13) were cut open.

[0163] • The locations of the front edge (11) and the back edge (12) of the product were recorded, as well as the distribution of any crease lines (there can typically be one crease line along the transverse centerline (4) as the product is typically folded in half along the middle when packaged).

[0164] • The front edge (11) of the product was taped to the benchtop. The back edge (12) of the product was taped to the benchtop after being stretched out in the longitudinal direction to lay flat and taut.

[0165] • The measurement of the length of the product was taken along the longitudinal centerline, from the midpoint of the front edge to the midpoint of the longitudinal back edge.

[0166] • Mark the longitudinal midpoint (M) on the bodyfacing (topsheet) side of the product at the longitudinal centerline of the product (i.e., at a distance equal to one-half the length of the product, measured from the front edge 12 of the product).

[0167] • Then, the 60 mm region of the article extending forward from the longitudinal midpoint M to the front waist edge is examined. If a line drawn 40 mm forward of the transverse centerline can be drawn without significant overlap of residual creases and folds, then that line is drawn and defined as LI. If the line 40 mm forward would significantly overlap residual creases and folds, then the 60 mm region extending forward of the longitudinal midpoint (M) is examined a second time, and a line LI is drawn within that region so as to minimize overlap with any residual creases and folds. If there are multiple line LI options that would also minimize overlap with residual creases and folds, then the option closest to 40 mm forward of the longitudinal midpoint (M) is preferred. For products that do not have a distinct front-to-back edge (e.g., due to the symmetry of these products relative to the transverse centerline), then for each sample, measure twice in each direction as described above, and then average the measurements.

[0168] • The transverse midpoint "C" is marked on line LI at the center of the width of the absorbent material layer (72). The point C will generally coincide with the longitudinal centerline, but due to tracking deviations in actual production, the point C can be offset a few millimeters to either side of the centerline. Thus, the point C coincides with the center of the absorbent material layer (72) on line LI. The point C is the location from which the center article caliper will be measured.

[0169] • Along line LI, two additional markers ("R" and "L") are marked on the bodyfacing (topsheet) side of the product. Marker "R" is drawn 30 mm from the transverse midpoint C, in a direction toward the right lateral edge of the product. Marker "L" is drawn 30 mm from the transverse midpoint C, in a direction toward the left lateral edge of the product. It is important to note that the "right" and "left" designations of the product are made with respect to the body orientation when worn. Markers "R" and "L" are the locations from which the right and left pad caliper will be measured.

[0170] • At line LI, if a stabilization element (100) is present, then its width W2 (i.e., the distance from one lateral edge to the other) is measured and recorded to the nearest 0.1 mm. This width is more conveniently measured using a light box (see Figure 5 ) because the light box more effectively distinguishes the absorbent material layer (72) from other components of the article, such as the topsheet or core wrap.

[0171] • Measure the width Wl of the absorbent material layer (72) at line LI (i.e., the distance from one lateral edge to the other) and record to the nearest 0.1 mm. If an acquisition layer (70) is present, the width of the acquisition layer can also be recorded in a similar manner.

[0172] • Remove the securing tape at both ends of the product and allow it to hang loose from the bench top.

[0173] • Using scissors, cut the front panel (20) and back panel (30) and leg elastics (86) from the core / pocket periphery, taking care not to damage any part of the core / pocket.

[0174] Thickness measurement procedure :

[0175] • Align the measurement point "C" directly below the center of the presser foot and slowly lower the presser foot until it makes contact with the topsheet side of the product.

[0176] • After the presser foot has been in contact with the product for 30 seconds, record the thickness to the nearest 0.01 mm and mark the test location.

[0177] • Repeat the above procedure for the "R" and "L" locations following the same operating protocol.

[0178] • Repeat the complete measurement procedure for all 10 parallel test products.

[0179] Results :

[0180] • The recorded value at each test location is the arithmetic average of ten independent recorded measurements, where: width Wl and width W2 are recorded to the nearest 0.1 mm, and center pad thickness (Cl), right pad thickness (C2), and left pad thickness (C3) are recorded to the nearest 0.01 mm.

[0181] Miscellaneous

[0182] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such quantity is meant to mean both the exact value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is meant to mean "about 40 mm."

[0183] Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any application disclosed or claimed herein or that it alone, or along with any other document or together with any relevant art, teaches, suggests or discloses any such application. Further, the citation of any document is not an admission that it is prior art with respect to any application disclosed or claimed herein or that it alone, or along with any other document or together with any relevant art, teaches, suggests or discloses such application. In addition, with respect to any document that has a priority date or filing date prior to the priority date or filing date of this application, the priority date or filing date of this application is used, not the priority date or filing date of the earlier document. Finally, documents referred to or cited in this application are not admitted to be prior art with respect to the application disclosed or claimed herein, unless expressly so admitted.

[0184] While particular embodiments of the present application have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the application. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this application.

Claims

1. An absorbent article comprising: a longitudinal centerline extending longitudinally and dividing the absorbent article into left and right halves; a transverse centerline extending in a transverse direction perpendicular to the longitudinal direction and dividing the absorbent article into a front half and a back half, wherein the absorbent article comprises: a liquid permeable topsheet; a liquid impermeable backsheet; and an absorbent core, wherein the absorbent core comprises a layer of absorbent material disposed within a core wrap, wherein the core wrap comprises a top layer and a bottom layer, the top layer substantially forming the wearer-facing side of the absorbent core and the bottom layer substantially forming the garment-facing side of the absorbent core, wherein the top layer and the bottom layer are independent layers; wherein the top layer comprises a mechanically integrated nonwoven, and wherein the top layer has a 2 basis weight.

2. The absorbent article according to claim 1, wherein the core wrap top layer has a 2 Up to 200g / m 2 Basis weight within the range.

3. The absorbent article according to claim 1, wherein the core wrap top layer and the core wrap bottom layer are longitudinally bonded by one or more longitudinal core wrap bond lines.

4. The absorbent article of claim 1, wherein the core wrap top layer is a hydroentangled fabric.

5. The absorbent article of claim 4, wherein the spunlace fabric comprises from about 20% to about 75% by weight of absorbent fibers, from about 1% to about 50% by weight of reinforcing fibers, and from about 10% to about 50% by weight of elastic fibers.

6. The absorbent article according to claim 1 further includes a narrow stabilizing element between the absorbent core and the top sheet, wherein the narrow stabilizing element has a width (W2) of no more than 50 mm at point C, and the point C is set at a distance of about 40 mm from the transverse center line toward the front end of the article and is laterally aligned with the absorbent material layer of the core, and the width is measured according to the "Width and Thickness Measurement Method" described therein.

7. The absorbent article according to claim 6, wherein the width (W2) of the narrow stabilization element is in the range of 20 mm to 50 mm.

8. The absorbent article according to claim 6, wherein the absorbent core extends outwardly at least 5 mm beyond point R and 5 mm beyond point L in the transverse direction, wherein point R and point L are respectively located 30 mm to the right and left of point C in the transverse direction, The stenosis stabilizing element does not extend to at least any of the points R and L in the transverse direction. wherein the absorbent article has a first thickness C1 at the point C, wherein the absorbent article has a second thickness C2 at point R and a third thickness C3 at point L, and The thickness ratio C1 / (C2+C3) is at least 0.6, and the thicknesses are measured according to the "Width and Thickness Measurement Method" disclosed herein.

9. The absorbent article according to claim 8, wherein the thickness C1 is less than 5 mm and the average value (C2+C3) / 2 is less than 4.5 mm.

10. The absorbent article of claim 6, wherein the narrow stabilizing element has a thickness of at least 50 g / m 2 and wherein the narrow stabilizing element comprises a material selected from the group consisting of: - a layer of cross-linked cellulose fibers; or - airlaid materials; or -Hydroplonitrile nonwovens.

11. The absorbent article of claim 1 , wherein the absorbent article further comprises an acquisition layer between the topsheet and the absorbent core, wherein the acquisition layer has a 2 Up to 70g / m 2 Basis weight within the range.

12. The absorbent article of claim 1, wherein the absorbent article does not comprise an acquisition layer between the topsheet and the absorbent core.

13. The absorbent article of claim 1, wherein the absorbent core comprises at least 10 g of superabsorbent polymer.

14. The absorbent article of claim 1, wherein the layer of absorbent material comprises 80% to 100% by weight superabsorbent particles.

15. The absorbent article according to claim 1, wherein the absorbent article is an adult incontinence pants, the adult incontinence pants comprising a front panel, a back panel and an absorbent pad assembly, wherein the front panel and the back panel are joined to each other along a left seam and a right seam, the absorbent pad assembly extends between the front panel and the back panel, and wherein the top panel, the bottom panel and the absorbent core at least partially form the absorbent pad assembly.

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