Molded fleece

Abstract

Spunbond nonwoven fabric (10) comprising the following: a. a first surface (12) and a second surface (14) and at least one first and one second optically detectable zone (110, 120) on at least one of the first and the second surface (12, 14), wherein each of the first and the second zone (110, 120) has a pattern of three-dimensional features (20, 22, 24), wherein each of the three-dimensional features (20, 22, 24) defines a microzone comprising a first region (300) and a second region (310), wherein the first and the second region (300, 310) have a value difference for an intensive property, wherein the intensive property is one or more of thickness, base weight, and volumetric density; and b. wherein the difference in value for the intensive property for at least one of the microzones in the first zone (110) differs from the difference in value for the intensive property for at least one of the microzones in the second zone (120); wherein in at least one of the microzones the first area (300) has a contact angle of more than 90 degrees, as measured by the contact angle test method described in detail herein.

Description

AREA OF TECHNOLOGY

[0001] The present invention relates to shaped, three-dimensional nonwovens and objects made from shaped three-dimensional nonwovens. BACKGROUND OF THE INVENTION

[0002] Nonwovens are useful for a wide variety of applications, including absorbent personal hygiene products, clothing, medical applications, and cleaning applications. Nonwoven hygiene products include infant care items such as diapers, children's care items such as training pants, feminine hygiene products such as sanitary napkins, and adult care products such as incontinence products, pads, and briefs. Nonwoven clothing includes protective workwear and medical clothing such as surgical gowns. Other medical applications of nonwovens include nonwoven wound dressings and surgical bandages. Cleaning applications for nonwovens include towels and wipes. Many other uses of nonwovens are well known. The foregoing list is not considered exhaustive.

[0003] Various properties of nonwovens determine their suitability for different applications. Nonwovens can be designed to exhibit different combinations of properties to meet diverse needs. Variable properties of nonwovens include liquid handling properties such as wettability, distribution, and absorption; strength properties such as tensile strength and tear resistance; softness properties; durability properties such as abrasion resistance; and aesthetic properties. The physical form of a nonwoven also influences its functionality and aesthetic properties. Nonwovens are initially manufactured in webs which, when laid on a flat surface, may have an essentially flat, featureless surface, or they may have a range of surface features such as openings or protrusions, or both.Nonwovens with openings or protrusions are often referred to as three-dimensionally shaped nonwovens. The present disclosure relates to three-dimensionally shaped nonwovens.

[0004] The subsequently published WO 2017 / 105997A1 describes a spunbond nonwoven fabric comprising a first surface and a second surface and at least one first and second visually distinguishable zone on at least one of the first and second surfaces, wherein each of the first and second zones has a pattern of three-dimensional features, wherein each of the three-dimensional features defines a microzone comprising a first area and a second area, wherein the first and second areas have a difference in the values ​​for an intensive property, and wherein the difference in the values ​​for an intensive property for at least one of the microzones in the first zone differs from the difference in the values ​​for the intensive property for at least one of the microzones in the second zone.

[0005] US 2015 / 0282999A1 discloses a garment lining in which a treatment is selectively applied to the front and back waist area. Despite previous advances in the field of nonwovens, there remains a need for improved nonwovens with three-dimensional surface features.

[0006] Furthermore, there remains a need for processes and equipment for producing improved nonwovens with three-dimensional surface features.

[0007] There remains a need for items, including absorbent products, that use improved nonwovens with three-dimensional surface features.

[0008] Furthermore, there remains a need for absorbent products that use nonwovens with three-dimensional surface features and that can be packaged in a compressed form, while minimizing the loss of three-dimensional surface features when opening the packaging.

[0009] Furthermore, there remains a need for absorbent products that use soft spunbond nonwovens with three-dimensional surface features that exhibit reduced linting properties during use.

[0010] Furthermore, there remains a need for improved nonwovens with three-dimensional surface features and physical integrity combined with softness, as measured by a tissue softness analyzer distributed by Emtec Electronic GmbH.

[0011] Furthermore, there remains a need for improved nonwovens with three-dimensional surface features with microzones and physical integrity, combined with at least one area of ​​a microzone that is hydrophobic and another area of ​​the same microzone that is hydrophilic.

[0012] Additionally, there remains a need for packaging for absorbent products that includes soft non-woven materials, which, compared to conventional absorbent product packaging, have a reduced bag stack height, so that the packaging is convenient for caregivers to handle and store, and so that manufacturers benefit from low distribution costs without loss of the aesthetic clarity, absorbency or softness of the manufactured absorbent product. SUMMARY OF THE INVENTION

[0013] The present invention relates to a spunbond nonwoven fabric. The spunbond nonwoven fabric has a first surface and a second surface and an optically detectable pattern of three-dimensional features on one of the first or the second surface. Each of the three-dimensional features defines a microzone comprising a first region and a second region.The first and second regions exhibit a difference in value for an intensive property, wherein the intensive property is one or more of thickness, base weight, and volumetric density, wherein the difference in value for the intensive property for at least one of the microzones in the first region differs from the difference in value for the intensive property for at least one of the microzones in the second region; and wherein in at least one of the microzones, the first region exhibits a contact angle of more than 90 degrees, as measured by the contact angle test method detailed herein. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a photograph of an example of the present revelation. Fig. Figure 2 is a photograph of an example of the present revelation. Fig. Figure 3 is a photograph of an example of the present revelation. Fig. Figure 4 is a cross-section of a section of a substance of the present disclosure, as it appears in Fig. 1 is shown. Fig. Figure 5A is a schematic representation showing the cross-section of a filament produced with a primary component A and a secondary component B in a side-by-side arrangement. Fig. 5B is a schematic representation showing the cross-section of a filament produced with a primary component A and a secondary component B in an eccentric sheath / core arrangement. Fig. 5C is a schematic representation showing the cross-section of a filament produced with a primary component A and a secondary component B in a concentric sheath / core arrangement. Fig. Figure 6 is a photograph of a perspective view of a trilobal bicomponent fiber. Fig. Figure 7 is a schematic representation of a device for producing a substance of the present disclosure. Fig. Figure 8 is a detail of a section of the device for joining a section of a material of the present disclosure. Fig. Figure 9 is a further detail of a section of the device for joining a section of a substance of the present disclosure. Fig. 10 is a detail of a section of the device for optionally additionally joining a section of a material of the present disclosure. Fig. Figure 11 is a photograph of an example of the present revelation. Fig. Figure 12 is a photograph of a section of a shaping band that is useful for the present disclosure. Fig. 13 is a cross-sectional view of a section of the in Fig. 12 depicted shaping bands. Fig. 14 is an image of a section of a mask used to define the in Fig. 12 shaping bands are to be produced. Fig. 15 is an image of a section of a mask used to define the in Fig. 16 shaping bands are to be produced. Fig. Figure 16 is a photograph of a section of a shaping band that is useful for the present disclosure. Fig. 17 is an image of a section of a mask used to define the in Fig. 18 shaping bands are to be produced. Fig. Figure 18 is a photograph of a section of a shaping band that is useful for the present disclosure. Fig. Figure 19 is a photograph of a section of a shaping band that is useful for the present disclosure. Fig. 20 is an image of a mask used to conceal the in Fig. 19 to produce the shaping band shown. Fig. 21 is a photograph of a substance of the present disclosure, which is on the in Fig. The shaping band shown in 19 is manufactured. Fig. Figure 22 is a perspective schematic view of a shaping band of the present revelation. Fig. Figure 23 is a top view of a nonwoven substrate containing nonwovens of the present disclosure. Fig. Figure 24 is a top view of a nonwoven substrate containing nonwovens of the present disclosure. Fig. Figure 25A is a top view of a substance of the present disclosure, from which sections for measuring the local base weight have been removed. Fig. Figure 25B is a top view of a substance of the present disclosure, from which sections for measuring the local base weight have been removed. Fig. Figure 26 is a graphical representation of a transverse direction variation of the base weight in a substance of the present disclosure. Fig. Figure 27 is a schematic view of a packaging of the present invention. Fig. Figure 28 is a top view of an absorption article of the present disclosure. Fig. Figure 29 is a top view of an absorption article of the present invention. Fig. Figure 30 is a cross-sectional view of section 29-29 of Fig. 28. Fig. Figure 31 is a top view of an absorption article of the present disclosure. Fig. Figure 32 is a cross-sectional view of section 32-32 of Fig. 31. Fig. Figure 33 is a top view of an absorption article of the present disclosure. Fig. Figure 34 is a cross-sectional view of section 34-34 of Fig. 33. Fig. Figure 35 is a cross-sectional view of section 35-35 of Fig. 33. Fig. Figure 36 is a photograph of an example of the present revelation. Fig. Figure 37 is a photograph of an example of the present revelation. Fig. Figure 38 is a photograph of an example of the present revelation. Fig. 39 is a photograph of a cross-section of the in Fig. 38 examples shown. Fig. Figure 40 is a perspective micro-CT view image of an example of the present disclosure. Fig. Figure 41 is a perspective micro-CT view image of an example of the present disclosure. Fig. 42 is a micro-CT image of a cross-section of the area in the Fig. 40 and Fig. 41 examples shown. Fig. 43 is a micro-CT image of a top view of the area in the Fig. 40 and Fig. 41 examples shown. Fig. Figure 44 is a graphical representation of various advantages of the invention of the present disclosure. Fig. Figure 45 is a photographic view of a section of an example of the present disclosure. Fig. Figure 46 is a photographic view of a section of an example of the invention of the present disclosure. Fig. Figure 47 is a photographic view of a section of an example of the invention of the present disclosure. Fig. Figure 48 is a photographic view of a section of an example of the invention of the present disclosure. Fig. 49 is a photograph of a cross-section of the area in the Fig. 47 and Fig. 48 examples shown. Fig. Figure 50 is a photographic view of a section of an example of the invention of the present disclosure. Fig. Figure 51 is a photographic view of a section of an example of the invention of the present disclosure. Fig. Figure 52 is a photographic view of a section of an example of the invention of the present disclosure. Fig. Figure 53 is a photographic view of a section of an example of the invention of the present disclosure. Fig. 54 is a micro-CT image of a top view of the area in the Fig. 40 and Fig. 41. Example shown after undergoing additional processing. Fig. 55 is a graphical representation of various advantages of the in Fig. 54 invention shown in the present disclosure. Fig. Figure 56 is a schematic representation of a device for producing a substance of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0014] The present disclosure provides a formed nonwoven fabric that is formed directly on a formed forming belt with continuous spunbond filaments in a single forming process. The fabric of the present disclosure can assume a shape corresponding to the shape of the forming belt. A fabric of the present disclosure, produced on a forming belt of the present disclosure in a process of the present disclosure, can be particularly advantageous for use in hygiene products, clothing, medical products, and cleaning products.The shaped nonwoven fabric can be fluid-permeable for use as a top layer, bottom layer, absorption layer, distribution layer or other component layer for a diaper, or as a top layer, bottom layer, absorption layer, distribution layer or other component layer for a sanitary napkin, or as a top layer, bottom layer, absorption layer, distribution layer or other component layer for an adult incontinence pad or briefs, or as a cushion for a floor cleaning device.

[0015] The advantageous features of the nonwoven fabric are described herein in some embodiments in connection with a total area of ​​the nonwoven fabric. The total area can be an area defined by dimensions suitable for specific applications where the various features of the invention offer advantageous properties. For example, the total area of ​​a fabric can be that of a fabric with dimensions that make it suitable for use as a top layer, bottom layer nonwoven, absorption layer, distribution layer, or other component layer for a diaper; or as a top layer, bottom layer nonwoven, absorption layer, distribution layer, or other component layer for a sanitary napkin; or as a top layer, bottom layer nonwoven, absorption layer, distribution layer, or other component layer for an adult incontinence pad or briefs; or as a pad for a floor cleaning device.Thus, the total area can be based on width and length dimensions ranging from 3 cm to 50 cm in width and from 10 cm to 100 cm in length, resulting in total areas of 30 cm. 2 up to 500 cm 2 This leads to the aforementioned areas. The areas mentioned above explicitly include any integer dimension between the area boundaries. For example, the total area within the aforementioned areas is 176 cm². 2The invention is disclosed by a width of 11 cm and a length of 16 cm. As can be seen from the description herein, the total area of ​​a formed nonwoven fabric can be smaller than the area of ​​the nonwoven web of which it is a part in commercial production. That is to say, in a given commercially produced nonwoven web, there can be a plurality of formed nonwoven fabrics according to the invention, each of the formed nonwoven fabrics having a total area that is smaller than the area of ​​the web on which it is produced.

[0016] Photographs of representative examples of shaped nonwovens 10 are in the Fig. Figures 1-3 show the shaped nonwoven fabric 10, which can be a spunbonded nonwoven substrate with a first surface 12 and a second surface 14. In the Fig. 1-3 is the second surface 14 facing the viewer and is opposite the first surface 12, which is in the Fig. 1-3 is invisible, however in Fig. Figure 4 is shown. The term “surface” is widely used to refer to the two sides of a web for descriptive purposes and is not intended to imply any required flatness or smoothness. Although the formed nonwoven fabric 10 is soft and flexible, it is described in a flattened state in relation to one or more XY planes parallel to the flattened state, and in web manufacturing technology, the plane corresponds to the machine transverse direction CD and the machine direction MD, respectively, as shown in the Fig. Figures 1-3 show the length L in the MD and the width W in the CD, which determine the total area A for the nonwoven fabric 10. As shown in Fig. Figure 4 shows a cross-section of a section of the in Fig. For the purposes of description, the three-dimensional features of the shaped nonwoven fabric 10 are described in such a way that they extend outwards in a Z-direction from an XY plane of the first surface 16 (see Figure 1). Fig. 4) In one embodiment, a maximum dimension of three-dimensional features in the Z-direction can define the maximum distance between the plane of the first surface 16 and an XY plane of the second surface 18, this distance being measurable as the average thickness AC of the nonwoven fabric 10. The average thickness can be determined by optical, non-contact means, or it can be determined by devices with spaced-apart flat plates that measure the thickness of the interposed nonwoven fabric at a predetermined pressure. It is not necessary for all three-dimensional features to have the same maximum dimension in the Z-direction; however, a plurality of three-dimensional features can have substantially the same maximum dimension in the Z-direction, determined by the fiber layering process and the properties of the forming tape, as discussed below.

[0017] The in the Fig. The exemplary materials shown in Figures 1-4 (as well as other materials disclosed herein) are liquid-permeable. In one embodiment, the entire material may be considered liquid-permeable. In another embodiment, areas or zones (described below) may be liquid-permeable. Liquid-permeable, as used herein in reference to the material, means that the material has at least one zone that allows liquid to pass through it under the conditions of use of a consumer product. For example, if the material is used as a top layer on a disposable diaper, it may have at least one zone that exhibits a degree of liquid permeability that allows urine, liquid stool, menstrual fluid, or any other bodily excretions to pass through to an underlying absorbent core.The term “liquid-permeable”, as used herein in reference to an area, means that the area has a porous structure which allows liquid to pass through it.

[0018] As in the Fig. As shown in Figures 1-4, the nonwoven fabric 10 can have a regular, repeating pattern consisting of a variety of separate, recognizably distinct three-dimensional features, including a first three-dimensional feature 20, a second three-dimensional feature 22, and a third three-dimensional feature 24, as shown in the Fig. 2 and Fig. 3 shown. For example, this differs in Fig. 1. The heart-shaped first three-dimensional feature 20 is recognizable from the smaller, essentially triangular second three-dimensional feature 22. The recognizable differences may be visual, such as recognizably different sizes and / or shapes.

[0019] The three-dimensional features of the nonwoven fabric 10 can be formed directly onto a forming strip with a pattern of corresponding three-dimensional features by depositing fibers, such as by carding, air spinning, solution spinning, or melt spinning. In a sense, the nonwoven fabric 10 is formed onto a forming strip that determines the shapes of the three-dimensional features of the fabric 10. However, it is important, as described herein, that the apparatus and method of the invention produce the nonwoven fabric 10 in such a way that, in addition to assuming the shape of the forming strip, it is endowed with advantageous properties for use in hygiene products, clothing, medical products, and cleaning agents due to the properties of the forming strip and the apparatus for the forming process.More precisely, due to the nature of the forming tape and other device elements, as described below, the three-dimensional features of the nonwoven fabric 10 exhibit intense properties that can differ between the first and second regions within a microzone (described in more detail below), or from feature to feature, in such a way that advantageous properties are conferred upon the nonwoven fabric 10 for use in hygiene products, clothing, medical products, and cleaning agents. For example, the first three-dimensional feature 20 can have a base weight or density that differs from the base weight or density of the second three-dimensional feature 22, and both can have a base weight or density that differs from the base weight or density of the second three-dimensional feature 22.which differs from that of the third three-dimensional feature 24 and offers favorable aesthetic and functional properties with regard to fluid uptake, distribution and / or absorption in diapers or sanitary napkins.

[0020] It is assumed that the difference in the intensive properties between the various three-dimensional features of the nonwoven fabric 10 is due to the fiber distribution and compaction resulting from the apparatus or process described below. Fiber distribution occurs during the fiber laying process, in contrast to, for example, a post-processing process such as water jet treatment or embossing. Since the fibers can move freely during a process such as melt spinning, with the movement being determined by the nature of the features, the air permeability of the forming belt, and other processing parameters, it is assumed that the fibers in a nonwoven fabric 10 are more stable and permanently shaped.

[0021] As in the Fig. As can be seen in Figures 1-3, and as can be seen from the present description, the various three-dimensional features can be delimited by optically recognizable areas (in relation to the interior of a three-dimensional feature) that are in the form of a closed figure (such as the heart shape in the Fig. 1 and Fig. 3 and the diamond shape in the Fig. 2 and Fig. 3) may be present. The closed figure can be a curvilinear closed figure such as the heart shape in the Fig. 1 and Fig. 3. The outlining, visually identifiable areas can be the areas of the nonwoven fabric 10 that are closest to the first surface 12 in the Z-direction, such as those in Fig. 4 shown areas 21, and which lie at least partially in or on the first level 16 when they are in a flattened state. For example, as in Fig. Figure 1 shows the first three-dimensional feature 20, which is heart-shaped, and as this is shown as an exemplary first three-dimensional feature 20A, it is defined by a curvilinear closed heart-shaped element. A curvilinear element can be understood as a linear element that has a tangential vector V at any point along its length, where the closed figure can be such that the tangential vector V has both MD and CD components that change the values ​​of more than 50% of the length of the linear element of the closed figure. Of course, the figure does not have to be completely 100% closed; the linear element can also have breaks that do not affect the overall impression of a closed figure.As discussed below in connection with the shaping tape, the outlining, visually identifiable curvilinear, closed heart-shaped element is formed by a corresponding closed heart-shaped raised element on the shaping tape to create the closed figure of a heart on the fabric 10. In a repeating pattern, the individual shapes (in the case of the first three-dimensional feature in . Fig. 1: a heart shape) to aesthetically pleasing, soft, fluffy features across the entire area OA of the second surface 14 of fabric 10. In an embodiment in which the nonwoven fabric 10 is used as a top layer for a diaper or sanitary napkin, the second surface 14 of the nonwoven fabric 10 can be body-side to provide better aesthetic and performance-related advantages in terms of softness, compression resistance, and fluid absorption.

[0022] More precisely, in the regular, repeating pattern of closed, three-dimensional features, as in Fig. As shown in Figures 1-3, it is assumed, without being bound to any theory, that the dimensions of the various features, the average base weight of the entire fabric 10 across its entire surface, and other parameters as described below, which define the various intensive properties, contribute to a beneficial improvement in compression recovery. It is assumed that the multitude of relatively closely spaced, relatively small, and relatively soft three-dimensional features can act as springs to resist compression and to rebound once a compressive force is removed.Compression resilience is important in the top layers, bottom layers, absorption layers, distribution layers, or other component layers of hygiene products such as diapers, sanitary napkins, or adult incontinence pads, diapers, or briefs, for example, because such products are typically packaged and folded into a compressed state. Hygiene product manufacturers want to retain most, if not all, of the manufactured thickness for aesthetic and performance reasons. The three-dimensional shape of molded features offers significant aesthetic advantages due to the soft look and feel and the appealing appearance of clear, well-defined shapes, including very small shapes such as those found in [reference to a specific product / model]. Fig. The two small hearts shown. The three-dimensional features also provide softness during use, improved absorbency, less leakage, and overall improved application. However, the necessary compression during folding, packaging, shipping, and storage of the hygiene products can cause a permanent loss of thickness in a top layer, bottom layer nonwoven, absorption layers, distribution layers, or other component layers of the absorbent product, thereby diminishing the functional benefits. We unexpectedly found that the nonwovens of the present disclosure retain their original three-dimensional features to a significant extent, even after being subjected to compression packaging and distribution in a compression-packed state.

[0023] Table 1 below shows compression recovery data for two embodiments of the present disclosure. Example 1 corresponds to the one in Fig. The nonwoven fabric 10 shown in section 1 is produced on a forming belt, as described in section 1. Fig. 12 and Fig. 14 described. Example 2 corresponds to the one in Fig. 2 shown nonwoven fabric 10 and is produced on a forming belt, as with reference to the Fig. 15 and Fig. 16 described. As can be seen from the data, the materials 10 according to the invention show a significant advantage with respect to compression recovery when measured by the compression aging test. In one form, packaging of the absorbent articles with the compression recovery properties of the present disclosure can have a reduced bag stack height, but still provide the aesthetic advantages and the absorbency and softness advantages of the diaper just manufactured; or as if they had never been compression-packed.This invention provides packaging with a reduced stacking height in the bag, allowing healthcare workers to easily handle and store the packaging, while also offering manufacturers reduced distribution costs, both of which are achieved while maintaining the original aesthetic clarity, absorption, or softness of the absorbent product. Example 1:

[0024] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration, as in Fig. Figure 6 shows a scanning electron microscopy (SEM) image of a cross-section of a bicomponent trilobal fiber. The nonwoven fabric was formed on a shaping belt with a repeating pattern as shown in Figure 6. Fig. 12 described spun, as below in relation to the Fig. 7 and Fig. 8 described, under motion at a linear speed of about 25 meters per minute, on an average base weight of 30 grams per square meter, with a repeating pattern of heart shapes, as in Fig. 1 shown. The fibers of the fabric were further bound on the first side 12 by heated compression rollers 70, 72 (described below) at 130 °C and wound onto a roll at the winder 75. Example 2:

[0025] A bicomponent spunbond nonwoven was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration, as shown in Fig. Figure 6 shows a scanning electron microscopy (SEM) image of a cross-section of a bicomponent trilobal fiber. The nonwoven fabric was formed on a shaping belt with a repeating pattern as shown in Figure 6. Fig. 16 described spun, as below in relation to the Fig. 7 and Fig. 8 described, moving at a linear speed of about 25 meters per minute, around a fabric 10 with an average base weight of 30 grams per square meter, with a repeating pattern of heart shapes, as in Fig. 2 shown, to form. The fibers of the material were further bound on the first surface 12 by heated compaction rollers 70, 72 (described below) at 130 °C. Table 1: Compression resilience 3-D-Vlies Roh(Vliesstoffdirekt vonder Rolle) 4 KPa (~96 mm IBSH) 14 KPa (~84 mm IBSH) 35 KPa (~68 mm IBSH) Dicke Dicke nachKompression ProzentDickenbeibehaltung (%) Dicke nachKompression ProzentDickenbeibehaltung (%) Dicke nachKompression ProzentDickenbeibehaltung (%) Beispiel 1 0,45 0,38 84,44 0,35 77,78 0,34 75,56 Beispiel 2 0,43 0,36 83,72 0,36 83,72 0,31 72,09

[0026] As can be seen from Table 1, the materials according to the invention retain considerable amounts of their thickness after compression at relatively high pressures. For example, the samples of Example 1 and Example 2 retain more than 70% of their original average thickness after being subjected to the compression aging test at a pressure of 35 kPa. The compression aging test is a simulation of the conditions a nonwoven fabric would experience if it were packaged in high-compression diaper packaging and then remained in such a state during distribution to a consumer, and then the packaging were finally opened by a consumer.

[0027] The present disclosure can employ the process of melt spinning. In melt spinning, no mass loss occurs in the extrudate. Melt spinning differs from other spinning processes, such as wet or dry spinning from solution, in which a solvent is eliminated from the extrudate by volatilization or diffusion, resulting in a mass loss.

[0028] Melt spinning can be carried out at temperatures from approximately 150 °C to approximately 280 °C, or in some embodiments from approximately 190 °C to approximately 230 °C. Fiber spinning speeds can exceed 100 meters per minute and range from approximately 1,000 to approximately 10,000 meters per minute, from approximately 2,000 to approximately 7,000 meters per minute, and from approximately 2,500 to approximately 5,000 meters per minute. The spinning speed can influence the brittleness of the spun fiber, and generally, the higher the spinning speed, the less brittle the fiber. Continuous fibers can be produced by spunbond or meltblown processes.

[0029] A nonwoven fabric 10 according to the invention can comprise continuous multi-component polymer filaments, which include a primary polymer component and a secondary polymer component. The filaments can be continuous bi-component filaments with a primary polymer component A and a secondary polymer component B. The bi-component filaments have a cross-section, a length, and a circumferential area. Components A and B can be arranged in substantially different zones across the cross-section of the bi-component filaments and can extend continuously along the length of the bi-component filaments. The secondary component B forms at least a portion of the circumferential area of ​​the bi-component filaments continuously along the length of the bi-component filaments. The polymer components A and B can be melt-spun into multi-component fibers on conventional melt-spinning equipment.The equipment is selected based on the desired multi-component configuration. Commercially available melt spinning equipment is supplied by Hills, Inc., located in Melbourne, Florida. The spinning temperature ranges from approximately 180°C to approximately 230°C. The processing temperature is determined by the chemical nature, molecular weights, and concentration of each component. The spunbond bicomponent filaments can have an average diameter of approximately 6 to approximately 40 micrometers, and preferably approximately 12 to approximately 40 micrometers.

[0030] Components A and B can either be arranged side-by-side, as shown in Fig. 5A shown, arranged, or in an eccentric shell / core arrangement, as shown in Fig. 5B is shown to obtain filaments exhibiting a natural helical crimp. Alternatively, components A and B can be arranged in a concentric mantle core arrangement, as shown in Fig. 5C shown. Additionally, components A and B can be arranged in a multilobal mantle / core arrangement, as shown in Fig. Figure 6 shows that other multi-component fibers can be produced using the compositions and processes of this disclosure. The bi-component and multi-component fibers can be arranged in a pie-slice, ribbon, or sea-island configuration, or any combination thereof. The sheath can be continuous or discontinuous around the core. The sheath-to-core weight ratio is from about 5:95 to about 95:5. The fibers of this disclosure can have different geometries, including round, elliptical, star-shaped, rectangular, and other various eccentricities.

[0031] Methods for extruding multi-component polymer filaments into such arrangements are widely known to those skilled in the art according to the prior art.

[0032] A wide variety of polymers are suitable for carrying out the present disclosure, including polyolefins (such as polyethylene, polypropylene and polybutylene), polyesters, polyamides, polyurethanes, elastomeric materials and the like.Non-restrictive examples of polymer materials that can be spun into filaments include natural polymers such as starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, chitin, chitosan and polyisoprene (cis and trans), peptides, polyhydroxyalkanoates, and synthetic polymers, including, but not limited to, thermoplastic polymers such as polyesters, nylons, polyolefins such as polypropylene, polyethylene, polyvinyl alcohol and polyvinyl alcohol derivatives, sodium polyacrylate (absorbent gel material), and copolymers of polyolefins such as polyethylene-octene or polymers with monomeric mixtures of propylene and ethylene, and biodegradable and compostable thermoplastic polymers such as polylactic acid filaments, polyvinyl alcohol filaments, and polycaprolactone filaments.In one example, the thermoplastic polymer is selected from the group consisting of: polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, styrene-butadiene-styrene block copolymer, polyurethane, and mixtures thereof. In another example, the thermoplastic polymer is selected from the group consisting of: polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, and mixtures thereof. Alternatively, the polymer can include one derived from bio-based monomers, such as bio-based polyethylene or bio-based polypropylene.

[0033] The primary component A and the secondary component B can be selected such that the resulting two-component filament provides improved nonwoven bonding and substrate flexibility. The primary polymer component A has a melting temperature that is lower than the melting temperature of the secondary polymer component B.

[0034] The primary polymer component A can comprise polyethylene or a statistical copolymer of propylene and ethylene. The secondary polymer component B can comprise polypropylene or a statistical copolymer of propylene and ethylene. Polyethylenes include linear low-density polyethylene and high-density polyethylene. Additionally, the secondary polymer component B can include additives to enhance the natural helical crimp of the filaments, lower the bonding temperature of the filaments, and improve the abrasion resistance, strength, and softness of the resulting fabric.

[0035] Inorganic fillers such as the oxides of magnesium, aluminum, silicon, and titanium can be added as cost-effective fillers or processing aids. Other inorganic materials include hydrated magnesium silicate, titanium dioxide, calcium carbonate, clay, chalk, boron nitride, limestone, diatomaceous earth, mica quartz, and ceramics.

[0036] The filaments of the present invention also contain a lubricant additive in an amount sufficient to impart the desired tactile quality to the fiber. As used herein, "lubricant additive" or "lubricant" means an external lubricant. Upon melting with the resin, the lubricant gradually separates or migrates to the surface during cooling or after manufacture, forming a uniform, invisibly thin coating, which provides permanent lubrication. The lubricant is preferably a fast bloom lubricant and may be a hydrocarbon with one or more functional groups selected from hydroxide, aryl and substituted aryls, halogens, alkoxys, carboxylates, esters, unsaturated carbons, acrylates, oxygen, nitrogen, carboxyl, sulfate, and phosphate.

[0037] During manufacturing, in a post-treatment, or both, the nonwoven fabric of the present invention can be treated with surfactants or other agents to make the web hydrophilic or hydrophobic. This is standard practice for nonwovens used in absorbent articles. For example, a nonwoven fabric used for a top layer can be treated with a hydrophilizing material or surfactant to make it permeable to bodily excretions such as urine. For other absorbent articles, the top layer can remain in its natural hydrophobic state or be made even more hydrophobic by the addition of a hydrophobizing material or surfactant.

[0038] Suitable materials for the manufacture of the multi-component filaments of the substance of the present disclosure include PH-835 polypropylene, available from LyondellBasell and Aspun-6850-A polyethylene, available from Dow Chemical Company.

[0039] If polyethylene is component A (sheath) and polypropylene is component B (core), the bicomponent filaments can comprise approximately 5 to approximately 95 wt% polyethylene and approximately 95 to approximately 5 wt% polypropylene. Alternatively, the filaments can comprise approximately 40 to approximately 60 wt% polyethylene and approximately 60 to approximately 40 wt% polypropylene.

[0040] Let us turn Fig. 7, where a representative production line 30 for the manufacture of material 10 of the present disclosure is disclosed. The production line 30 is arranged to produce a material from bicomponent continuous filaments, but it is understood that the present disclosure includes nonwovens manufactured with mono- or multicomponent filaments with more than two components. Bicomponent filaments may be trilobal.

[0041] Production line 30 comprises a pair of extruders 32 and 34, each driven by extruder drives 31 and 33, to extrude the primary polymer component A and the secondary polymer component B separately. Polymer component A is fed into each extruder 32 from a first hopper 36, and polymer component B is fed into each extruder 34 from a second hopper 38. From extruders 32 and 34, polymer components A and B can be fed through respective polymer lines 40 and 42 into filters 44 and 45 and melt pumps 46 and 47, which pump the polymer into a spinning pack 48. Spindles for extruding bicomponent filaments are well known to those skilled in the art and are therefore not described in detail here.

[0042] In general terms, the spinning package 48 comprises a housing enclosing a plurality of plates stacked one on top of the other, with a pattern of openings arranged to create flow paths for the separate guiding of polymer components A and B through the spinneret. The spinning package 48 has openings arranged in one or more rows. The spinneret openings form a downward-extending curtain of filaments as the polymers are extruded through the spinneret. For the purposes of this disclosure, spinnerets can be arranged to form sheath / core or side-by-side two-component filaments that are extruded into the Fig. 5A, Fig. 5B and Fig. 5C are illustrated, as well as non-circular fibers, such as trilobal fibers as in Fig. Figure 6 is shown. Furthermore, the fibers can be a single component comprising a polymer component, such as polypropylene.

[0043] Production line 30 also includes a quench blower 50, which is positioned adjacent to the curtain of filaments extending from the spinneret. Air from the quench blower 50 quenches the filaments extending from the spinneret. The quench air can be directed from one side of the filament curtain or from both sides of the filament curtain.

[0044] A damper 52 is positioned below the spinneret and receives the quenched filaments. Fiber drawing units or aspirators for use as dampers in melt-spun polymers are widely known. Suitable fiber drawing units for use in the process of the present disclosure include a linear fiber damper of the type shown in US 3,802,817 A and eductive guns of the type shown in US 3,692,618 A and US 3,423,266 A, the disclosures of which are incorporated by reference.

[0045] In general terms, the damper 52 comprises an elongated vertical passage through which the filaments are drawn by the intake of air that enters from the sides of the passage and flows downwards through it. A shaped, endless, at least partially foraminous forming belt 60 is positioned below the damper 52 and receives the continuous filaments from the outlet opening of the damper 52. The forming belt 60 is a belt and runs around the guide rollers 62. A vacuum 64, positioned below the forming belt 60 where the filaments are deposited, presses the filaments against the forming surface. Although the forming belt 60 is described as a belt in Fig. As shown in Figure 8, it is understood that the forming belt can also take other forms, such as a drum. Details of specific shaped forming belts are explained below.

[0046] During operation of production line 30, hoppers 36 and 38 are filled with the respective polymer components A and B. The polymer components A and B are melted and extruded through polymer lines 40 and 42 and the spinning pack 48 via the respective extruders 32 and 34. Although the temperatures of the molten polymers vary depending on the polymers used, when polyethylene and polypropylene are used as primary component A and secondary component B, respectively, the temperatures can range from approximately 190 °C to approximately 240 °C.

[0047] As the extruded filaments extend below the spinneret, an airflow from the quench blower 50 at least partially quenches the filaments, inducing the crystallization of molten filaments in certain fibers. The quench air can flow in a direction substantially perpendicular to the length of the filaments at a temperature of approximately 0 °C to approximately 35 °C and a speed of approximately 100 to approximately 400 feet per minute. The filaments can be sufficiently quenched before being collected on the forming belt 60 so that the compressed air, which passes through the filaments and the forming surface, can align them.Quenching the filaments reduces their stickiness, preventing them from sticking too tightly to each other before joining, and allowing them to be moved or arranged on the forming belt during filament gathering and web formation.

[0048] After quenching, the filaments are drawn into the vertical passage of the damper 52 by a flow from the fiber drawing unit. The damper can be positioned 30 to 60 inches below the base of the spinneret.

[0049] The filaments can be deposited through the outlet opening of the damper 52 onto the shaped, moving forming belt 60. While the filaments are in contact with the forming surface of the forming belt 60, the vacuum 64 draws the air and fibers against the forming belt 60 to form a nonwoven web of continuous filaments that assume a shape corresponding to the shape of the forming surface. As described above, because the filaments are quenched, they are not too sticky, and the vacuum can move or arrange the filaments on the forming belt 60 as they are collected and formed into the fabric 10.

[0050] Production line 30 further includes one or more binding devices, such as the cylindrical compression rollers 70 and 72, which form a roller gap through which the fabric can be compacted, i.e., calendered, and which can be heated to also bind fibers. One or both of the compression rollers 70, 72 can be heated to provide improved properties and benefits for the nonwoven fabric 10 by joining sections of the fabric. For example, it is assumed that heating sufficient to provide thermal bonding improves the tensile strength properties of the fabric 10. The compression rollers can be a pair of smooth-surface stainless steel rollers with independent heating controls. The compression rollers can be heated by electric elements or hot oil circulation.The roller gap between the compaction rollers can be hydraulically controlled to apply a desired pressure to the material as it passes through the compaction rollers on the forming belt. In an embodiment with a forming belt thickness of 1.4 mm and a spunbond nonwoven with a base weight of 30 grams per square meter, the roller gap between compaction rollers 70 and 72 can be approximately 1.4 mm.

[0051] In one embodiment, the upper compaction roller 70 can be heated sufficiently to melt binding fibers on the first surface 12 of the fabric 10, thereby giving the fabric strength so that it can be removed from the forming belt 60 without loss of integrity. As in the Fig. 8 and Fig. As shown in Figure 9, when, for example, rollers 70 and 72 rotate in the direction indicated by the arrows, the tape 60 with the spunbond nonwoven fabric laid on it enters the roller gap formed by rollers 70 and 72. The hot roller 70 can heat the sections of the nonwoven fabric 10 that are pressed against it by the raised resin elements of tape 60, i.e., in areas 21, to produce bonded fibers 80 on at least the first surface 12 of fabric 10. As can be understood from the description herein, the bonded areas thus formed can adopt the pattern of the raised elements of the forming tape 60. For example, the bonded areas thus formed can be an essentially continuous network or an essentially semi-continuous network on the first surface 12 of areas 21, which exhibit the same pattern as the hearts of Fig. 1 and Fig. 11. By adjusting the temperature and residence time, the bonding can be primarily limited to fibers that are closest to the first surface 12, or a thermal bond to the second surface 14 can be achieved, as in Fig. 11 is shown (which also represents point bindings 90, as discussed in more detail below), and Fig. 45-49. The bond can also be a discontinuous network, for example as point bonds 90, as discussed below.

[0052] The raised elements of the forming strip 60 can be selected to produce different network properties of the forming strip and the connected areas of the nonwoven substrate 11 or the nonwoven fabric 10. The network corresponds to the resin that forms the raised elements of the forming strip 60 and can comprise essentially continuous, essentially semi-continuous, discontinuous options, or combinations thereof. These networks can describe the raised elements of the forming strip 60 with respect to their appearance in the XY planes of the forming strip 60 or the three-dimensional features comprising the nonwoven substrate 11 or the nonwoven fabric 10 of the present invention.

[0053] An "essentially continuous" network refers to an area in which any two points can be connected by an unbroken line that runs completely within the area along its entire length. This means that the essentially continuous network has "continuity" in all directions parallel to the first plane and is only terminated at the edges of this area. The term "essentially" in conjunction with "continuous" is intended to indicate that, while absolute continuity can be achieved, minor deviations from absolute continuity may be tolerable as long as these deviations do not noticeably affect the performance characteristics of the fiber structure (or a compression molding element) according to its design and planning.

[0054] A “substantially semi-continuous” network refers to an area that has “continuity” in all, or at least one, directions parallel to the first plane, where no two arbitrary points on this area can be connected by an unbroken line that lies entirely within the area along its entire length. The semi-continuous framework may also exhibit continuity in only one direction parallel to the first plane. Analogous to the continuous region described above, while absolute continuity in all directions, or at least in one direction, is preferred, slight deviations from such continuity may be tolerable as long as these deviations do not noticeably impair the performance characteristics of the fiber structure.

[0055] “Discontinuous” network refers to individual and separate surfaces that are discontinuous in all directions parallel to the first level.

[0056] After compaction, the material can leave the forming belt 60 and be calendered through a roller gap formed by calender rollers 71, 73, and subsequently the material can be wound onto a roll. As shown in the schematic cross-section of Fig. As shown in Figure 10, the calender rolls can be stainless steel rolls with an engraved pattern roll 84 and a smooth roll 86. The engraved roll can have raised sections 88 that can provide additional compaction and bonding to the fabric 10. The raised sections 88 can be a regular pattern of relatively small, spaced-apart "pins" that form a pattern of relatively small dot bonds 90 in the roll gap of the calender rolls 71 and 73. The percentage of dot bonds in the nonwoven fabric 10 can range from 3% to 30% or from 7% to 20%.

[0057] The engraved pattern can be a variety of closely spaced, regular, generally cylindrical, and generally flat-tipped pin shapes, with pin heights ranging from 0.5 mm to 5 mm and preferably from 1 mm to 3 mm. Pin-jointing calender rollers can form closely spaced regular dot bonds 90 in the nonwoven fabric 10, as shown in Fig. Figure 11 shows further bonding methods. Other bonding techniques can be used, for example, by hot air gluing.

[0058] As with reference to the following Fig. As described in section 56, the air-through bonding process can be another approach to producing higher-volume nonwoven structures suitable for this application. The air-through bonding process involves applying hot air to the surface of the nonwoven fabric. The hot air flows through holes in a plenum located directly above the nonwoven. However, unlike conventional hot-air ovens, the air is not forced through the nonwoven. Negative pressure, or suction, draws the air through the open conveyor skirt that supports the nonwoven as it passes through the oven. Drawing the air through the nonwoven allows for much faster and more uniform heat transfer and minimizes fabric deformation. Beyond conventional air-through bonding units, it would be conceivable to place the bonding unit on top of the 3D tape while maintaining a vacuum beneath the tape to mimic the air-through bonding process for this specific application.

[0059] Binders used in the air-bonding process include crystalline binder fibers, bicomponent binder fibers, and powders. When using crystalline binder fibers or powders, the binder melts completely, forming molten droplets within the cross-section of the nonwoven. Bonding occurs at these droplets upon cooling. In the case of sheath / core binder fibers, the sheath is the binder and the core is the carrier fiber. In one embodiment, for a nonwoven comprising sheath / core binder fibers, the sheath comprises polyethylene and the core comprises polypropylene. For such a nonwoven, the air-bonding process temperature can range from 110°C to 150°C, and the residence time can range from 0.5 to 10 seconds, 5 to 30 seconds, or 30 to 60 seconds, as the air-bonding time depends on the base weight, the desired strength, and the processing speed.Products manufactured using forced-air ovens tend to be bulky, open, soft, firm, stretchy, breathable, and absorbent.

[0060] Spot bonding, as used here, is a method for thermally bonding a nonwoven fabric, web, or substrate. This method involves passing a web through a nip between two rollers, consisting of a heated, outward-facing, patterned or engraved metal roller and a smooth or patterned metal roller. The outward-facing patterned roller may have a variety of raised, generally cylindrical pins that create circular spot bonds. The smooth roller may or may not be heated, depending on the application. In a nonwoven production line, the fabric, which could be an unbonded fiber web, is fed into the calender nip, and the fiber temperature is raised to the point where fibers thermally fuse together at the tips of the engraved spots and against the smooth roller.The heating time is typically on the order of milliseconds. The material properties depend on process settings such as roll temperatures, web speeds, and roll gap pressures, which can be determined by a person skilled in the art for the desired degree of spot bonding. Other types of spot bonding, commonly known as hot calender bonding, can consist of different geometries for the bonds (other than circular), such as oval, linear, circular, etc. In the exemplary embodiment disclosed herein, the spot bonding produces a pattern of spot bonds consisting of circles with a diameter of 0.5 mm and a total bond area of ​​10%. Other embodiments include bond shapes in which the raised pins have a longest dimension of about 0.1 mm to 2.0 mm across the bonding surface of a pin, and the total bond area ranges from 5% to 30%.

[0061] As in Fig. As shown in Figure 11, in one embodiment the heated compaction roller 70 can form a bonding pattern which is a substantially continuous net bonding pattern 80 (e.g. interconnected heart-shaped bonds) on the first surface 12 of nonwoven fabric 10 (in Fig. (11 not shown, as it is turned away from the viewer) and the engraved calender roll 73 can form relatively small spot bonds 90 on the second surface 14 of fabric 10. The spot bonds 90 secure loose fibers that would otherwise be prone to fuzzing or pilling during use of the fabric 10. The advantage of the resulting structure of the nonwoven fabric 10 is most evident when it is used as the top layer in a hygiene product, such as a diaper or sanitary napkin. When used in a hygiene product, the first surface 12 of the nonwoven fabric 10 can be relatively flat (relative to the second surface 14) and have a relatively large number of bonds, because the heated compaction roll forms bonds 80 on the areas of the fabric that are pressed through the raised elements of the forming belt 60.This bond gives the nonwoven fabric 10 structural integrity, but can be relatively stiff or rough against a user's skin. Therefore, the first surface 12 of the nonwoven fabric 10 in a diaper or sanitary napkin can be oriented so that it faces the inside of the article, i.e., away from the wearer's body. Likewise, the second surface 14 can face the body and be in contact with it during use. The relatively small dot bonds 90 are less likely to be perceived visually or tactilely by the user, and the relatively soft three-dimensional features remain visually free of lint and pilling during use, while feeling soft to the touch. Another bond can be used instead of, or in addition to, the bond mentioned above.

[0062] The shaping tape 60 can be manufactured according to the methods and processes described in US 6,610,173 A, issued to Lindsay et al. on August 26, 2003, or US 5,514,523 A, issued to Trokhan et al. on May 7, 1996, or US 6,398,910 A, issued to Burazin et al. on June 4, 2002, or US 2013 / 0199741A1 published on behalf of Stage et al. on August 8, 2013, in each case with the improved features and patterns disclosed herein for the manufacture of spunbonded nonwoven webs. The disclosures made by Lindsay, Trokhan, Burazin and Stage hereby describe tapes that are representative of papermaking tapes made with hardened resin on a woven reinforcing element, these tapes, with improvements, being used as described herein.

[0063] An example of a shaping band 60 of the type useful in the present disclosure and which, according to the disclosure of US 5 514 523 A, is in Fig. Figure 12 illustrates this. As shown therein, a reinforcing element 94 (such as a woven band of filaments 96) is thoroughly coated with a liquid photosensitive polymeric resin to a preselected thickness. A film or negative mask containing the desired repeating elements of the raised element pattern (e.g., Fig. 14) is arranged side by side on the liquid photosensitive resin. The resin is then exposed to light of a suitable wavelength through the film, such as UV light for a UV-curable resin. This light exposure causes the resin to cure in the exposed areas (i.e., in the white or unprinted sections in the mask). Uncured resin (resin beneath the opaque areas in the mask) is removed from the system, leaving the cured resin, which forms the pattern shown, for example, the cured resin elements 92 in Fig. 12. Other patterns can also be formed, as discussed herein.

[0064] Fig. Figure 12 shows a section of a shaping belt 60, which is used to produce the in Fig. The nonwoven fabric 10 shown is useful. As shown, the forming tape 60 can contain cured resin elements 92 on a woven reinforcing element 94. The reinforcing element 94 can be made of woven filaments 96, as is known in the field of papermaking tapes, including resin-coated papermaking tapes. The cured resin elements can have the general structure described in Fig. 12 is shown, and are achieved by using a mask 97 with the in Fig. 14 dimensions shown. As in the schematic cross-section in Fig. As shown in Figure 13, the hardened resin elements 92 flow around and are cured to be “fixed” to the reinforcing element 94, and can have a width at a distal end DW of about 0.020 in to about 0.060 in, or of about 0.025 in to about 0.030 in, and an overall height above the reinforcing element 94, referred to as the top layer, OB, of about 0.030 in to about 0.120 in or about 0.50 in to about 0.80 in, or about 0.060 in. Fig. Figure 14 shows a section of a mask 97, which illustrates the design and representative dimensions for a repeating unit of the repeating heart design in the Fig. The nonwoven fabric 10 shown in Figure 1 is represented. The white section 98 is transparent to UV light and allows, during the tape manufacturing process as described in US 5,514,523 A, UV light to cure an underlying resin layer, which is cured to form the raised elements 92 on the reinforcing element 94. After removal of the uncured resin, the forming tape 60, which has a cured resin design as shown in Figure 1, is applied. Fig. 12 shown, produced by sewing the ends of a length of the band, the length of which can be determined by the design of the device, as shown in Fig. 7 shown.

[0065] Likewise, Fig. 15 represents a section of a mask 97, which represents the design for a repeating unit of the repeating design in the Fig. The nonwoven fabric 10 shown in Figure 2 represents the white section 98, which is transparent to UV light. During the tape manufacturing process, this allows UV light to cure an underlying resin layer, which then hardens to form the reinforcing element 94. After removing the uncured resin, the forming tape 60, which contains a cured resin structure as shown in Figure 2, is used to create the reinforcing element 94. Fig. 16 shows, produced by sewing the ends of a length of the band, the length of which can be determined by the design of the device, as in Fig. 7 shown.

[0066] Furthermore, in another, non-restrictive example Fig. 17 represents a section of a mask that represents the design for a repeating unit of the repeating design in the Fig. The nonwoven fabric 10 shown in Figure 18 represents the white section 98, which is transparent to UV light. During the tape manufacturing process, this allows UV light to cure an underlying resin layer, which then hardens to form the reinforcing element 94. After washing off the uncured resin, the shaping tape 60 is finished with a cured resin design, as shown in Figure 18. Fig. 18 shown, produced by sewing together the ends of a length of fabric 10.

[0067] Another example of a portion of a shaping band 60 of the type that is useful in the present disclosure is given in Fig. 19 shown. The section of the shaping band 60, which is in Fig. Figure 19 shows a separate tape pattern 61, which can have a length L and a width W corresponding to the length L and width W of the total area OA of a nonwoven fabric 10. That is, the shaping tape 60 can have separate tape patterns 61 (as explained in more detail below with reference to Figure 19). Fig. 22 is discussed), each of which has a separate total area DPOA of the ribbon pattern, which corresponds to the total area OA of the nonwoven fabric 10. Fig. 20 represents a section of a mask that defines the design for a repeating unit of the repeating design in the Fig. The nonwoven fabric 10 shown in Figure 21 represents the white section 98, which is transparent to UV light. During the tape manufacturing process, this allows UV light to cure an underlying resin layer, which then hardens to form the reinforcing element 94. After washing off the uncured resin, the shaping tape 60 is finished with a cured resin design, as shown in Figure 21. Fig. 19 shown, produced by sewing together the ends of one length of the band.

[0068] The section of the shaping band that is in Fig. Figure 19 illustrates a further advantage of the present disclosure. The section of a shaping band 60, which is shown in Fig. As shown in 19, one can in Fig. The material shown in 21 forms 10. The one in Fig. The nonwoven fabric 10 shown in Figure 21 can have dimensions of a width W and a length L, as well as a total area OA, which makes it suitable, for example, for use as a top layer in a disposable diaper. The nonwoven fabric 10, which is produced on a forming belt 60, as shown in Figure 21, ... total area OA, which makes it suitable, for example, for use as a top layer in a disposable diaper. Fig. 19 illustrates, differs from that in the Fig. Figures 1-3 show that the pattern of three-dimensional features formed by the separate resin elements 92 on the forming strip 60 is not present in a normal, repeating pattern across the entire surface. Accordingly, the pattern of three-dimensional raised elements in the separate strip pattern surface DPOA can be described as an irregular pattern comprising different sections, which are referred to as zones. The difference between the zones may be optical, i.e., a visually perceptible difference, or the difference may produce different average intensive properties in the nonwoven fabric 10, such as base weight or density, or combinations of optical and intensive properties.An optically discernible difference exists if an observer under normal indoor lighting conditions (e.g., 20 / 20 visibility, sufficient light for reading) can visually perceive a pattern between the zones, such as the first zone 112 and the second zone 122.

[0069] The nonwoven fabric 10 can also have visually identifiable zones that correspond to the zones of the shaping tape. As in Fig. As shown in Figure 21, the fabric 10 can, for example, have at least two, three, or four optically identifiable zones. A first zone 110 with a first pattern of three-dimensional features and the first average intensity properties can have a first area located substantially centrally within the total area OA. A second zone 120 with a second pattern of three-dimensional features and second average intensity properties can have a second area which, in one embodiment, is generally distributed around and completely surrounds the first zone 110 within the total area OA. A third zone 130 with a third pattern of three-dimensional features and third average intensity properties can have a third area which, in one embodiment, is generally distributed around and completely surrounds the second zone 120 within the total area OA.A fourth zone 140 with fourth three-dimensional features and fourth average intensity properties can have a fourth area that is positioned at any location within the total area OA, such as at a front area of ​​an upper layer, such as the one in . Fig. The heart design shown in Figure 21 is shown. In general, there can be n zones, where n is a positive integer. Each of the n zones can have an nth pattern of three-dimensional features, an nth area, and nth average intensity properties.

[0070] The visually identifiable zones, as in Fig. Figure 21 shows that three-dimensional features can include visually identifiable features. These different three-dimensional features can be bounded by areas of relatively high density (with respect to the interior of a three-dimensional feature) in the form of a closed figure, such as the heart in the Fig. 1 and Fig. 3, and the diamond shape in the Fig. 2 and Fig.3. In general, the three-dimensional features, as discussed in more detail below, including in the context of microzones, can be defined by a first region and a second region, wherein the first region and the second region are visually distinct from each other and there is a common intensive property assigned to each of the first and second regions, and there is a difference in the common intensive property value of the first region and the second region. In one embodiment, the three-dimensional features can be defined by a first region and a second region, wherein the first region is located at a higher height (dimension measured in the Z-direction) relative to the plane of the first surface than the second region.In another embodiment, the three-dimensional features can be defined by a first area and a second area, the first area being on a higher base than the second area.

[0071] As can be seen, instead of having a constant, repeating pattern that is uniformly distributed over the entire forming strip, the forming strip 60 of the present disclosure enables the production of a nonwoven fabric having repetitions of irregular separate strip patterns 61, each separate strip pattern 61 being like the one in Fig.The individual tape patterns 61 shown in Figure 19 are separate. Each of these tape patterns can be used to form a nonwoven fabric 10 with a total area OA suitable for use in a disposable absorbent product, such as a diaper or sanitary napkin. The nonwoven fabrics 10 can be produced sequentially, i.e., in a row, and optionally one after the other in parallel production webs, each production web being a sequential row of nonwoven fabrics 10. The sequential row of nonwoven fabrics 10 can be produced in a machine direction along an axis parallel to the machine direction. The nonwoven material can then be slit or otherwise cut to produce nonwoven fabrics 10 that can be used as top layers in disposable absorbent products, such as diapers or sanitary napkins.

[0072] In one embodiment, the pattern within each separate DPOA band pattern area can be the same or different. That is, the sequentially spaced separate band patterns can be essentially identical, or they can differ from one another in their optical appearance and / or in their intensive properties produced in nonwoven substrates manufactured on them. For example, as schematically shown in Fig.Figure 22 shows that the patterns of three-dimensionally raised elements in the first forming zone 112 differ from the separate band pattern 61A and from the pattern of the three-dimensionally raised elements in the first forming zone 112 from the separate band pattern 61B. The forming band 60 thus offers flexibility in the production of nonwoven webs 10 suitable for use in consumer goods, including disposable absorbent products. For example, in a diaper pack, the top layers of at least two diapers may differ from each other because they were produced sequentially in a spunbond process as described herein, wherein sequential separate band patterns have different zone patterns. In one embodiment, the nonwoven pattern of the top layer or the bottom layer for one diaper size may differ from the nonwoven pattern of the top layer or bottom layer of another diaper size, thus providing a caregiver with a visual indication of the diaper size.Similarly, sanitary napkins can use a fabric 10 for an upper layer, where the optical pattern of three-dimensional features indicates the absorbency of the sanitary napkin. In any case, the various structures of the fabrics 10 can be produced on a single tape, with the separate tape patterns being manufactured differently as desired.

[0073] Thus, the invention can be described with reference to Fig.22 is described as a forming belt with an axis A parallel to a longitudinal direction, which is a machine direction. The forming belt 60 can have a plurality of separate belt patterns 61 arranged in at least one sequential relationship with respect to the longitudinal direction. Each separate belt pattern 61 can have a separate belt pattern total area DPOA, defined in a rectangular pattern by a length L and width W, as specified with reference to the separate belt pattern 61A. Each individual belt pattern can have, within its total area DPOA, a first forming zone 112 with a first pattern of three-dimensionally raised elements extending outward from the plane of the first surface, and a second forming zone 122 with second three-dimensionally raised elements extending outward from the plane of the first surface.The first shape zone can have a first air permeability value, and the second shape zone can have a second air permeability value, and the first air permeability value can differ from the second air permeability value. The pattern within each sequentially ordered separate band pattern total area DPOA can be the same or different.

[0074] As an example, and with reference to the individual band pattern 61 of the shaping band 60, which is in Fig. 19 is shown, and the fleece 10, which is in Fig.As shown in Figure 21, the following properties were determined. The first zone 110 of the nonwoven fabric 10 can have an average base weight of approximately 5 grams per square meter to approximately 30 grams per square meter; the second zone 120 can have an average base weight of approximately 50 grams per square meter to approximately 70 grams per square meter; and the third zone 130 can have an average base weight of approximately 25 grams per square meter to approximately 60 grams per square meter. The difference in base weight from one zone to the next can be attributed to a difference in the air permeability of the forming strip 60. In the embodiment used for the production of the nonwoven fabric 10, which is shown in Figure 21, the following properties are determined: Fig.As shown in Figure 20, where the base weights for zones 110, 120, and 130 are 15 grams per square meter, 53 grams per square meter, and 25 grams per square meter respectively, the air permeability of the respective zones 112, 122, and 132 of the forming strip 60 is 379 cubic feet per minute, 805 cubic feet per minute, and 625 cubic feet per minute, respectively. Thus, by varying the air permeability in the zones within the forming strip 10, the intensive properties of the average base weight and average density in the zones can be facilitated across the entire surface of the fabric 10.

[0075] As can be seen from the description of the shaping band 60, which is in Fig. 22 and with reference to Fig.As described in Section 23, the nonwoven substrate 11 produced on belt 60 can in one embodiment be described as a nonwoven substrate 11 with a plurality of sections described herein as material 10 which are arranged during production on the forming belt 60 in at least one sequential relationship with respect to the longitudinal direction, i.e., in the machine direction. Fig.Figure 23 is a schematic representation of a spunbond nonwoven substrate 11, which represents sequentially ordered fabrics 10, each fabric 10 having a different pattern within the different zones. Each fabric 10 can have a total area OA defined in a rectangular pattern by a length L and a width W. Each sequentially arranged fabric 10 can have, within its total area OA, at least a first zone 110 with a first pattern of three-dimensional features and first average intensive properties, and a first region located within the total area OA; a second zone 120 with a second pattern of three-dimensional features and second average intensive properties, with a second region located substantially within the total area OA. Optionally, more zones, e.g.,A third zone 130 with a third pattern of three-dimensional features and a third average intensity property, and with a third area within the total area OA, may be present. As shown in the exemplary schematic representation of . Fig. As shown in Figure 23, the first pattern 110A of fabric 10A may differ from the first pattern 110B of fabric 10B and may differ from the first pattern 110C of fabric 10C. The same may be true for the second zones 120A, 120B, and 120C.

[0076] In general, the sequentially ordered nonwovens 10 of the nonwoven material 11 produced on the forming belt 60 can vary in their respective total areas, intensive properties, and optical appearance. A common intensive property is an intensive property shared by more than one zone (with reference to a zonal pattern, such as the one in Fig.21 shown) or area (for three-dimensional features, such as the regular, repeating patterns, as in Fig. (as shown in Figure 1). Such intensive properties of the nonwovens 10 can be average values ​​and can include, without limitation, volumetric density, base weight, and thickness. If, for example, volumetric density is a common intensive property of two differential zones or areas, a volumetric density value in one zone or area may differ from a volumetric density value in the other zone or area. Zones (such as a first zone and a second zone) can be identifiable areas that can be distinguished from one another visually and by different intensive properties averaged within the zone.

[0077] After production, the individual nonwovens 10 can be cut to size and used for their intended purposes, such as for top layers in disposable absorbent products. For example, a disposable diaper 1006 in a spread-out orientation in Fig. Figure 24 illustrates this. A fabric 10 is cut to the appropriate total area and glued into the diaper 1006 using methods known in the trade. Fabrics 10 can be cut into a diaper 1006 before assembly, or during the diaper manufacturing process, the nonwoven substrate 11 can be formed into a web with other diaper components and cut to size after assembly.

[0078] As with reference to Fig.As can be seen from Figure 24, in one embodiment the nonwoven substrate 11 produced on belt 60 can be described as a nonwoven fabric 11 with a plurality of sections described herein as fabric 10, which are arranged during production on the forming belt 60 in at least one sequential relationship with respect to the longitudinal direction, i.e., in the machine direction, and during production on the forming belt 60 in at least one side-by-side relationship, i.e., in the transverse direction. Fig. Figure 24 is a schematic representation of a spunbond substrate 11 and shows sequentially ordered material 10 in adjacent machine-direction production lanes 13, wherein the adjacent machine-direction production lanes have materials 10 arranged side by side, in Fig.Figure 24 illustrates 10D, 10E, and 10F. Each fabric 10 can have a total area OA defined in a rectangular pattern by a length L and a width W. Each sequentially arranged fabric 10 can, within its total area OA, have at least a first zone 110 with a first pattern of three-dimensional features and first average intensity properties, and a first area located within the total area OA; a second zone 120 with a second pattern of three-dimensional features and second average intensity properties, with a second area located substantially within the total area OA. Optionally, more zones can be present, e.g., a third zone 130 with a third pattern of three-dimensional features and a third average intensity property, and with a third area located within the total area OA.Each fabric 10 in adjacent production webs can be essentially identical, or they can differ from one another in terms of size, visual appearance, and / or intensive properties. After production, the nonwoven substrate 11 can be wound into production webs for processing into consumer products, or it can be slit and then wound.

[0079] By using a representative sample for comparing base weight differences in a fabric 10 produced with a regular, repeating, uniform pattern and a fabric 10 with a non-uniform, zonal pattern, the nonwoven fabric 10 of Example 1 was compared with a fabric having a pattern similar to that in Fig.21 are compared and referred to as Example 3. Example 3 is a bicomponent spunbond nonwoven fabric produced on the apparatus disclosed herein by a spinning ratio of 50:50 of polyethylene sheath (Aspun-6850-A, available from Dow Chemical Company) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration. The trilobal spunbond bicomponent fibers were laid down on a forming belt 60 moving at a linear speed of about 25 meters per minute to an average base weight of 30 grams per square meter on a forming belt with a zonal pattern, as shown in Fig. 19. The second substrate was formed under identical conditions, but exhibited at least one section with a regular, repeating, uniform pattern on a shaping band, as shown in Fig.Figure 16 shows the basis weight from which the base weight was determined. The fiber spinning conditions, throughput, forming strip line speed, and compaction roller bonding temperature were identical for both substrates. Example 3

[0080] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration to an average basis weight of 30 grams per square meter. A nonwoven fabric was produced as described in the Fig. 7 and Fig. 8 described, manufactured and moved at a forming belt speed of approximately 25 meters per minute to produce a fabric with a zonal pattern as in Fig.20 is shown to form. The fibers of the fabric were further bound on the first surface 12 by heated compaction rollers 70, 72 at 130 °C and the fabric was wound onto a roll on the winder 75. Example 4

[0081] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration to an average basis weight of 30 grams per square meter. A nonwoven fabric was produced as described in the Fig. 7 and Fig. 8 described, manufactured and moved at a forming belt speed of approximately 25 meters per minute to produce a fabric with a repeating (non-zonal) pattern as in Fig.2 shown to form. The fibers of the fabric were further bound on the first surface 12 by heated compaction rollers 70, 72 at 130 °C, and were wound onto a roll at the winder 75.

[0082] Table 2 below shows the average local base weight, measured according to the localized base weight test procedure herein, and averaged over 10 samples. The samples for measurement were prepared from the substances as described in the Fig. 25A and Fig. 25B shows where the dark rectangles are, where a 3 cm 2 The sample was removed for measurement. As can be seen, the materials are labeled A - E across the transverse direction (CD). The measurements show not only a significant difference in base weight between the zones of the zonal material, but also a CD distribution that can be graphically represented in Fig. 26 is shown. Table 2: Measured average base weight distribution in nonwoven fabric 10 in grams per square meter (gsm) area as in Fig. 25 shown Example 3: Zonal base weights of fabric Example 4: Non-zonal fabric base weights A 48 grams per square meter 43 grams per square meter B 79 grams per square meter 37 grams per square meter C 14 grams per square meter 32 grams per square meter D 65 grams per square meter 36 grams per square meter E 54 grams per square meter 36 grams per square meter

[0083] As can be seen in Table 2, fabrics 10 produced on shaping belts 60 with zones of different air permeability exhibit a significant change in the fiber placement and thus in the base weights within the CD of nonwoven fabric 10, which suggests the ability of the fibers to move with air in zones of high permeability.

[0084] The non-zonal, repeating pattern fabric 10 has approximately the same base weights within the CD of the fabric.

[0085] In addition to differences in air permeability of the various zones of the forming tape 60, the structure of the forming tape 60 can influence other intensive properties of the zones in the fabric 10, such as average thickness, average softness, average compression resistance, and liquid absorption properties.

[0086] Another aspect of this invention relates to spunbond nonwoven production lines in which multiple beams are used to improve the layup, opacity, and uniformity of the fabric. In some cases, the apparatus may include triple spunbond nonwoven beams (known in the prior art as "SSS") and be combined with meltblowing devices (M), for example in an apparatus known as an "SSMMS" spunbond nonwoven line.

[0087] In the nonwoven fabric 10, calendering to create point connections 90 can reduce linting. The term "linting" refers to the tendency of fibers to loosen and detach from the fabric 10. This loosening and detachment can occur due to friction with the manufacturing equipment during the production of the disposable absorbent product or with another surface, such as a person's skin, that interacts with the fabric 10. In some applications, such as top layers in disposable absorbent products, linting is a negative consumer phenomenon. However, fiber binding in place can also be negative for consumers, as it can create roughness on the surface of an otherwise soft nonwoven substrate.We unexpectedly discovered that the nonwoven substrates and nonwovens of the present disclosure can withstand an increase in bonding (and consequently a reduction in pilling) with minimal loss of softness. Bonding can be achieved by relatively closely spaced spot ties, the spacing being determined by the desired degree of pilling reduction. Bonding can also be achieved by known methods for chemical or thermal bonding of nonwovens, such as thermal bonding, ultrasonic bonding, pressure bonding, latex adhesive bonding, and combinations of these methods. The pilling reduction by bonding is illustrated with reference to Examples 5 and 6 below. Example 5

[0088] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration to an average base weight of approximately 30 grams per square meter on a forming belt as described in the Fig. 7 and Fig. 8 was described as being produced under motion at a linear speed of about 25 meters per minute to create a fabric with the repeating pattern as in Fig. 36. Fibers of the material were further bound on a first surface 12 by compaction rollers 70, 72, the compaction roller 70 being heated to 130 °C to form substantially continuous bonds 80. Example 6

[0089] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration to an average base weight of approximately 30 grams per square meter on a forming belt as described in the Fig. 7 and Fig. 8 was described as being produced under motion at a linear speed of about 25 meters per minute to create a fabric with the repeating pattern as in Fig.37 described to form. Fibers of the fabric were further bound on a first surface 12 by compression rollers 70, 72, the compression roller 70 being heated to 130 °C to form substantially continuous bonds 80. The fibers of the fabric were further calendered on the calender rollers 71, 73, the roller 73 being an engraved roller with raised sections 88 in the form of pins with a pin height of 1.25 mm and an open gap of 0.62 mm in a 10% spot bond pattern. The roller 73 was heated to 135 °C to form spot bonds 90 on the second side 14 of fabric 10, as described in Fig. 11 shown.

[0090] The materials 10 of Examples 5 and 6 differed only in the absence or presence of the spot bonds 90. The second side 14 of the materials 10 was subjected to a pilling test according to the pilling degree test to determine the effectiveness of the spot bonds in securing fibers to the surface of the material. The results of the pilling test of Examples 5 and 6 are shown in Table 3. Table 3: MR fuzz formation results Sample No. MD lint formation value (mg / cm³) 2 ) Example 5 0,36 Example 6 0,19

[0091] As shown above, the spot ties 90 result in a dramatic decrease in the MD pilling value. It unexpectedly retained its softness, absorbency, and aesthetic advantages despite the tying treatment and now also exhibits the desired resistance to pilling during consumer use.

[0092] The absorbent products described in this disclosure are typically packaged for shipping, storage, and sale. The packaging may include polymer films and / or other materials. Graphics and / or markings relating to the properties of the absorbent products may be molded, printed, positioned, and / or placed on outer sections of the packaging. Each package may contain a variety of absorbent products. The absorbent products may be packaged under compression to reduce the size of the packages while still providing an adequate quantity of absorbent products per package. Packaged under compression, the absorbent products allow healthcare professionals to easily handle and store the packages, while also providing manufacturers with distribution savings due to the reduced package size. Fig.Figure 27 illustrates an example package 1000 containing a variety of absorbent articles 1004. The package 1000 defines an interior space 1002 in which the variety of absorbent articles 1004 are located. The variety of absorbent articles 1004 are arranged in one or more stacks 1006.

[0093] Packaging of the absorbent articles of the present disclosure may have a stacking height in the bag of less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 85 mm but greater than about 75 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm or less than about 74 mm, specifically indicating all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby, according to the test of the stacking height in the bag described herein.Alternatively, the packagings of the absorption articles of the present disclosure may have a stacking height in the bag of about 70 mm to about 100 mm, of about 70 mm to about 95 mm, of about 72 mm to about 85 mm, of about 72 mm to about 80 mm or of about 74 mm to about 78 mm, specifying all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby, according to the test of the stacking height in the bag described herein. General description of an absorption article

[0094] The three-dimensional nonwovens 10 of the present disclosure can be used as a component of absorbent articles such as diapers, children's care articles like training pants, hygiene articles like sanitary napkins, and adult articles such as incontinence products, pads, and briefs. An example of an absorbent article in the form of a diaper 220 is shown in the Fig. 28-30 shown. Fig.Figure 28 is a top view of the exemplary, flat-lying diaper 220, with sections of the structure removed to better illustrate the construction of the diaper 220. The carrier-side surface of diaper 220 in Fig. Figure 28 points towards the viewer. This diaper 220 is shown for illustrative purposes only, since the three-dimensional nonwoven materials of the present disclosure can be used as one or more components of an absorbent article, such as the top layer, the absorption layer, the top layer and the absorption layer, or the top layer and the absorption and / or distribution system (“ADS”). In any case, however, the three-dimensional nonwoven materials of the present disclosure can be liquid-permeable.

[0095] The absorbent article 220 can comprise a liquid-permeable material or top layer 224, a liquid-impermeable material or bottom layer 225, an absorbent core 228 positioned at least partially between the top layer 224 and the bottom layer 225, and barrier leg cuffs 234. The absorbent article can also include an ADS 250, which in the illustrated example comprises a distribution layer 254 and an absorption layer 252, which are discussed below. The absorbent article 220 can also include elasticized sealing cuffs 232 with rubber bands 233, which are connected to a basic unit of the absorbent article, usually via the top layer and / or bottom layer, and are essentially flush with the basic unit of the diaper.

[0096] The Fig. 28 and Fig.Figure 31 also represents common closure diaper components, such as a fastening system having tabs 242 that are attached towards the rear edge of the article and interact with an attachment zone 244 on the front of the absorbent article. The absorbent article may also include other common elements not shown, such as a rear elastic waistband, a front elastic waistband, transverse cuffs, and / or a lotion application.

[0097] The absorption article 220 may also have a front waistband 210, a rear waistband 212 opposite the front waistband 210 in the longitudinal direction, a first sideband 203, and a second sideband 204 opposite the first sideband 203 in the longitudinal direction. The front waistband 210 is the edge of the article that is to be placed toward the front of the user when worn, and the rear waistband 212 is the opposite edge. The absorption article 220 may have a longitudinal axis 280 extending from the lateral midpoint of the front waistband 210 to a lateral midpoint of the rear waistband 212 of the article, dividing the article into two substantially symmetrical halves with respect to the longitudinal axis 280 when the article is laid flat and viewed from above, as shown in Fig.28. The absorption article 220 may also have a transverse axis 290 extending from the midpoint along the length of the first side edge 203 to the midpoint along the length of the second side edge 204. The length L of the article may be measured along the longitudinal axis 280 from the front waist edge 210 to the back waist edge 212. The width W of the absorption article may be measured along the transverse axis 290 from the first side edge 203 to the second side edge 204. The absorption article may include a crotch point C, which is defined here as the point located on the longitudinal axis at a distance of two-fifths (2 / 5) of the article's length, starting from the front edge 210 of the article 220. The article may include a front waist area 205, a back waist area 206, and a crotch area 207.The front waist area 205, the back waist area 206 and the crotch area 207 can each define 1 / 3 of the length L in the longitudinal direction of the absorption article.

[0098] The top layer 224, the bottom layer 225, the absorption core 228 and the other components of the article can be assembled in a variety of configurations, in particular by, for example, gluing or hot stamping.

[0099] The absorption core 228 can comprise an absorption material comprising at least 80 wt.%, at least 85 wt.%, at least 90 wt.%, at least 95 wt.%, or at least 99 wt.% of the superabsorbent polymers, and a core wrap that encloses the superabsorbent polymers. The core wrap can typically comprise two materials, substrates, or nonwoven materials 216 and 216' for the top and bottom of the core. These types of cores are known as air-felt-free cores. The core can comprise one or more channels that are Fig. Figure 28 shows the four channels 226, 226' and 227, 227'. The channels 226, 226', 227 and 227' are optional features. The kernel can have no channels or any number of channels.

[0100] These and other components of the exemplary absorption articles will now be discussed in more detail. upper class

[0101] In the present disclosure, the top layer (the section of the absorbent article that is in contact with the skin of the wearer and absorbs the liquids) can be formed from a section of, or all of, one or more of the three-dimensional nonwovens described herein and / or have one or more of the nonwoven materials positioned thereon and / or connected to it, such that the nonwoven material(s) contact(s) the skin of the wearer. Other sections of the top layer (besides the three-dimensional nonwoven materials) can also contact the skin of the wearer. The three-dimensional nonwoven materials can be positioned as a strip or a patch on the usual top layer 224. Alternatively, the three-dimensional nonwoven material can form only a central CD region of the top layer.The middle CD area can extend over the entire MD length of the upper layer or less than the full MD length of the upper layer.

[0102] The upper layer 224 can be connected to the lower layer 225, the absorption core 228, and / or any other layers as is known to those skilled in the art. Normally, the upper layer 224 and the lower layer 225 are directly joined to each other at some locations (e.g., at or near the perimeter of the absorption article) and indirectly joined to each other at other locations by directly connecting them to one or more other elements of article 220.

[0103] The top layer 224 can be adapted to the wearer's skin, feel soft, and be non-irritating. Furthermore, at least one section of the top layer 224 can be fluid-permeable, allowing fluids to easily penetrate its thickness. In addition, a section of the top layer 224, or the entire top layer 224, can be treated with surfactants or other agents to either make the web hydrophilic or hydrophobic. Each section of the top layer 224 can be coated with a lotion and / or skin care composition, as is generally disclosed in the technology. The top layer 224 can also include or be treated with antibacterial agents. lower class

[0104] The underlayer 225 is generally the section of the absorbent article 220 that is positioned adjacent to the clothing-side surface of the absorbent core 228 and prevents, or at least inhibits, the excretions absorbed and contained therein from soiling items such as bed linen and underwear. The underlayer 225 is typically impermeable, or at least substantially impermeable, to liquids (e.g., urine). The underlayer may, for example, be or comprise a thin plastic film, such as a thermoplastic film with a thickness of approximately 0.012 mm to approximately 0.051 mm. Other suitable underlayer materials may include breathable materials that allow vapors to escape from the absorbent article 220 while continuing to prevent, or at least inhibit, liquids from passing through the underlayer 225.

[0105] The lower layer 225 can be connected to the upper layer 224, the absorption core 228 and / or any other element of absorption article 220 by fastening methods known to those skilled in the art.

[0106] The absorbent article may comprise a sublayer comprising an outer cover or outer cover nonwoven. An outer cover or outer cover nonwoven of the absorbent article 220 may cover at least a portion or all of the sublayer 225 to form a soft, apparel-side surface of the absorbent article. The outer cover or outer cover nonwoven may be formed from the high-volume, three-dimensional nonwoven materials described herein. Alternatively, the outer cover or outer cover nonwoven may comprise one or more known outer cover materials. If the outer cover comprises one of the three-dimensional nonwoven materials of this disclosure, the three-dimensional nonwoven material of the outer cover may correspond to a three-dimensional nonwoven material (i.e.,(same material, same pattern) or not, which is used as the top layer, or the top layer and the absorption layer, of the absorption article. In other cases, the outer cover may have a printed or otherwise applied pattern that matches or visually resembles the pattern of the three-dimensional nonwoven materials used as the top layer, or the top layer and absorption layer laminate, of the absorption article. The outer cover may be bonded to at least one section of the underlayer 225 by mechanical bonding, ultrasonic bonding, thermal bonding, adhesive bonding, or other suitable fastening methods. Absorption core

[0107] The absorbent core is the component of the absorbent article with the highest absorbency and comprises an absorbent material and a core wrap or core bag that encloses the absorbent material. The absorbent core does not include the uptake and / or distribution system or any other components of the absorbent article that are neither an integral part of the core wrap or core bag nor located within it. The absorbent core may include, consist substantially of, or be composed of a core wrap, an absorbent material (e.g., superabsorbent polymers and little or no cellulose fibers), as discussed, and adhesive.

[0108] The absorption core 228 may comprise an absorption material with a high amount of superabsorbent polymers (hereinafter referred to as "SAP") enclosed within the core shell. The SAP content may be 70 wt.%–100 wt.% or at least 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 90 wt.%, 95 wt.%, 99 wt.%, or 100 wt.% based on the weight of the absorption material contained within the core shell. The core shell is not considered as absorption material for the purpose of assessing the percentage of SAP in the absorption core. The absorption core may contain air felt with or without superabsorbent polymers.

[0109] The term "absorbent material" refers to a material that exhibits a certain degree of absorption or liquid-holding properties, such as SAP, cellulose fibers, and synthetic fibers. Adhesives used in the manufacture of absorbent cores typically have little or no absorption properties and are not considered absorbent material. The SAP content can be higher than 80 wt.%, for example, at least 85 wt.%, at least 90 wt.%, at least 95 wt.%, at least 99 wt.%, and even up to and including 100 wt.% of the weight of the absorbent material contained in the core casing. This air-filled core is relatively thin compared to a conventional core, which usually consists of between 40-60 wt.% SAP and a high cellulose fiber content. The absorbent material can, in particular, be less than 15 wt.% or less than 10 wt.%.-% natural, cellulosic or synthetic fibers, less than 5% by weight, less than 3% by weight, less than 2% by weight or less than 1% by weight, or even be essentially free of natural, cellulosic and / or synthetic fibers.

[0110] As stated above, the air-felt-free cores, containing very little or no natural cellulose and / or synthetic fibers, are very thin compared to conventional cores. This makes the overall absorbency product thinner than absorbency products with cores containing mixed SAP and cellulose fibers (e.g., 40–60% cellulose fibers). This core thickness may lead consumers to perceive reduced absorption and performance, although this is not technically the case. Currently, these thin cores are typically used with essentially flat or perforated top layers. Furthermore, absorbency products with these thin air-felt-free cores have a reduced capillary void due to the presence of little or no natural, cellulose, or synthetic fibers in the cores.Therefore, sometimes there may not be enough capillary space in the absorbent article to fully absorb multiple leaks of bodily excretions or a single large leak.

[0111] To solve such problems, the present disclosure provides absorbent articles with these thin, air-filled cores in combination with one of the high-volume, three-dimensional nonwoven materials described herein as the top layer, or as the top layer and absorption layer laminate. In such a case, the absorption and performance perceived by the consumer are increased thanks to the increased thickness of the absorbent article due to the additional thickness provided by the high-volume, three-dimensional nonwoven material. Furthermore, when used with these air-filled cores and as the top layer, or top layer and absorption layer laminate, the three-dimensional nonwovens add capillary voids to the absorbent article while still allowing for a minimal stack height, thereby passing on cost savings to consumers and manufacturers.Therefore, the absorbent articles of the present disclosure can easily absorb multiple leaks of bodily excretions or a single large leak through this increased capillary cavity. Additionally, absorbent articles comprising the nonwoven materials as a top layer, or top layer and absorbent layer laminate, offer consumers an aesthetically pleasing top layer compared to a flat top layer or a perforated top layer with increased thickness, thus improving consumer perceptions of absorbency and performance.

[0112] The exemplary absorption nucleus 228 of the absorption article 220 of the Fig. 31-32 is isolated in the Fig.Figures 33-35 illustrate. The absorption core 228 can have a front face 480, a back face 282, and two longitudinal sides 284, 286 connecting the front face 480 and the back face 282. The absorption core 228 also comprises a generally flat top and a generally flat bottom. The front face 480 of the core is the side of the core that is to be placed against the front waist edge 210 of the absorption article. The core 228 can have a longitudinal axis 280' that substantially corresponds to the longitudinal axis 280 of the absorption article 220, as shown in a top view and in a planar view as in Fig.28. The absorption material may be distributed in greater quantities towards the front 480 than towards the rear 282, as the front of the special absorption article may require higher absorption. The front and rear sides 480 and 282 of the core may be shorter than the longitudinal sides 284 and 286 of the core. The core sheath may be formed of two nonwoven materials, substrates, laminates, or other materials 216, 216', which may be sealed at least partially along the sides 284, 286 of the absorption core 228. The core sheath may be sealed at least partially along the front 480, the rear 282, and the two longitudinal sides 284, 286, such that substantially no absorption material can escape from the core sheath of the absorption article. The first material, substrate or nonwoven 216 can at least partially surround the second material, substrate or nonwoven 216', as shown in the illustration in Fig.34 to form the core encapsulation. The first material 216 can surround a section of the second material 216' near the first and second lateral edges 284 and 286.

[0113] The absorption core may contain an adhesive to immobilize, for example, the SAP polymers or other absorption materials within the core shell and / or to ensure the integrity of the core shell, particularly when the core shell consists of two or more substrates. The adhesive may be a hot-melt adhesive, such as that supplied by HB Fuller. The core shell may extend over an area larger than strictly necessary to accommodate the absorption material within it.

[0114] The absorption material can be a continuous layer present within the core shell. Alternatively, it can consist of individual pockets or strips of absorption material enclosed within the core shell. In the first case, the absorption material can be obtained, for example, by applying a single continuous layer of absorption material. The continuous layer of absorption material, particularly SAP, can also be obtained by combining two absorbing layers with discontinuous application patterns of absorption material, the resulting layer being, for example, as disclosed in US patent application Publication No. US 2008 / 0312622A1 for Hundorf et al., substantially continuously distributed over the surface of the absorption particle polymer material.The absorbing core 228 can have a first absorption layer and a second absorption layer. The first absorption layer can have the first material 216 and a first layer 261 of absorption material, which may have 100% or less SAP. The second absorption layer can have the second material 216' and a second layer 262 of absorption material, which may have 100% or less SAP. The absorbing core 228 can also have a fiber-containing thermoplastic adhesive material 251 that at least partially binds each layer of the absorbing material 261, 262 to the associated material 216 or 216'. This is shown as an example in [reference]. Fig.Figures 34-35 show the first and second SAP layers being applied as transverse strips or "application surfaces" such that they have the same width as the desired application area for absorbing material on their respective substrates prior to joining. The strips can contain varying amounts of absorbing material (SAP) to provide a profiled base weight along the longitudinal axis of the core 280. The first material 216 and the second material 216' can form the core encapsulation.

[0115] The fiber-containing thermoplastic adhesive material 251 can be in at least partial contact with the absorbent material 261, 262 in the contact surfaces, and it can be in at least partial contact with the materials 216 and 216' in the bonding areas. This gives the fiber-containing layer of thermoplastic adhesive material 251, which on its own essentially has a two-dimensional structure with a relatively small thickness, an essentially three-dimensional structure compared to its dimension in the longitudinal and transverse directions. This allows the fiber-containing thermoplastic adhesive material to provide cavities to cover the absorbent material in the contact surfaces, thus immobilizing this absorbent material, which may have 100% SAP or less.

[0116] The thermoplastic adhesive for the fiber layer can have elastomeric properties, so that the web formed by the fibers on the SAP layer is able to be stretched while the SAP swells. Superabsorbent polymer (SAP)

[0117] The SAP, which is useful in the present disclosure, can include a variety of water-insoluble but water-swellable polymers that are able to absorb large quantities of liquids.

[0118] The superabsorbent polymer can exist in particle form, allowing it to flow freely in its dry state. Absorbent polymer particle materials can be prepared from poly(meth)acrylic acid polymers. However, starch-based absorbent polymer particle materials can also be used, as well as polyacrylamide copolymer, ethylene maleic anhydride copolymers, cross-linked carboxymethyl cellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and starch-grafted polyacrylonitrile copolymer.

[0119] SAP can take on numerous forms. The term "particle" refers to granules, fibers, flakes, spheres, powders, platelets, and other shapes and forms known to those skilled in the art in the field of superabsorbent polymer particles. SAP particles can be in the form of fibers, i.e., elongated, needle-shaped superabsorbent polymer particles. The fibers can also be in the form of a long filament, which may be woven. SAP can also be spherical particles. The absorption core can contain one or more types of SAP.

[0120] For most absorbent articles, fluid discharges from a carrier occur predominantly in the front half of the article, particularly in the case of a diaper. The front half of the article (as defined by the area between the front edge and a transverse line, positioned at a distance of half a length L from the front waist edge 210 or the rear waist edge 212) can therefore comprise the majority of the core's absorbency. Thus, at least 60%, or at least 65%, 70%, 75%, 80%, or 85% of the SAP may be present in the front half of the article, while the remaining SAP may be located in the rear half. Alternatively, the SAP distribution may be uniform throughout the core or may exhibit other suitable distributions.

[0121] The total amount of SAP present in the absorbent core can also vary depending on the intended user. Newborn diapers may require less SAP than infant, child, or adult incontinence diapers. The amount of SAP in the core can range from approximately 5 to 60 g or from 5 to 50 g. The average base weight of SAP in the (or at least one, if there are multiple) separation area 8 of the SAP can be at least 50, 100, 200, 300, 400, 500, or more g / m². 2 The areas of the channels (e.g., 226, 226', 227, 227') present in deposition area 8 are derived from the deposition area of ​​the absorption material to calculate this average base weight. core envelope

[0122] The core shell can be made from a single substrate, material, or nonwoven fabric folded around the absorption material, or it can comprise two (or more) substrates, materials, or nonwoven fabrics bonded together. Typical bonding configurations are the so-called C-shell and / or a sandwich shell. In a C-shell, as in the Fig. 29 and Fig. As shown in Figure 34, the longitudinal and / or transverse edges of one of the substrates are folded over the other substrate to form envelopes. These envelopes are then attached to the outer surface of the other substrate, usually by gluing.

[0123] The core shell can be formed from any material suitable for receiving and containing the absorption material. Typical substrate materials used in the manufacture of conventional cores can be used, in particular paper, tissue paper, films, fabrics or nonwovens, or laminates or composites of any of these.

[0124] The substrates can also be air-permeable (in addition to being liquid- or fluid-permeable). Films useful in this respect can therefore incorporate micropores.

[0125] The core casing can be at least partially sealed along all sides of the absorption core, so that essentially no absorption material escapes from the core. "Essentially no absorption material" means that less than 5 wt%, less than 2 wt%, less than 1 wt%, or approximately 0 wt% absorption material escapes from the core casing. The term "sealing" is to be understood in a broad sense. The seal need not extend along the entire circumference of the core casing, but can be discontinuous along a portion or over its entirety, for example, formed as a series of sealing points spaced apart along a line. A seal can be formed by gluing and / or thermal bonding.

[0126] When the core shell is formed by two substrates 216, 216', four seals can be used to enclose the absorption material 260 within the core shell. For example, a first substrate 216 can be placed on one side of the core (the top, as shown in the Fig.(Figures 33-35) are arranged and extend around the longitudinal edges of the core to at least partially wrap the opposite underside of the core. The second substrate 216' can be located between the wrapped flaps of the first substrate 216 and the absorption material 260. The flaps of the first substrate 216 can be bonded to the second substrate 216' to provide a strong seal. This so-called C-shell construction can offer advantages, such as improved resistance to bursting in a wet loaded condition compared to a sandwich shell. The front and back surfaces of the core encapsulation can then also be sealed by bonding the first and second substrates to provide complete enclosure of the absorption material over the entire circumferential edge of the core.For the front and back of the core, the first and second substrates can extend in a substantially planar direction and be joined together, forming a so-called sandwich structure for these edges. In this sandwich structure, the first and second substrates can extend outward on all sides of the core and be sealed flat, or substantially flat, along all or part of the core's circumference, usually by bonding and / or thermal / pressure joining. In one example, neither the first nor the second substrate needs to be shaped to allow for rectangular cutting to facilitate fabrication; however, other shapes are also within the scope of this disclosure.

[0127] The core envelope can also be formed from a single substrate that can enclose the absorption material like a parcel envelope and can be sealed along the front and back of the core and a longitudinal seal. SAP separation area

[0128] The absorbent material deposition area 208 can be defined by the perimeter of the layer formed by the absorbent material 260 within the core encapsulation, as seen from the top of the absorbent core. The absorbent material deposition area 208 can have various shapes, in particular a so-called "dogbone" or "hourglass" shape, which tapers along its width toward the central or "step" region of the core. In this way, the absorbent material deposition area 8 can have a relatively narrow width in a region of the core intended for placement in the step region of the absorbent article, as shown in Fig. 28 shown. This can provide better wearing comfort. The absorption material deposition area 8 can also generally be rectangular, as for example in the Fig.Figures 31-33 illustrate the deposition areas; however, other deposition areas, such as rectangular, "T-", "Y-", "hourglass" or "dogbone" shapes, are also within the scope of this disclosure. The absorption material can be produced using any suitable method that allows for relatively accurate deposition of SAP at a relatively high rate. Channels

[0129] The absorption material deposition area 208 can include at least one channel 226 which is at least partially oriented in the longitudinal direction of the article 280 (i.e., has a vector component in the longitudinal direction), as shown in the Fig. 28 and Fig.29. Other channels may be oriented at least partially in the transverse direction (i.e., have a vector component in the transverse direction) or in any other direction. Hereinafter, the plural form 'channels' is used to mean 'at least one channel'. The channels may have a length L' projected onto the longitudinal axis 280 of the article, which is at least 10% of the length L of the article. The channels may be formed in various ways. For example, the channels may be formed by zones within the absorption material deposition area 208 that are substantially free of, or free from, absorption material, in particular SAP.In another example, the channels can be formed by zones within the absorption material deposition area 208, where the core absorption material comprises cellulose, air felt, SAP, or combinations thereof, and the channels can be substantially free of, or devoid of, absorption material, particularly the SAP, cellulose, or air felt. Additionally or alternatively, the channel(s) can also be formed by continuous or discontinuous bonding of the top of the core casing to the bottom of the core casing through the absorption material deposition area 208. The channels can be continuous, but it is also conceivable that the channels could be discontinuous. The uptake distribution system or uptake distribution layer 250, or any other layer of the article, can also include channels, which may or may not correspond to the channels of the absorption core.

[0130] In some cases, the channels may be present at least on the same plane in the longitudinal direction as step point C or transverse axis 260 in the absorption article, as in Fig. Figure 28 shows the two longitudinally extending channels 226, 226'. The channels may also extend from the crotch area 207 or may be located in the front waist area 205 and / or in the back waist area 206 of the article.

[0131] The absorption core 228 can also comprise more than two channels, for example at least 3, at least 4, at least 5, or at least 6 or more. Shorter channels may also be present, for example in the posterior waist region 206 or the anterior waist region 205 of the core, as shown by the pair of channels 227, 227' in Fig. 28 is shown on the front of the article. The channels may comprise one or more channels arranged symmetrically or otherwise relative to the longitudinal axis 280.

[0132] Channels can be particularly useful in the absorption core when the absorption material deposition area is rectangular, as they can improve the core's flexibility to such an extent that using a non-rectangular (shaped) core becomes less advantageous. Of course, channels can also be present in an SAP layer with a shaped deposition area.

[0133] The channels can be aligned entirely longitudinally and parallel to the longitudinal axis, or entirely transversely and parallel to the transverse axis, but can also have at least sections that are curved.

[0134] To reduce the risk of liquid leakage, the longitudinal main channels may not extend to any of the edges of the absorbent material deposition area 208 and may therefore be completely enclosed within the absorbent material deposition area 208 of the core. The smallest distance between a channel and the nearest edge of the absorbent material deposition area 208 may be at least 5 mm.

[0135] The channels can have a width Wc along at least part of their length, which is, for example, at least 2 mm, at least 3 mm, at least 4 mm, up to, for example, 20 mm, 16 mm, or 12 mm. The width of a channel or channels can be constant over substantially the entire length of the channel, or it can vary along its length. If the channels are formed by an absorption material-free zone within the absorption material deposition area 208, the width of the channels is considered to be the width of the free material zone, disregarding the possible presence of the core encapsulation in the channels. If the channels are not formed by absorption material-free zones, for example, mainly by binding the core encapsulation through the absorption material zone, then the width of the channels is the width of this bond.

[0136] At least some or all of the channels can be permanent, meaning that their integrity is maintained, at least partially, in both dry and wet conditions. Permanent channels can be achieved by providing one or more adhesive materials, such as the fiber layer of adhesive material or construction glue, which helps to bond a substrate to an absorbent material within the channel walls. Permanent channels can also be formed by connecting the top and bottom layers of the core encapsulation (e.g., the first substrate 216 and the second substrate 216') and / or the top layer 224 to the bottom layer 225 through the channels.Typically, an adhesive can be used to bond both sides of the core cladding or the top and bottom layers through the channels; however, it is also possible to bond using other known methods, such as pressure bonding, ultrasonic bonding, heat bonding, or a combination thereof. The core cladding or top layer 224 and the bottom layer 225 can be bonded continuously or intermittently along the channels. Advantageously, the channels can remain or become visible, at least through the top layer and / or bottom layer, when the absorbent article is fully loaded with a liquid. This can be achieved by manufacturing the channels to be substantially free of SAP so that they do not swell, and by making them sufficiently large so that they do not close when wet.Furthermore, connecting the core shell to itself or the upper layer to the lower layer via the channels can be advantageous. cuff

[0137] The absorbent article may comprise a pair of leg cuffs 34. Each leg cuff may be formed by a piece of material connected to the absorbent article so that it can extend upward from a surface of the absorbent article facing the wearer and provide enhanced containment of fluids and other bodily excretions approximately at the junction of the wearer's torso and legs. The leg cuffs are bounded by a near edge 64 that is directly or indirectly connected to the upper layer 224 and / or the lower layer 225, and by a free end edge 266 that is intended to contact the wearer's skin and form a seal with it. The leg cuffs 234 extend at least partially between the anterior waist edge 210 and the posterior waist edge 212 of the absorbent article on opposite sides of the longitudinal axis 280 and are present at least in the plane of the gait point (C) or gait area.The leg cuffs can be connected to the base unit of the article at their proximal edge 264 by a bond 265, which may be produced by gluing, fusion bonding, or a combination of other suitable joining methods. The bond 265 at the proximal edge 264 may be continuous or discontinuous. The bond 265 closest to the raised section of the leg cuffs defines the proximal edge 264 of the standing section of the leg cuffs.

[0138] The leg cuffs can be integrated into the top layer 224 or the bottom layer 225, or they can be a separate material attached to the basic unit of the article. Each leg cuff 234 can include one, two, or more elastic threads 235 near the freestanding end edge 266 to provide a better seal.

[0139] In addition to the leg cuffs 234, the article may include sealing cuffs 232, which are connected to the base unit of the absorbent article, in particular to the upper layer 224 and / or the lower layer 225, and are positioned externally in relation to the leg cuffs. The sealing cuffs 232 can provide a better seal around the wearer's thighs. Each leg cuff sealing cuff may include one or more elastic threads or elastic elements 233 in the base unit of the absorbent article between the upper layer 224 and the lower layer 225 in the area of ​​the leg openings. All or part of the leg cuff sealing cuffs and / or sealing cuffs may be treated with a lotion or other skin care composition. Intake distribution system

[0140] The absorption articles of the present disclosure may comprise an absorption-distribution layer or system 250 (“ADS”). One function of the ADS is to rapidly absorb one or more of the fluids and efficiently distribute them to the absorption core. The ADS may comprise one, two, or more layers, which may form a single layer or remain separate layers that may be attached to one another. In one example, the ADS may comprise two layers: a distribution layer 254 and an absorption layer 252, which is arranged between the absorption core and the top layer; however, the present disclosure is not limited thereto.

[0141] In one example, the three-dimensional nonwoven materials of the present disclosure can comprise the top layer and the receiving layer as a laminate. A distribution layer can also be provided on the clothing-side of the top layer / receiving layer laminate. carrier layer

[0142] In a case where the high-volume, three-dimensional nonwoven materials of the present disclosure comprise a top layer and a receiving layer laminate, the distribution layer may need to be supported by a carrier layer (not shown), which may comprise one or more nonwoven materials or other materials. The distribution layer may be applied to or positioned on the carrier layer. Accordingly, the carrier layer may be positioned between the receiving layer and the distribution layer and be in a mutually facing relationship with the receiving layer and the distribution layer. Distribution layer

[0143] The distribution layer of the ADS can comprise at least 50 wt.% cross-linked cellulose fibers. The cross-linked cellulose fibers can be compressed, twisted, or crimped, or a combination thereof, including compressed, twisted, and crimped. This type of material is disclosed in US Patent Publication No. US 2008 / 0312622A1 (Hundorf). The cross-linked cellulose fibers provide greater elasticity and thus increased resilience of the first absorption layer to compression in product packaging or under conditions of use, such as under the weight of a carrier. This can provide the core with a higher void volume, permeability, and liquid absorption, resulting in reduced leakage and improved dryness.

[0144] The distribution layer comprising the cross-linked cellulose fibers of the present disclosure may include other fibers, but this layer may advantageously comprise at least 50 wt.% or 60 wt.% or 70 wt.% or 80 wt.% or 90 wt.% or even up to 100 wt.% of the layer of cross-linked cellulose fibers (including the cross-linked cellulose fibers). Receptive layer

[0145] If a three-dimensional nonwoven material of the present disclosure is provided only as the top layer of an absorbent article, the ADS 250 may comprise a capture layer 252. The capture layer may be arranged between the distribution layer 254 and the top layer 224. In such a case, the capture layer 252 may comprise a nonwoven material, for example, a hydrophilic SMS or SMMS material comprising a spunbond nonwoven, a melt bubble, and another spunbond nonwoven layer, or alternatively, a carded, chemically bonded staple fiber nonwoven. The nonwoven material may be latex-bonded. fastening system

[0146] The absorbent article may include a fastening system. The fastening system may be used to provide lateral tension around the circumference of the absorbent article to hold it to the wearer, as is common for zip-up diapers. This fastening system may not be necessary for exercise panty articles, as the waist area of ​​these articles is already tied. The fastening system may include a fastening element such as adhesive strips, hook-and-loop fastener components, interlacing fasteners such as side flaps and slits, buckles, buttons, snap fasteners, and / or hybrid fastening components, although any other suitable fastening mechanisms are also within the scope of this disclosure. An attachment zone 244 is normally provided on the garment-side surface of the front waist area 205 to allow the fastening element to be detachably attached to it. Front and rear lateral lobes

[0147] The absorption article can comprise front side lobes 246 and rear side lobes 240. The side lobes can be an integrated part of the basic unit, as formed from the top layer 224 and / or the bottom layer 226 as side elements. Alternatively, as in Fig.Figure 28 illustrates that the side flaps can be separate elements attached by gluing, hot stamping, and / or pressure bonding. The rear side flaps 240 can be stretchable to facilitate the attachment of the tabs 242 to the impact zone 244 and to hold the adhesive-secured diapers in place around the wearer's waist. The rear side flaps 240 can be elastic or stretchable to provide a more comfortable fit that better conforms to the body's contours. This is achieved by initially conforming the absorbent article comfortably to the wearer and maintaining this fit throughout the wearing period, even long after the absorbent article has become saturated with liquids or other bodily excretions. This is because the elasticized side flaps allow the sides of the absorbent article to expand and contract. Elastic waist element

[0148] The absorbent article 220 may have at least one elastic waist element that contributes to improved fit and retention. The elastic waist element is generally designed to expand and contract elastically to dynamically adapt to the wearer's waist. The elastic waist element may extend longitudinally outward from at least one waist edge of the absorbent core 228 and generally forms at least one section of the end edge of the absorbent article. Disposable diapers may be designed to have two elastic waist features, one positioned in the front waist area and one in the back waist area. Color signals

[0149] In one form, the absorbent articles of the present disclosure may have different colors in different layers or sections thereof (e.g., top layer and absorption layer, top layer and nonwoven core cover, a first section and a second section with a top layer, a first section and a second section of the absorption layer). The different colors may be shades of the same color (e.g., dark blue and light blue) or may actually be different colors (e.g., violet and green). The different colors may, for example, have a Delta E in the range of about 1.5 to 10, about 2 to 8, or about 2 to 6. Other Delta E ranges are also within the scope of the present disclosure.

[0150] In one instance, different layers of the absorbent material can be bonded using a colored adhesive. The colored adhesive can be applied to any suitable layer(s) in a pattern. The adhesive pattern may or may not complement the pattern of the top layer. Such a pattern can enhance the illusion of depth in an absorbent material. In certain cases, the colored adhesive can be blue.

[0151] In other cases, each of the layers may include markings, such as printed ink, to support the appearance, depth impression, absorption impression, or quality impression of the absorption articles.

[0152] In other cases, the colors may be complementary to or registered with the patterns of three-dimensional features of the nonwoven fabric 10, which is used as a component in an absorbent article. For example, a fabric with first and second zones of optically distinct patterns of three-dimensional features may also have color printed on it to emphasize, highlight, contrast with, or otherwise modify the change in the optical appearance of fabric 10. The color enhancers can be useful in communicating certain functional properties of the nonwoven fabric 10 to a user of an absorbent article during use. The color may be used in combination with structural, three-dimensional features in a component, or in combinations of components, to provide an optically distinguishable absorbent article.For example, a second top layer or absorption layer may have a printed pattern of color(s) that complements the pattern of three-dimensional features of a fabric 10 used as a top layer in an absorption article. Another example is an absorption article comprising: 1) an absorption core with a channel, 2) a top layer with a three-dimensional pattern that is registered with or accentuates the channel(s) in the core, and 3) a graphic, colored component, printed ink, or markings visible from the top layer's visible surface (body-side surface) or the bottom layer's visible surface (garment-side surface) to further emphasize the functional features of the core channel(s) and the overall performance of the absorption article.

[0153] A further characterization of the novel aspects of the present disclosure can be achieved by focusing on the three-dimensional structures in an optically perceptible zone. Each zone discussed above, such as zones 110, 120, and 130, can be further described in terms of the microzones. A microzone is a section of the nonwoven fabric 10 within a zone that has at least two optically perceptible areas, and there is a difference in the common intensive properties between these two areas. A microzone may comprise a section of the nonwoven fabric 10 that traverses two or more zone boundaries, has at least two optically perceptible areas, and there is a difference in the common intensive properties between these two areas.

[0154] The advantage of including microzones in the present disclosure is to illustrate that, in addition to the differences in average intensity properties within a zone, such as zones 110, 120, and 130, as discussed above, the present disclosure also provides materials that exhibit differences in the actual and / or average intensity properties between areas defined by the three-dimensional features within a zone, the three-dimensional features being precisely positioned according to the design of the forming strip used to manufacture the materials. The difference in intensity properties between the areas of the three-dimensional features provides additional optical and functional advantages. The sharp optical contrast between the areas can provide extremely fine, optically distinguishable designs within a zone and between zones.Similarly, the precise placement of areas, made possible by the precisely manufactured shaping strip, can provide excellent and tailored softness, strength, and fluid handling properties for the zones. Thus, in one embodiment, the invention provides the unexpected combination of differences in the average intensity properties between the zones and, simultaneously, differences in the intensity properties of the areas that form a microzone.

[0155] Areas defined by three-dimensional features can be described with reference to Fig. 38 and Fig. 39 can be understood. Fig. Figure 38 shows a light microscope image of a section of a substance 10 according to the present disclosure, and Fig. Figure 39 shows a scanning electron micrograph (SEM) of a cross-section of the in Fig. 38 shown sections of fabric. Thus, the Fig. 38 and Fig.39 a section of a nonwoven fabric 10, which has been enlarged to describe the otherwise visually recognizable characteristics of the fabric in more detail. The section of the nonwoven fabric 10, which is in Fig. Figure 38 is shown, which is approximately 36 mm in CD and has sections of at least three optically distinct zones, as discussed below.

[0156] Both Fig. 38 and Fig. Figure 39, which shows a section of a pattern of a nonwoven fabric 10, is a first zone 110 (on the left side of Fig.38) characterized by generally MD-oriented rows of first regions 300 of variable width, separated by MD-oriented rows of second regions 310 of variable width. The first region is also the three-dimensional feature 20 that defines the first and second regions 300, 310. In one embodiment, a three-dimensional feature is a section of the nonwoven fabric 10 formed between or around a raised element of the forming strip, which in this description is the first region 300, such that the resulting structure has a relatively larger dimension in the Z-direction. The adjacent second region 310 generally shares an intensive feature with the first region 300 and, in one embodiment, has relatively lower thickness values, i.e., a smaller dimension in the Z-direction.The relative dimensions of the Z-direction with respect to a plane of the first surface 16, as described above, are in . Fig. Figure 39 illustrates. Absolute dimensions are not critical; however, the dimensional differences can be visually distinguished on the nonwoven fabric 10 even without magnification.

[0157] The invention disclosed allows for advantageous properties that can best be expressed with reference to the areas defined by three-dimensional features in microzones. For example, as in Fig.Figure 38 shows that in zone 110, for each three-dimensional feature 20, a visible distinction exists between a first region 300 and a second region 310. As explained above, the visible distinction in the nonwoven fabric 10 may be present without magnification; the magnified views used here serve for clarity. Any region extending beyond the boundary between a sufficient amount of the first region 300 and the second region 310, such that a difference in their respective intensity properties can be determined within the region, may be a microzone. Additionally, light microscopy or micro-CT imaging of a structure can also be used to determine the location of regions and the area of ​​a microzone.

[0158] The in Fig.The section of nonwoven fabric 10 shown in Figure 38 further illustrates an advantageous property of the fabric 10 insofar as the differences in intensive properties between adjacent areas can be differences across zones. Thus, a microzone can be identified that spans an area encompassing the second area 310 of zone 120 and the first area 300 of zone 130. In certain embodiments, including the one shown in the Fig. 38 and Fig. In the nonwoven fabric 10 shown in Figure 39, the difference in the intensive properties exhibited by the areas in microzones may mean that a zone boundary may have a significantly different size than the differences between intensive properties exhibited by the areas within a zone.

[0159] Regardless of which zone or zonal boundary a particular microzone comprises, the three-dimensional features can be characterized by the differences between the intensive properties of the regions they define. In general, the nonwoven fabric of the present disclosure can be a spunbond nonwoven with a first surface that defines a plane. The fabric can have multiple three-dimensional features, each three-dimensional feature defining a first region and a second region, the regions sharing a common intensive property that has a different value between them. In one embodiment, the first region can be distinguished by being located at a greater height relative to the plane of the first surface than the second region, thus exhibiting a difference in the common intensive property of thickness of each region.The two regions can also be distinguished by their different densities, base weights, and volumetric densities. That is, within a microzone of the spunbond nonwoven, the two regions can be differentiated with respect to common intensive properties, selected from properties consisting of thickness, base weight, and volumetric density. In one embodiment, one or both regions of a microzone can be liquid-permeable. In another embodiment, the higher-density region of a microzone can be liquid-permeable.

[0160] Within zone 110 of the in Fig.In the material section shown in Figure 38, for example, three-dimensional features 20 can be present that define at least two regions, a first region 300 and a second region 310. The difference in thickness, base weight, and volumetric density between the first and second regions for the in Fig. 38 depicted zones 110 can each contain 274 micrometers, 1 gram per square meter and 0.437 g / cm² 3 be.

[0161] Also within zone 130 of the in Fig. In the material section shown in Figure 38, for example, three-dimensional features 20 may be present that define at least two regions, a first region 300 and a second region 310. The difference in thickness, base weight, and volumetric density between the first and the second region for the [unclear text] Fig. 38 depicted zones 130 can each have 2083 micrometers, 116 grams per square meter and 0.462 g / cm² 3 be.

[0162] Furthermore, within zone 120 of the in Fig. In the material section shown in Figure 38, for example, three-dimensional features 20 may be present that define at least two areas, a first area 300 and a second area 310. The difference in thickness, base weight, and volumetric density between the first and second areas for the [material section shown in Figure 38] Fig. The 38 depicted fabric section can each be 204 micrometers, 20 grams per square meter and 0.53 g / cm². 3 In the illustrated embodiment, zone 120 forms what appears in an unmagnified view of nonwoven fabric 10 as a sewn boundary between zones 110 and 130.

[0163] Furthermore, in a zone which forms the border between zones 120 and 130 of the in Fig.The material sections shown in Figure 38 comprise, for example, at least two areas: a first area 300 in zone 130 and a second area 310 in zone 120. The difference in thickness, base weight, and volumetric density between the first and second areas for the material in Figure 38 is shown in Figure 38. Fig. The 38 tissue sections shown can each measure 2027 micrometers, 58 grams per square meter and 0.525 g / cm². 3 be.

[0164] The microzones are described in more detail below with reference to the Fig. 40-42 and those in Fig. The data presented in section 44 is discussed. Fig. Figures 40-42 are micro-CT scans of a section of a nonwoven fabric 10, whose pattern is similar to that of the one in Fig. The nonwoven fabric shown in section 38 resembles 10. The microCT scan allows the description of the same features as in Fig. 38 shown, in a slightly different way and in a manner that allows for a very accurate measurement of the intensive properties.

[0165] As in Fig. As shown in Figure 40, zones 110, 120, and 130, with their respective three-dimensional features, are clearly visible. As in the Fig. 40 and Fig. As shown in Figure 41, the three-dimensional features are the dark colored sections, where the dark color also represents the first area 300 of a three-dimensional feature 20, and the adjacent light sections are the second area 310 for the three-dimensional feature 20.

[0166] The microCT scan allows the image to be "sliced" and divided cross-sectionally, as shown by the section plane 450 in Fig. 41 shown. A sectioning plane can be placed at any point on the image; for the purposes of the present disclosure, the sectioning plane 450 cuts a cross-section substantially parallel to the Z-axis in order to obtain the cross-sectional image in Fig. to generate 42.

[0167] MicroCT technology allows for precise and direct measurement of intensive properties. Thickness measurements can be performed directly from displayed cross-sections based on scale magnification, such as the one shown in Fig. The cross-section shown in Figure 42 is further detailed. The color difference between the first and second areas is representative and proportional to the differences in base weight, volumetric density, and other intensive properties, which can also be measured directly. The microCT methodology is explained below in the section "Test Procedures".

[0168] Fig. Figure 43 is a microCT scan image of the section of nonwoven fabric 10 that is in the Fig. 40 and Fig. Figure 41 shows the use for specific first and second areas, represented as numbered sections of nonwoven fabric 10, which can be analyzed. Fig.43 specific areas were manually selected and analyzed to measure thickness, base weight, and volumetric density, and the data are presented in Fig. 44 reproduced.

[0169] Fig. Figure 44 shows data for the grouping of measurements of the first and second areas within the in Fig. The three zones shown in the diagram are 44. The x-axis represents the areas where the numbers correspond to the numbered areas in the diagram. Fig.43. Measurements of the first range are designated Fn (e.g., F1), and measurements of the second ranges are designated Sn (e.g., S1). Thus, ranges 1–5 are first ranges F1, each located in zone 110. Ranges 6–10 are second ranges S1, also located in zone 110. Similarly, the first ranges F2 are ranges 16–20 in zone 120, and ranges 11–15 and 21–25 are second ranges S2 in zone 120. Finally, ranges 31–35 are first ranges F3 in zone 130, and ranges 26–30 are second ranges S2 in zone 130. The numbered ranges are across all three graphs of Fig. 44 are shown continuously, however, for the sake of simplicity, zones 110, 120 and 130 are only shown on the thickness distribution map.

[0170] The in Fig.The 44 graphs shown graphically represent the magnitude difference in intensive properties between the first and second regions within each zone and can be used to graphically visualize the difference in intensive properties for pairs of regions that form a microzone. For example, it can be seen that in Zone 110, the base weight may be essentially the same between the two regions, but the thickness can vary from about 400 micrometers in the first regions to about 40 micrometers in the second regions, or by a difference of about 10x. The volumetric density in Zone 110 can range from about 0.1 g / cm³. 3 up to approximately 0.6 g / cm³ 3 They vary. Similar quantifiable distinctions apply to each of the zones shown.

[0171] In this way, with reference to Fig. 43 and Fig.44 jointly, a further characterization of the advantageous structure of a material 10 of the present disclosure may be understood. The nonwoven fabric 10 can be described as having at least two optically distinct zones, e.g., zones 110 and 120, wherein each of the zones has a pattern of three-dimensional features, each of the three-dimensional features defining a microzone with first and second regions, e.g., regions 300, 310, and wherein the difference of the values ​​for at least one of the microzones in the first zone differs quantifiably from the difference of the values ​​for at least one of the microzones in the second zone. For example, in Fig.43 Two representative microzones 400 in zone 130 are designated as the pair of areas marked as areas 31 and 27 and 33 and 26. That is, the first area 31 and the second area 27 form one microzone, and the first area 33 and the second area 26 form another microzone. Likewise, two representative microzones 400 in zone 120 are designated as the pair of areas marked as areas 19 and 24 and 17 and 22. Starting from Fig. 44. Tables 4-7 can be filled out as shown: Table 4: Illustrative examples of thickness differences in microzones Thickness (micrometers) Difference in thickness (micrometers) Zone 130 Microzone 1 First area 31 1802 1709 Second area 27 93 Microzone 2 First area 33 2548 2484 Second area 26 64 Zone 120 Microzone 1 First area 19 242 172 Second area 24 70 Microzone 2 First area 17 235 183 Second area 23 52 Table 5: Illustrative examples of differences in base weight in microzones Base weights (grams per square meter) Differences in base weights (grams per square meter) Zone 130 Microzone 1 First area 31 124 107 Second area 27 17 Microzone 2 First area 33 106 72 Second area 26 34 Zone 120 Microzone 1 First area 19 32 5 Second area 24 27 Microzone 2 First area 17 42 30 Second area 23 12 Table 6: Illustrative examples of differences in volumetric density in microzones Volumetric density (g / cm³) 3 ) Difference in volumetric density (g / cm³) 3 ) Zone 130 Microzone 1 First area 31 0,069 0,116 Second area 27 0,185 Microzone 2 First area 33 0,041 0,49 Second area 26 0,531 Zone 120 Microzone 1 First area 19 0,133 0,251 Second area 24 0,384 Microzone 2 First area 17 0,185 0,044 Second area 23 0,229 Table 7: Illustrative examples of differences in intensity properties in different zones: Thickness (micrometers) Thickness differences Base weights (grams per square meter) Base weight differences Volumetric density (g / cm³) 3 ) Volumetric density differences Zone 130 First Area 32 2147 2118 149 135 0,069 0,423 Zone 110 Second Area 8 29 14 0,492

[0172] The four representative microzones from two zones are shown in Tables 4-6 for illustration. It should be understood, however, that each pair of first and second areas in Fig. 43 could be quantified in the same way to fill in additional rows in Table 4, but this is not done for the sake of conciseness. In general, for any fabric with two or more zones, each zone having a pattern of three-dimensional features, the microzones can be defined, the intensive properties can be measured, and, as here, with reference to the Fig. 43 and Fig.44 illustrated in tables to show both the difference in values ​​for intensive properties within a zone and the differences in the values ​​of intensive properties between an area of ​​the first zone and another area in a second zone.

[0173] A microzone spanning two zones, such as zones 110 and 130, can exhibit even greater differences in intensity properties compared to a microzone within a single zone. For example, when considering the data for a microzone spanning a first region of zone 130, say region 32, and a second region of zone 110, say region 8, the microzone shows dramatic differences in thickness, base weight, and volumetric density. The thickness of region 32 of zone 130 is approximately 2100 micrometers, while the thickness of region 8 of zone 110 is approximately 29 micrometers, or a difference of about 72x.Similarly, the base weight of the first area 32 of zone 130 can be as high as 150 grams per square meter, while the base weight of the second area 8 of zone 110 can be approximately 14 grams per square meter, or a difference of about 10 times. Furthermore, the volumetric density of the first area 32 of zone 130 can be approximately 0.069 g / cm³. 3 the volumetric density of the second area 8 of zone 110 is approximately 0.492 g / cm³ 3 or may have a difference value of approximately 7X.

[0174] For each parameter of the measured intensive properties of the different regions of a microzone, such a measurement is performed using the micro-CT method described herein. The resolution used for the method supports the derivation of the intensive properties of microzone regions, so that comparisons of differences and ratio comparisons of regions, as described herein, can be dimensioned.

[0175] A further characterization of substance 10 can be made with reference to the Fig. 45-49, in which the SEMs describe certain aspects of the nonwoven fabric 10 and the areas within it in more detail. Fig. 45-49 are photographs of enlarged sections of Zone 110 of the in Fig. 38 shown fabric. The one in Fig. Nonwoven fabric 10 shown in section 38 was produced according to the method described above with reference to Fig. 7 produced in which the material was processed through a roller gap formed by compression rollers 70 and 72, wherein the roller 72, which contacts the first side 12, is heated to bring about a partial bonding of the fibers in the second areas 301. Fig. 45 (facing the belt) and 46 (facing the heated compaction roller) are each SEMs of a section of the second surface 14 and the first surface 12, respectively, magnified by 20x. Fig.Figures 47 (facing the belt) and 48 (facing the heated compaction roller) are photographs of a section of the second surface 14 and the first surface 12 respectively, enlarged by 90x, and show in detail the advantageous structural characteristics of the partial bonding of fibers formed by the compaction rollers 70 and 72.

[0176] How best to in the Fig. 47 and Fig. 48 can be seen, as well as in the cross-sectional view of Fig.49, the heated compaction rollers can induce thermal bonding of fibers to varying degrees with a beneficial effect on the entire fabric 10. As shown, the fibers in contact with a heated roller, e.g., roller 70 in contact with the first surface 12 of fabric 10, can be melt-bonded, so that the first surface 12 experiences relatively more fiber-to-fiber bonding than the second surface 14. In one embodiment, the bonded fibers 80 of the first surface can be substantially all melt-bonded to effectively form a film skin of bonded fibers, while the fibers in the second area 310 on the second side 14 may experience little to no bonding. This feature allows a nonwoven fabric 10 to be used in an absorbent article, e.g.,as an upper layer, to maintain physical integrity during manufacture and use, as well as relative softness on one side, which may be the skin-contacting side facing the user.

[0177] Even in the microzones with the greatest thickness difference, this "bond thinning" serves the purpose of maintaining web integrity, while softness or other beneficial properties such as fluid handling characteristics are not significantly affected. As with reference to the Fig. As can be seen from Figures 50-53, the difference in the degree of thermal fiber bonding can be such that the fibers on the first surface 12 may be completely or substantially completely bonded to a second area 310, with the degree of thermal fiber bonding on the second surface 14 in a first area 300 being minimal to no thermal bonding.

[0178] Fig.Figure 50 again shows the section of nonwoven fabric 10, which is in Fig. 38 is shown. Fig. 51-53 show enlarged images of a microzone located in Fig. 50 is designated as a first area 300 and a second area 310, which visually appears to be a hole or an opening. Fig. 51 and Fig. Figures 52 show the microzone as it appears on the second surface 14, magnified to 40X and 200X respectively. Fig.Figure 53 shows the second region 310 as it appears on the first page 12 under 200x magnification. The fibers in the second region 310 are completely, or substantially completely, bound, whereas the fibers in the first region 300 are completely, or substantially completely, unbound. The advantage of the structure shown is that a microzone can act as a fluid-permeable opening, while the bound regions of the second region 310 can simultaneously serve to maintain the physical integrity of the material 10.

[0179] Microzones therefore play a significant role in the overall physical structure and function of a fabric 10 according to the present invention. By creating relatively closely spaced, precisely designed three-dimensional features, which is made possible by the shaping band of the present disclosure, a fabric 10 can exhibit visually distinct zones, microzones, and three-dimensional features that offer functional superiority, at least in terms of softness and liquid handling, as well as visually appealing aesthetic designs. The potential difference in the physical properties of the first and second surfaces allows the nonwoven fabric 10 to be designed for both strength and softness, as well as for form and function.

[0180] Fig. Figure 54 is a microCT scan image of the section of nonwoven fabric 10, similar to the one in the Fig. 40 and Fig.41 shown, which, however, were subjected to the additional processing step of forming spot bonds 90 in the roll gap of the calender rolls 71 and 73. As above in relation to the discussion of the Fig. 43 and Fig. As described in Figure 44, for certain spot-bonding microzones 400, the first and second areas, represented as numbered sections of the nonwoven fabric 10, can be analyzed and include spot-bonding areas, particularly in numbered sections 31-35. For example, adjacent areas 32 and 26 form a microzone 400 in the third zone 130. Fig. 54. The specific areas were visually highlighted to identify regions that include the additional point-binding areas and analyzed to measure thickness, base weight, and volumetric density, and these data are presented in Fig.55 reproduced, quantifying and comparing the thickness, base weight and volumetric density of all areas, including the point bonding areas.

[0181] Fig. Figure 55 shows data for the grouping of measurements of the first and second areas within the in Fig. The three zones shown are 54. The x-axis represents the areas where the numbers correspond to the numbered areas in the diagram. Fig.43. Measurements of the first range are designated Fn (e.g., F1), and measurements of the second ranges are designated Sn (e.g., S1). Thus, ranges 1–5 are first ranges F1, each located in zone 110. Ranges 6–10 are second ranges S1, also located in zone 110. Similarly, the first ranges F2 are ranges 16–20 in zone 120, and ranges 11–15 and 21–25 are second ranges S2 in zone 120. Finally, ranges 31–35 are second ranges, but are point bindings 90, located in Fig. 55 are designated as B1 to distinguish them in this revelation as being formed by a point-connection process. First regions F3 in Zone 130 are regions 26-30 and 36-40, while regions 41-44 are second regions S2 in Zone 130. The numbered regions are across all three graphs of Fig.The entire 55 area is shown, however, for the sake of simplicity, zones 110, 120 and 130 are only shown on the thickness distribution map.

[0182] The in Fig.The graphs shown graphically represent the magnitude difference in intensive properties between the first and second regions within each zone of a material that has undergone a calender point bonding step. They can be used to graphically visualize the difference in intensive properties for pairs of regions that form a microzone. For example, it is evident that in Zone 110, the base weight between the two regions can vary more within a narrower range than the thickness or volumetric density. For example, the thickness can vary from about 325 micrometers in the first region to about 29 micrometers in the second regions of Zone 110, a difference of about 10 times. The volumetric density in Zone 110 can range from about 0.08 g / cm³. 3 up to approximately 0.39 g / cm³ 3 They vary. Similar quantifiable distinctions apply to each of the zones shown.

[0183] In general, areas within a microzone can exhibit widely varying values ​​for base weight, thickness, and volumetric density.

[0184] In this way, with reference to Fig. 54 and Fig. 55 jointly, a further characterization of the advantageous structure of a substance 10 of the present disclosure, in particular with regard to the thermal calendering point bonds 90, can be understood. For the purpose of description on zone 130, three-dimensional features defining a microzone, which includes first and second regions that are point-bonded regions, can be identified, and the values ​​of intensive properties can be quantified. For example, in Fig.54. A representative point-binding microzone 400 in zone 130 will be the pair of areas labeled as areas 26 and 32 or 30 and 35. That is, the first area 26 and the second area 32 form a point-binding microzone 400, and the first area 30 and the second area 35 form a point-binding microzone 400.

[0185] The differences in certain intensive properties for point-binding microzones are in Fig.55. For example, considering the two point-bonding microzones 400 described above, e.g., the two point-bonding microzones 400 of the respective areas 26 and 32 and 30 and 35, it is evident that there is a slight difference in base weight between the first and second areas, in the range of approximately 55 to approximately 60 grams per square meter. However, the same areas exhibit a significant difference in thickness, ranging from approximately 430 micrometers to approximately 460 micrometers to approximately 125 micrometers, and a significant difference in volumetric density of approximately 0.13–0.14 g / cm³. 3 up to approximately 0.41-0.48 g / cm³ 3 Further differences in the intensive properties can be found by referring to Fig. 55 are observed.

[0186] The bonding points 90 therefore play a significant role in the overall physical structure and function of a material 10 of the present invention. By adding bonding points 90 to the material 10, which comprise relatively closely spaced, precisely designed three-dimensional features, as made possible by the shaping band of the present disclosure, a material 10 can be further improved to exhibit an unexpected combination of optically distinct zones, microzones, and three-dimensional features, providing functional superiority in the high-performance combination of softness, strength, low linting, and liquid handling, as well as visually appealing aesthetic designs.The bonding point feature ensures that a nonwoven fabric 10 is designed for the highest combined performance of strength, softness, fluid handling and visual aesthetics, especially considering both form and function.

[0187] One advantage of the formed nonwoven webs of the present disclosure is improved softness. The softness can be measured using the Emtec Tissue Softness Analyzer, available from Emtec Paper Testing Technology, Emtec Electronic, GmbH. Table 5 below lists the softness values ​​as TS7 measurements of the Emtec Tissue Softness Analyzer, according to the Emtec test procedure described below. For all of the following Examples 7-9, the nonwoven was produced on a tape as described in Fig. 16 is described, whereby the nonwoven fabric has a similar appearance to that described in Fig. 2. Table 5: TS7 values ​​for shaped fleeces of the Revelation Example No. Page TS7 value (dB V2 rms) FS / SS ratio Example 7 First surface 10,30 1,35 Second surface 7,59 Example 8 First surface 3,51 0,98 Second surface 3,59 Example 9 First surface 9,61 1,48 Second surface 6,47 Example 7:

[0188] A bicomponent spunbond nonwoven web was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration, as discussed above with reference to Example 2. The nonwoven was formed on a forming belt with a repeating pattern as shown in Fig. 16 spun under motion at a linear speed of about 25 meters per minute to produce a fabric 10 with an average base weight of 25 grams per square meter with a repeating pattern of heart shapes, as in Fig. 2 shown, to form. Fibers of the material were compacted by compaction rollers 70, 72, but instead of being calendered, further bonding was achieved by an air-bonding unit, as shown below with reference to Fig.56 is described at a temperature of 145 degrees C. Example 8:

[0189] A bicomponent spunbond nonwoven fabric produced by spinning a 30:70 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (HG475 FP, available from Borealis) in a circular fiber configuration, using a double-beam spunbond process as described in Fig. 56 described, the nonwoven was produced on a shaping belt with a repeating pattern as in Fig. 16 described spun, as above in relation to Fig. 7 described, under motion at a linear speed of approximately 152 meters per minute, on an average base weight of 35 grams per square meter, to create a repeating pattern of heart shapes, as in Fig. 2 shown, to form. The difference between shaped nonwoven fabrics, which are formed according to the method of Fig.The difference between 7 and example 8 is that example 8 is based on a hybrid of the in Fig. The procedure described in section 7 and the one described below are Fig. The procedure was carried out as described in section 56. In particular, the procedure comprised two spindle beams, as described in section 56. Fig. Figure 56 shows that the final heating step was carried out by calender rollers 71, 73, instead of an air-bonding process. The fibers of the fabric were bonded on the first surface 12 by heated compression rollers 70A and 72A at 110 °C after the first jet 48A and by compression rollers 70B and 72B at 110 °C after the second jet 48B, and then calendered at approximately 140 °C on the calender rollers 71 and 73 before being wound onto a roll at the winder 75. Example 9:

[0190] A bicomponent spunbond nonwoven fabric produced by spinning a 30:70 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (HG475 FP, available from Borealis) in a circular fiber configuration, using a double-beam spunbond process as described in Fig. 56 was described, manufactured. The nonwoven fabric was placed on a shaping belt with a repeating pattern as described in Fig. 16, spun under motion at a linear speed of approximately 228 meters per minute, to an average base weight of 25 grams per square meter, to create a repeating pattern of heart shapes, as in Fig.2 shown, to form. The fibers of the fabric were further bound on the first surface 12 by heated compaction rollers 70A and 72A at 110 °C after the first jet 48A and compaction rollers 70B and 72B at 110 °C after the second jet 48B and at three heat zones 100°C, 135°C and 135°C of the air-drying device 76 (as shown in Fig. 56 shown) hot air flow-bound, before they were wound onto a roller at the winder 75.

[0191] Examples 7-9 are representative of shaped nonwovens of the present disclosure that exhibit improved softness, as indicated by the Emtec measurements. The measured Emtec values ​​can range from approximately 1 dB V 2 rms up to approximately 15 dB V 2 rms, or about 3 dBV 2 rms up to about 10 dB and V 2 rms, or about 5 dBV 2 rms up to approximately 8 dBV 2The rms value is generally . In general, the measured Emtec values ​​for either the first surface or the second surface can be any integer value up to approximately 15 dBV. 2 rms, and any range of integers between 1 and 15. Furthermore, in general, the ratio of the measured Emtec value for the first side to the second side can be between 1 and 3, and any real number between 1 and 3.

[0192] Without being bound to any theory, it is assumed that the improvement in softness exhibited by the shaped nonwoven fabric of the present invention is achieved by the method and apparatus of the invention, which allows for different intensity properties in relatively small areas, including the disclosed zones and microzones. The ability to design and produce shaped nonwoven fabrics with the disclosed differences in, for example, base weight, density, or thickness, while simultaneously providing a consolidated fabric useful for surface layers, for example, in absorbent articles, eliminates the previously existing technical contradictions between surface structure and softness.This means that the formed nonwovens of the present disclosure can provide visibly recognizable surface texture, including in irregular patterns, as well as superior softness, as indicated by measured Emtec values. Furthermore, the formed nonwovens of the present disclosure can offer visibly recognizable surface texture in combination with physical integrity and reduced pilling properties, as well as superior softness, as indicated by measured Emtec values.

[0193] As discussed above, in an example, a process for producing a shaped nonwoven fabric may be a modified version of the process described with reference to Fig. 7 is described. A modification is described with reference to Fig. 56 described. As in Fig.As shown in Figure 56, the process can also include a tape 60, as described above in a melt spinning process in which more than one spinning beam is used. As shown schematically in the figure of only the spin packs 48A and 48B, two beams can be used to melt spin fibers onto tape 60, with a compaction process 70A, 72A and 70B, 72B taking place after each beam. The vacuum boxes 64A and 64B can also each be operatively connected to each spinning beam 48A and 48B.

[0194] After spinning fibers onto tape 60, and after compaction, including optional thermal bonding during compaction, as described above, the formed nonwoven web can be subjected to additional heating by the air dryer 76, which has several chambers, such as three chambers 76A, 76B and 76C, each of which is independently temperature controlled.

[0195] Examples 7 and 9 above were produced on a twin-beam process line and in a Fig.The 56 schematically illustrated processes are air-flow bonded. Without being bound to any theory, it is assumed that air-flow bonding preserves much of the three-dimensionality of the three-dimensional features of the formed nonwoven, as indicated by the difference in the TS7 values ​​in Table 5. Alternatively, it is assumed that if a formed nonwoven with fewer sides is desired, calender bonding tends to balance the TS7 values, as shown by Example 8 in Table 5. Thus, the process parameters can be controlled as described herein to achieve a predetermined softness per side, i.e., surface, of a formed nonwoven. In addition to the advantages described above, a further advantage of the formed nonwovens of this disclosure relates to the ability to provide a nonwoven with microzones that have a hydrophobic region and a separate hydrophilic region.The hydrophilicity and / or hydrophobicity in a specific region of the microzone can be determined by a time-to-wick measurement using the time-to-wick test procedure described in this document and / or a contact angle measurement using the contact angle test procedure described in this document. As used herein, the term "hydrophilic" with respect to a specific region of the microzone means that, when tested using the time-to-wick test procedure, the time-to-wick for that specific region is less than 10 seconds. As used herein, the term "hydrophobic" with respect to a specific region of the microzone means that, when tested using the contact angle test procedure, the contact angle for that specific region is 90° or greater.

[0196] Table 6 below describes the contact angle and time-to-wick measurements for shaped nonwovens, as detailed herein. For both of the following examples 10 and 11, the nonwoven was produced on a tape as described in Fig. 16 is described, whereby the nonwoven fabric has a similar appearance to that described in Fig. 2. Table 6: Contact angle and time-to-wick values ​​for shaped nonwovens of the Revelation Example No. Area Contact angle(θc) Time-to-Wick (seconds) Example 10 First area 135 60 Second area 0 0,307 Example 11 First area 126 60 Second area 0 2,360 Example 10:

[0197] A bicomponent spunbond nonwoven web was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration, as discussed above with reference to Example 2. The nonwoven was formed on a forming belt with a repeating pattern as shown in Fig.16 spun under motion at a linear speed of about 25 meters per minute to produce a fabric 10 with an average base weight of 25 grams per square meter with a repeating pattern of heart shapes, as in Fig. 2 shown, to form. Fibers of the fabric were compacted by compaction rollers 70, 72, but instead of being calendered, further bonding was achieved by an air-bonding unit, as shown below in relation to Fig. 56 described, reached at a temperature of 145 °C.

[0198] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylates with PEG diesters), supplied by Pulcra Chemicals, was then applied to the reverse side of the nonwoven fabric (i.e., the flat side opposite the side with the relatively cushion-like three-dimensional features) using a kiss-coating process. The coating process was carried out using a Reicofil kiss-roll and omega drying procedure, both of which are state-of-the-art. The surfactant used in the kiss-roll process had a 6% surfactant concentration in water at a temperature of 40 °C. The kiss-roll contact angle was set to 250°, and the drying temperature was 80 °C. The nonwoven fabric was then brought into contact with the Kiss roller operating at a speed of 13 rpm, thereby impregnating the nonwoven fabric with 0.45 wt% surfactant (% surfactant is the weight of added surfactant per 1 m²). 2 divided by 1 m2 nonwoven fabric) was added. Example 11:

[0199] A bicomponent spunbond nonwoven web was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration, as discussed above with reference to Example 2. The nonwoven was formed on a forming belt with a repeating pattern as shown in Fig. 16 spun under motion at a linear speed of about 25 meters per minute to produce a fabric 10 with an average base weight of 25 grams per square meter with a repeating pattern of heart shapes, as in Fig. 2 shown, to form. Fibers of the fabric were compacted by compaction rollers 70, 72, but instead of being calendered, further bonding was achieved by an air-bonding unit, as below with reference to Fig.56 described, reached at a temperature of 145 °C.

[0200] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylates with PEG diesters), supplied by Pulcra Chemicals, was then applied to the front side of the nonwoven fabric (i.e., the side with the relatively cushion-like three-dimensional features) using an inkjet printing process. The inkjet printing was performed using a Dimatix DMP 2831 inkjet printer equipped with a cartridge model # DMC-11610 / PM 700-10702-01 (10 pL). The printhead temperature was 40 °C. The surfactant used in the inkjet printing process consisted of 75 w / w Stantex S 6327 and 25% w / w ethanol.Surfactant was printed into the second regions of the microzones of the nonwoven fabric by orienting the sample so that the second regions of a first row of microzones were aligned with the printhead direction and printing a first row of straight lines with the droplet spacing set to 170 µm. The sample was then rotated so that the second regions of a second row of microzones were aligned with the printhead and printing a second row of straight lines at 170 µm. The base weight of the fibers in the second region is approximately 16.0 grams per square meter. The base weight of the surfactant printed onto the second region using the inkjet method is approximately 0.25 grams per square meter. Accordingly, it was determined that the amount of surfactant printed locally onto the second region was approximately 1.6 wt.The surfactant content is -% (0.25 grams per square meter / 16.0 grams per square meter). Overall, the ratio between printed line width and line spacing determined that the amount of surfactant printed on the nonwoven sample is approximately 0.2 wt% surfactant.

[0201] In addition to Stantex S 6327, the use of other surfactants to make the first and / or second area of ​​certain microzones hydrophilic and / or hydrophobic (by any application method) is considered to be within the scope of protection of this disclosure. Other potential surfactants for use in the processes and nonwovens detailed here include: non-ionic surfactants including esters, amides, carboxylic acids, alcohols, ether polyoxyethylene, polyoxypropylene, sorbitan, ethoxylated fatty alcohols, alyl phenol polyethoxylates, lecithin, glycerol esters and their ethoxylates and sugar-based surfactants (polysorbates, alkyl polyglycosides), and anionic surfactants including sulfonates, sulfates, phosphates, alkali metal salts of fatty acids, fatty alcohol monoesters of sulfuric acid, linear alkylbenzenesulfonates, alkyldiphenyl oxidesulfonates, lignosulfonates, olefinsulfonates, sulfosuccinates and sulfated ethoxylates of fatty alcohols.and cationic surfactants including amines (primary, secondary, tertiary), quaternary ammonium compounds, pyridinium, quaternary ammonium salts - QAS, alkylated pyridinium salts, primary, secondary, tertiary alkylamines and alkanolamides, and zwitterionic surfactants including amino acids and derivatives, amine oxide, betaine and alkylamine oxides, and polymeric surfactants including polyamines, carboxylic acid polymers and copolymers, EO / PO block copolymers, ethylene oxide polymers and copolymers and polyvinylpyrrolidone, and silicone surfactants including dimethylsiloxane polymers with hydrophilic and perfluorocarboxylic acid salts and fluorosurfactants.

[0202] The shaped nonwovens described in detail above exhibit microzones with regions exhibiting differences in intensive properties, the intensive properties being selected from the group consisting of base weight, volumetric density, and thickness. Such identically shaped nonwovens may also simultaneously exhibit regions of the microzones that are, in particular and separately, hydrophobic and / or hydrophilic. Each of the shaped nonwoven examples described in detail herein (e.g., samples comprising zones and / or microzones with regions exhibiting differences in thickness, base weight, and / or volumetric density, and / or surfaces with the various TS7 values ​​disclosed herein) may further exhibit regions of a microzone exhibiting differences in hydrophilicity, as described in this document.Hydrophilicity can be achieved by selectively applying surfactant(s) to specific regions within the microzones of the formed nonwoven fabric. For example, the second region of a microzone may have a surfactant applied to it, while the first region of the same microzone may not. Similarly, the first region of a microzone may have a surfactant applied to it, while the second region of the same microzone may not. For instance, within a microzone, the first or second region may have a surfactant concentration of approximately 0.01% to approximately 5.0%, approximately 0.05% to approximately 4.0%, or approximately 1.0% to approximately 3.0%, respectively, and any concentric region may have a concentration of 0.01% to approximately 5.0%, while the other region has no surfactant (i.e., is surfactant-free).As an example, in a microzone, the second region may contain a surfactant of approximately 0.01% to approximately 5.0%, approximately 0.05% to approximately 4.0%, approximately 1.0% to approximately 3.0%, and in any concentric region in the range of 0.01% to approximately 5.0%, and the first region contains no surfactant (i.e., is surfactant-free). Accordingly, some formed nonwovens disclosed in this document have a microzone with at least one of the first and second regions, containing a surfactant, and the ratio of the percentage surfactant content in the first region to the percentage surfactant content in the second region is less than 1. Furthermore, some formed nonwovens disclosed in this document have a microzone with at least the second region of the microzone, containing a surfactant, and the ratio of the percentage surfactant content in the first region to the percentage surfactant content in the second region is less than 1.

[0203] As another example, the second region of a microzone can contain a specific amount or percentage of surfactant, while the first region of the same microzone can contain a different amount or percentage of surfactant. For example, in a microzone, the first region might contain approximately 0.01% to 2.0% surfactant, approximately 0.05% to 1.5%, approximately 0.1% to 1.0% surfactant, and in any concentric region, the concentration might range from 0.01% to 2.0%, while the second region might contain a different amount. Furthermore, the second area in a microzone can have a surfactant concentration of approximately 0.01% to approximately 5.0%, approximately 0.05% to approximately 4.0%, approximately 1.0% to approximately 3.0%, and in any concentric area in the range of 0.01% to approximately 5.0%, and the first area can have a different amount.The percentage of surfactant for a specific area of ​​a microzone can be determined by taking the grams per square meter of surfactant located in that area and dividing this by the base weight of the molded nonwoven fibers contained in the same area. The grams per square meter of surfactant located in a specific area can be determined using any currently known method that is state of the art (e.g., gravimetric, etc.). The base weight of the molded nonwoven fibers contained in a specific area of ​​a microzone can also be determined using any currently known method that is state of the art (e.g., gravimetric, micro-CT, etc.).For specific microzone examples, the base weight ranges / examples of fibers included in the first and second areas are described in detail above.

[0204] A surfactant can be applied to the formed nonwovens by any known method that conforms to the state of the art. Specific examples include KISS coating, inkjet printing, engraved printing, offset engraved printing, flexographic printing of the surfactant, and registered printing of the surfactant. Each of these methods can apply the surfactant to either the first and / or second surface of the formed nonwovens. For the entire formed nonwoven (taking into account all the individual zones and microzones on the fabric), the surfactant can be added to the formed nonwoven in an amount of approximately 0.01% to approximately 2.0%, approximately 0.05% to approximately 1.5%, approximately 0.1% to approximately 1.0%, and to any concentric area in the range of approximately 0.01% to approximately 2.0%.To calculate the percentage of surfactant added to the entire formed nonwoven fabric, the grams per square meter of surfactant in the entire formed nonwoven fabric are divided by the base weight of the entire formed nonwoven fabric. The grams per square meter of surfactant in the entire formed nonwoven fabric can be determined using any method that meets current state of the art (e.g., gravimetrically, etc.). The base weight of the entire formed nonwoven fabric can likewise be determined using any method that meets current state of the art (e.g., gravimetrically, micro-CT, etc.).

[0205] Now referring to the Fig. 38 and Fig. Figure 39, which shows a section of a pattern of a nonwoven fabric 10, is a first zone 110 (on the left side of Fig.38) characterized by generally MD-oriented rows of first regions 300 of variable width, separated by MD-oriented rows of second regions 310 of variable width (where the first and second regions are located in a microzone). The first region is also the three-dimensional feature 20 that defines the first and second regions 300, 310. In one embodiment, a three-dimensional feature is a section of the nonwoven fabric 10 formed between or around a raised element of the forming strip, which in this description is the first region 300, such that the resulting structure has a relatively larger dimension in the Z-direction, a relatively higher base weight, and a lower volumetric density compared with the second region 310. Furthermore, the first region 300 can be hydrophobic and the second region 310 hydrophilic.The targeted addition of a surfactant to the second region 310 of the microzone can cause the second region to be hydrophilic. Accordingly, the first region 300 of the microzone may exhibit a contact angle greater than approximately 90°, or between approximately 90° and approximately 140°, or between approximately 110° and approximately 135°, or between approximately 125° and approximately 135°, or any concentric region between approximately 90° and approximately 140°, when tested using the contact angle test procedure described herein. The second region 310 of the microzone may exhibit a contact angle of less than 90° when tested using the contact angle test procedure described herein. The first region 300 of the microzone may exhibit a time-to-wick value greater than approximately 10 seconds or between approximately 10 seconds and 60 seconds, as measured using the time-to-wick test procedure described herein.The second area 310 of the microzone can exhibit a time-to-wick value of less than approximately 10 seconds, less than approximately 5 seconds, less than approximately 2.5 seconds, less than approximately 1 second, or less than approximately 0.5 seconds, as measured by the time-to-wick test method described herein. The formed nonwovens considered herein incorporate one of the detailed parameter ranges for contact angle and / or time-to-wick measurements for the first area and / or the second area, in combination with any of the other intensive properties / property differences disclosed herein for the same or different areas within the same or different microzone on the formed nonwoven.

[0206] Molded nonwovens with the microzones described in detail above, with areas that have differences in base weight, density or thickness, while such areas of a particular microzone are simultaneously separately hydrophobic and / or hydrophilic, can offer many useful applications, such as top layer materials for baby care, care products for women and adult incontinence products, as well as use in medical pads, wipes and cleaning covers, etc.

[0207] The dimensions and values ​​disclosed herein should not be construed as being strictly limited to the exact numerical dimensions and / or values ​​stated. Instead, unless otherwise stated, each of these dimensions and / or values ​​should have the meaning of the stated dimension and / or value and a functionally appropriate range surrounding that dimension and / or value. For example, a dimension disclosed as "40 mm" should mean "about 40 mm".

[0208] Every document referenced herein, including any references to or related patents or applications, is hereby incorporated herein by reference in its entirety, unless expressly excluded or otherwise limited. The citation of a document does not imply that it is recognized as prior art for any embodiment disclosed or claimed herein, or that it teaches, suggests, or discloses such embodiment, either alone or in combination with other referenced literature. Furthermore, should any meaning or definition of a term in this document conflict 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 document shall prevail.

[0209] Although certain embodiments of the present invention have been presented and described, it is obvious to the person skilled in the art that various further changes and modifications can be made without deviating from the basic concept and scope of protection of the present invention. Therefore, the appended claims are intended to cover all such changes and modifications that fall within the scope of protection of the invention. Test procedure: Compression aging test; Initial thickness measurement: • Cut out five 3-inch by 3-inch samples for each nonwoven fabric to be measured. • Number each sample from 1 to 5. • Check the thickness at 0.5 kPa with the 65 mm standard foot using a Thwing Albert thickness gauge according to standard procedure. • Record the initial thickness for each of the five samples. • Record the average thickness of the five samples. Aging compression methods and aging thickness measurement • Stack the five samples alternately, with each one separated by a paper towel, the stack beginning and ending with sample number 1 and 5. • Place the alternately stacked samples into an aluminium sample holder with a suitable weight (4 kPa, 14 kPa or 35 kPa) placed on top of the samples. • Place the stacked samples in an oven at 40 °C for 15 hours. • Remove the weight after 15 hours, separate the samples and test the thickness of each sample at 0.5 kPa to the 65 mm standard foot using a Thwing Albert thickness gauge according to standard procedure. • Record the aging thickness value for each of the five samples. • Record the average aged thickness of the five samples. Analysis reports: • Record average initial and aged thicknesses by position number • Thickness restoration index: (Average aged thickness / average initial thickness) * 100 Localized base weight

[0210] The localized base weight of the nonwoven fabric can be determined using several available methods. However, a simple, representative method involves a die-cutting tool with an area of ​​3.0 cm². 2 This method is used to cut a sample of the web from a selected area within the total surface area of ​​a nonwoven fabric. The sample is then weighed and divided by its area to obtain the localized base weight of the nonwoven fabric in grams per square meter. The results are presented as the mean of two samples per selected area. Fuzz formation degree test

[0211] The linting test is used to determine the amount of fibers that are removed from a nonwoven material under an abrasive force (i.e., the linting rate).

[0212] The lint formation degree test uses the following materials: • Sutherland ink rub tester weighing 2 pounds, available from Danilee Co, San Diego, TX. • Factory rollers, 320 grit size, aluminum oxide cloth, manufactured by Plymouth Coatings, (617) 447-7731. This material may also be ordered through McMaster Carr, part number 468.7A51, (330) 995-5500. • Double-sided tape, 3M #409, available from the Netherland Rubber Company, (513) 733-1085. • Fiber removal tape, 3M #3187, available from the Netherland Rubber Company, (513) 733-1085. • Analytical balance (+ / - 0.0001 g) • Paper cutter • 2200 g weight (metal) 170 mm × 63 mm. • Thick peel-off paperboard - 0.0445 inch (1.13 mm) thick. Material production

[0213] Measure and cut the aluminum oxide cloth into 7.5-inch (19.0 cm) long pieces. Measure and cut 6.5-inch (16.5 cm) lengths of 3M #3187 tape, two pieces for each sample. Fold over approximately 0.25 inches (0.6 cm) at each end of the 3M #3187 tape for ease of handling. Place the 3M #3187 tape on the thick release paper for later use. Sample preparation

[0214] Before handling or testing any of the materials, wash your hands with soap and water to remove excess grease. Latex gloves may be worn. Cut a sample of the nonwoven fabric to be tested to a size of at least 11 cm in MD and 4 cm in CD. Unfold the nonwoven sample with the side to be tested facing down. Cut a piece of 3M #409 double-sided tape from a roll, at least 11 cm long. Remove the backing and apply the side of the double-sided tape that was facing the backing along the machine direction (MD) to the sample nonwoven. Replace the backing over the exposed tape. Using a paper cutter, cut test samples within the covered area to 11 cm MD and 4 cm CD. Testing procedure 1. Attach the cut piece of aluminum oxide cloth to a Sutherland ink rub tester using the 2-pound weight. Place a second cut piece of aluminum oxide cloth on top of the thick release paper board (a new piece is used for each test). Place both on the 2-pound weight. Fold the sides down in staples, ensuring the aluminum oxide cloth and thick release paper board lie flat. 2. Place the sample on a Sutherland ink rub tester, centering it on the metal plate. Place the 2200 g weight on the sample for 20 seconds. 3. Place the metal plate and the 2-pound weight on the Sutherland ink rub tester. 4. Switch on the friction tester. If the backlight is not illuminated, press the reset button. Press the counter button to set the friction cycles to 20 cycles. Select speed 1, the slow speed (light is not illuminated), using the speed knob. Press "Start". 5. Once the friction tester is switched off, carefully remove the aluminum oxide cloth / weight, ensuring that none of the loose microfibers (lint) are lost. In some cases, the microfibers will adhere to both the aluminum oxide cloth and the surface of the sample fleece. Place the weight upside down on the bench. 6. Weigh the fiber removal tapes with the attached release paper. Hold the fiber removal tape by the folded ends, peel off the release paper, and set it aside. Carefully place the tape onto the aluminum oxide cloth to remove all lint. Peel off the fiber removal tape and return it to the release paper. Weigh and record the weight of the fiber removal tapes. 7. Hold another piece of the pre-weighed fiber release tape by its folded ends. Carefully place the fiber release tape onto the surface of the rubbed nonwoven sample. Place a flat metal plate flat on top of the fiber release tape. 8. Place the 2200 g weight on top of the metal plate for 20 seconds. Peel off the fiber release tape. Hold the pre-weighed fiber release tape by the folded ends to avoid fingerprints. Place the pre-weighed fiber release tape back onto the release paper. The weight of the fiber release tapes is weighed and recorded. 9. The lint weight is the sum of the weight increase of both fiber shedding bands. 10. The lint weight is given as the average of 10 measurements. Calculations:

[0215] For a given sample, the weight in grams of lint collected from the aluminum oxide cloth is added to the weight in grams of lint collected from the rubbed sample fleece. The combined weight in grams is multiplied by 1000 to convert to milligrams (mg). To convert this measurement from an absolute weight loss to a weight loss per unit area, the total weight of lint is divided by the area of ​​the rubbed region. Air permeability tests

[0216] The air permeability test is used to determine the degree of airflow, in cubic feet per minute (cfm), through a forming strip. The test is performed using a Textest Instruments FX3360 Portair Air Permeability Tester, available from Textest AG, Sonnenbergstrasse 72, CH 8603 Schwerzenbach, Switzerland. The unit uses a 20.7 mm perforated plate for air permeability ranges between 300 and 1000 cubic feet per minute. If the air permeability is less than 300 cubic feet per minute, the plate size must be reduced; if it is greater than 1000 cubic feet per minute, the plate size must be increased. Air permeability can be measured in localized zones of a forming strip to identify variations in air permeability across the strip. Testing procedure 1. Turn on the FX3360 device. 2. Select a predefined method with the following settings: a. Material: Standard b. Measurement property: Air permeability (AP) c. Test pressure: 125 Pa (Pascals) d. T-factor: 1.00 e. Test point spacing: 0.8 inches 3. Place the 20.7 mm opening plate on the top side of the forming strip (the side with the three-dimensional protrusions) at the position of interest. 4. Select “Spot Measurement” on the touchscreen of the test unit. 5. Reset the sensor before measurement, if necessary. 6. After resetting, select the "Start" button to begin the measurement. 7. Wait until the measurement has stabilized and record the cubic foot reading on the screen. 8. Select the "Start" button again to stop the measurement. In-bag stack height check

[0217] The in-bag stacking height of a package of absorbent products is determined as follows: equipment

[0218] A thickness gauge with a flat, rigid, horizontal sliding plate is used. The thickness gauge is configured such that the horizontal sliding plate moves freely in a vertical direction, while always being held in a horizontal orientation directly above a flat, rigid, horizontal base plate. The thickness gauge includes a suitable device for measuring the gap between the horizontal sliding plate and the horizontal base plate to within ± 0.5 mm.

[0219] The horizontal sliding plate and the horizontal base plate are larger than the surface area of ​​the absorbent packaging that is in contact with each plate; that is, each plate extends beyond the contact surface of the absorbent packaging in all directions. The horizontal sliding surface exerts a downward force of 850 ± 1 gram (8.34 N) on the absorbent packaging, which can be achieved by placing a suitable weight on the center of the upper surface of the horizontal sliding plate that is not in contact with the packaging, so that the total mass of the sliding plate plus the additional weight is 850 ± 1 gram. Testing procedure

[0220] Absorption article packaging is equilibrated at 23 ± 2 °C and 50 ± 5 % relative humidity before measurement.

[0221] The horizontal sliding plate is lifted and an absorbent material package is placed centrally under the horizontal sliding plate in such a way that the absorbent materials inside the package are in a horizontal orientation (see Fig.27) Any handle or other packaging feature on the packaging surface that would come into contact with one of the plates is folded flat against the surface of the packaging to minimize its effect on the measurement. The horizontal sliding plate is lowered slowly until it makes contact with the top of the packaging and is then released. The gap between the horizontal plates is measured to ± 0.5 mm ten seconds after the horizontal sliding plate is released. Five identical packages (packages of the same size and with the same number of absorbents) are measured, and the arithmetic mean is reported as the package width. The "in-bag stack height" = (package width / number of absorbents per stack) × 10 is calculated and recorded to ± 0.5 mm. Methods for micro-CT measurement of intensive properties

[0222] The micro-CT measurement method for intensive properties measures the base weight, thickness, and volumetric density values ​​in optically perceptible areas of a substrate sample. It is based on the analysis of a 3D X-ray image of the sample obtained on a micro-CT scanner (a suitable device is the Scanco µCT 50, available from Scanco Medical AG, Switzerland, or equivalent). The micro-CT instrument is a cone-beam microtomograph with a shielded cabinet. A maintenance-free X-ray tube with an adjustable focal spot diameter is used as the source. The X-ray beam passes through the sample, where some of the X-rays are attenuated. The degree of attenuation correlates with the dimensions of the material through which the X-rays must pass. The transmitted X-rays then proceed to the digital detector array, generating a 2D projection image of the sample.A 3D image of the sample is generated by collecting multiple individual projection images of the sample during rotation, which are then recombined into a single 3D image. The device is connected via an interface to computer-based software for controlling image acquisition and storing the raw data. The 3D image is then analyzed using image analysis software (suitable software is MATLAB, available from The MathWorks, Inc., Natick, MA, or similar) to measure intensive properties such as base weight, thickness, and volumetric density of regions within the sample. Rehearsal preparation:

[0223] To obtain a sample for measurement, a single layer of the dry substrate material is spread out flat and a circular piece with a diameter of 30 mm is punched out.

[0224] If the substrate material is a layer of an absorbent article, for example, a top layer, a bottom layer fleece, an absorption layer, a distribution layer, or another component layer, then the absorbent article is adhered to a solid, flat surface in a planar configuration. Carefully separate the individual substrate layer from the absorbent article. A scalpel and / or cryogenic sprays (such as Cyto-Freeze, Control Company, Houston, Texas) can be used to remove a substrate layer from any underlying layers, if necessary, to prevent longitudinal and lateral expansion of the material. Once the substrate layer has been removed from the article, the sample is punched as described above.

[0225] If the substrate material is in the form of a wet wipe, open a new pack of wet wipes and remove the entire stack from the packaging. Take a single wet wipe from the center of the stack, spread it out flat, and allow it to dry completely before punching the sample for analysis.

[0226] A sample can be cut from any location containing the optically detectable zone to be analyzed. Within a zone, areas to be analyzed are those associated with a three-dimensional feature that defines a microzone. The microzone comprises at least two optically detectable areas. A zone, a three-dimensional feature, or a microzone may be optically detectable due to changes in texture, elevation, or thickness. Areas within different samples of the same substrate material can be analyzed and compared. Care should be taken to avoid wrinkles, creases, or tears when selecting a sampling location. Image capture:

[0227] Set up and calibrate the micro-CT scanner according to the manufacturer's instructions. Place the sample in the appropriate holder between two rings of low-density material with an inner diameter of 25 mm. This ensures that the central section of the sample lies horizontally and is scanned without any other materials directly adjacent to the upper and lower surfaces. Measurements should be taken in this area. The 3D imaging field of view is approximately 35 mm on each side in the xy-plane, with a resolution of approximately 5000 by 5000 pixels and a sufficient number of 7-micrometer thick slices collected to fully encompass the z-direction of the sample. The reconstructed 3D image resolution contains isotropic voxels of 7 micrometers. Images are acquired with a source at 45 kVp and 133 µA without an additional low-energy filter.These current and voltage settings can be optimized to generate maximum contrast in the projection data with sufficient X-ray penetration through the sample, but after optimization, they are kept constant for all substantially similar samples. A total of 1500 projection images are acquired with an integration time of 1000 ms and 3 averages. The projection images are reconstructed into the 3D image and stored in 16-bit RAW format to preserve the full detector output signal for analysis. Image processing:

[0228] Load the 3D image into the image analysis software. Adjust the 3D image below the threshold to a value that separates and removes the background signal caused by the air, but preserves the signal from the sample fibers within the substrate.

[0229] Three 2D images with intensive properties are generated from the threshold 3D image. The first is the baseline image. To generate this image, the value for each voxel in an xy-plane slice is summed with all its corresponding voxel values ​​in the other z-direction slices that contain a signal from the sample. This produces a 2D image where each pixel now has a value equal to the sum signal across the entire sample.

[0230] To convert the raw data values ​​in the base weight image into real values, a base weight calibration curve is generated. A substrate is obtained that has a substantially similar composition to the sample to be analyzed and a uniform base weight. The procedures described above are followed to obtain at least ten replica samples of the calibration curve substrate. The base weight is accurately measured by recording the mass to the nearest 0.0001 g, dividing by the sample area, and converting to grams per square meter (gsm) for each of the single-layer calibration samples. The mean value is then calculated to the nearest 0.01 grams per square meter. Following the procedures described above, a micro-CT image of a single layer of the calibration sample substrate is obtained.Following the procedures described above, the micro-CT image is processed and a base weight image with raw data values ​​is generated. The actual base weight value for this sample is the average base weight value measured in the calibration samples. Next, two layers of the calibration substrate samples are stacked on top of each other, and a micro-CT image of the two layers of the calibration substrate is acquired. A base weight raw data image of both layers together is generated, the actual base weight of which is equal to twice the average base weight value measured in the calibration samples.Repeat this process of stacking individual layers of the calibration substrate, acquire a micro-CT image of all layers, and generate a raw data base weight image of all layers whose actual base weight is equal to the number of layers multiplied by the average base weight measured in the calibration samples. A minimum of four different base weight calibration images will be obtained. The base weight values ​​of the calibration samples must include values ​​above and below the base weight values ​​of the original sample being analyzed to ensure accurate calibration. The calibration curve is generated by linear regression based on the raw data compared to the actual base weight values ​​for the four calibration samples. This linear regression must have an R² value of at least 0.95; if not, please repeat the entire calibration procedure.This calibration curve is now used to convert the raw data values ​​into actual base weights.

[0231] The second 2D image of an intensive property is the thickness image. To generate this image, the upper and lower surfaces of the sample are identified, and the distance between these surfaces is calculated, yielding the sample thickness. The upper surface of the sample is identified by starting at the topmost z-direction slice and evaluating each slice to traverse the sample and locate the z-direction voxel for all pixel positions in the xy-plane where the sample signal was first detected. The same procedure is followed to identify the lower surface of the sample, except that the z-direction voxels are all positions in the xy-plane where the sample signal was last detected. Once the upper and lower surfaces have been identified, they are smoothed with a 15x15 median filter to remove signals from stray fibers.The "2D thickness image" is then generated by counting the number of voxels that exist between the upper and lower surfaces for each pixel position in the xy-plane. This raw thickness value is then converted into the actual distance, in micrometers, by multiplying the number of voxels by the 7 µm disk thickness resolution.

[0232] The third 2D image of intensive properties is the volumetric density image. To generate this image, each xy-plane pixel value in the base weight image, in units of grams per square meter, is divided by the corresponding pixel in the thickness image, in units of micrometers. The units of the volumetric density image are grams per cubic centimeter (g / cm³). 3 ). Intensive properties of microCT base weight, thickness and volumetric density:

[0233] Begin by identifying the area to be analyzed. An area to be analyzed is one associated with a three-dimensional feature that defines a microzone. The microzone comprises at least two optically detectable areas. A zone, three-dimensional feature, or microzone can be optically detectable due to changes in texture, elevation, or thickness. Next, identify the boundary of the area to be analyzed. The boundary of an area is identified by optically discriminating against differences in intensity properties compared to other areas within the sample. For example, an area boundary can be identified by optically detecting a difference in thickness when compared to another area in the sample.Each of the intensive properties can be used to distinguish area boundaries on the physical sample itself from any of the microCT images of intensive properties. Once the area boundary has been identified, draw an oval or circular "area of ​​interest" (ROI) within the interior of the area. The ROI should have an area of ​​at least 0.1 mm² and be selected to measure an area with intensive property values ​​that are representative of the identified area. From each of the three intensive property images, calculate the average base weight, average thickness, and average volumetric density within the ROI. These values ​​are then adjusted as the base weight of the area to the nearest 0.01 grams per square meter, the thickness to the nearest 0.1 micrometer, and the volumetric density to the nearest 0.0001 g / cm³. 3 record. Emtec testing procedure

[0234] TS7 and TS750 values ​​are measured using an EMTEC Tissue Softness Analyzer (“Emtec TSA”) (Emtec Electronic GmbH, Leipzig, Germany) connected to Emtec TSA software (version 3.19 or equivalent) running on a computer. According to Emtec, the TS7 value correlates with the actual softness, while the TS750 value correlates with the perceived smoothness / roughness of the material. The Emtec TSA comprises a rotor with vertical blades that rotate on the test specimen at a defined and calibrated rotational speed (set by the manufacturer) and a contact force of 100 mN. The contact between the vertical blades and the specimen generates vibrations that produce sound, which is recorded by a microphone inside the device. The recorded sound file is then analyzed by the Emtec TSA software.Sample preparation, equipment operation and testing procedures are carried out according to the specifications of the equipment manufacturer. Sample preparation

[0235] Test specimens are prepared by cutting square or circular samples from a finished product. The test specimens are cut to a length and width (or diameter if circular) of not less than approximately 90 mm and not more than approximately 120 mm in any of these dimensions to ensure that the specimen can be properly clamped in the TSA device. The specimens are selected to avoid perforations, creases, or folds within the test area. Please prepare 8 substantially similar replica specimens for testing purposes. Equilibrate all specimens at TAPPI standard temperature and relative humidity conditions (23°C ± 2°C and 50% ± 2%) for at least 2 hours prior to performing the TSA test, which is also carried out under TAPPI conditions. Testing procedure

[0236] Calibrate the instrument according to the manufacturer's instructions using the 1-point calibration procedure with Emtec reference standards (ref. 2 samples). If these reference samples are no longer available, please use the appropriate reference samples provided by the manufacturer. Calibrate the instrument according to the manufacturer's recommendations and instructions so that the results are comparable to those obtained using the 1-point calibration procedure with Emtec reference standards (ref. 2 samples).

[0237] Prepare eight repeat samples of a substance for testing purposes. Place one test sample into the instrument with one surface facing upwards and perform the test according to the manufacturer's instructions. Upon completion, the software will display values ​​for TS7 and TS750. Adjust each of these values ​​to the nearest 0.01 dBV. 2The test sample is recorded. The test specimen is then removed from the device and discarded. This test is performed individually on the same surface of four replica samples, and then on the other surface of the other four replica samples. The first surface tested can be either the first surface 12 or the second surface 14 of a shaped nonwoven fabric, as disclosed herein.

[0238] The four test result values ​​for TS7 and TS750 of the first tested surface are averaged (using a simple numerical average); the same is done for the four test result values ​​for TS7 and TS750 from the second tested surface. The individual mean values ​​of TS7 and TS750 for both the first and second tested surfaces on a given test specimen are averaged to the nearest 0.01 dB V. 2Record the rms. Additionally, the TS7 ratio of the first tested surface to the second tested surface is calculated by dividing the average TS7 of the first tested surface by the average TS7 of the second tested surface. Contact angle and time-to-wick testing methods

[0239] Contact angle and time-to-wick measurements are determined using a sessile drop experiment. A specified volume of distilled water type II reagent (as defined in ASTM D1193) is applied to the surface of a test specimen using an automated liquid delivery system. A high-speed video camera records time-stamped images of the drop over a period of 60 seconds at a rate of 900 frames per second. The contact angle between the drop and the surface of the test specimen is determined for each recorded image using image analysis software. Time-to-wick is determined as the time it takes for the contact angle of a drop penetrating the test specimen to decrease to a contact angle of < 10°. All measurements are performed at a constant temperature (23°C ± 2°C) and relative humidity (50% ± 2%).

[0240] An automated contact angle tester is required to perform this test. The system consists of a light source, a video camera, a horizontal sample stage, a liquid delivery system with pump and microsyringe, and a computer equipped with software for video image acquisition, image analysis, and evaluation of contact angle data. A suitable instrument is the OCA 20 optical contact angle measurement system (DataPhysics Instruments, Filderstadt, Germany) or an equivalent. The system must be capable of dispensing an 8.2 microliter drop and capturing images at a rate of 900 frames per second. The system is calibrated and operated according to the manufacturer's instructions unless explicitly stated otherwise in this test procedure.

[0241] To obtain a test specimen for measurement, a single layer of the dry substrate material is laid flat, and a test specimen approximately 15 mm wide and 70 mm long is punched out. The width of the specimen can be reduced as needed to ensure that the area in question is not obscured by surrounding features during testing. With a narrower specimen strip, care must be taken to ensure that the liquid droplet does not reach the edge of the specimen during testing, as this would necessitate repeating the test. Pre-condition the specimens at 23 °C ± 2 °C and approximately 50% ± 2% relative humidity for 2 hours prior to testing. Sample preparation

[0242] A test sample can be punched out from any point containing the optically detectable zone to be analyzed. Within a zone, areas to be analyzed are those associated with a three-dimensional feature that defines a microzone. The microzone comprises at least two optically detectable areas. A zone, a three-dimensional feature, or a microzone can be optically detectable due to changes in texture, elevation, or thickness. Areas within different test samples made from the same substrate material can be analyzed and compared. Care should be taken to avoid creases, wrinkles, or cracks when selecting a sampling location.

[0243] If the substrate material is a layer of an absorbent article, such as a top or bottom layer nonwoven, an absorption layer, a distribution layer, or another component layer, then adhere the absorbent article to a firm, flat surface in a planar configuration. Carefully separate the individual substrate layer from the absorbent article. A scalpel and / or cryogenic sprays (such as Cyto-Freeze, Control Company, Houston, Texas) may be used to remove a substrate layer from any underlying layers, if necessary, to prevent longitudinal and lateral expansion of the material. Once the substrate layer has been removed from the article, proceed with punching out the test specimen as described above. If the substrate material is in the form of a wet wipe, open a new pack of wet wipes and remove the entire stack from the package.Take a single wet wipe from the middle of the stack, spread it out flat and allow it to dry completely before punching the sample for analysis. Testing procedure

[0244] The test sample is positioned on the horizontal sample stage with the test area within the camera's field of view, directly below the needle of the liquid delivery system, and the test side facing upwards. The sample is secured so that it lies flat but unloaded, and any interaction between the liquid droplet and the underlying surface is avoided to prevent unnecessary capillary forces. A blunt-tipped stainless steel needle (ID 0.23 mm, OD 0.41 mm) with a thickness of 27 mm is positioned above the test sample, with at least 2 mm of the needle tip within the camera's field of view. The sample stage is adjusted to achieve a distance of approximately 3 mm between the needle tip and the surface of the test sample. An 8.2-microliter droplet of distilled water reagent is dispensed at a rate of 1 microliter per second and is allowed to fall freely onto the surface of the test sample.Video image acquisition is initiated before the drop touches the surface of the test specimen, and subsequently, a continuous series of images is collected for a duration of 60 seconds after the drop touches the surface of the test specimen. This procedure is repeated for a total of five (5) substantially similar replicated test areas. A fresh test specimen is used, or care is taken to ensure that the area previously wetted by the drop is avoided during subsequent measurements.

[0245] In each image captured by the video camera, the test specimen surface and the droplet contour are identified and used by the image analysis software to calculate and record the contact angle for each droplet image to the nearest 0.1 degrees. The contact angle is the angle formed by the surface of the test specimen and the tangent to the surface of the liquid droplet in contact with the test specimen. For each set of images from a test, time zero is the time at which the liquid droplet comes into contact with the surface of the test specimen. The contact angle is measured and recorded on the droplet image corresponding to time zero plus five (5) seconds. The contact angle at five seconds is reported as 0° if the droplet was completely absorbed by the test specimen within five seconds. This procedure is repeated for the five replicated test areas.Calculate the arithmetic mean of the contact angle at time zero plus five seconds for the five replicated test areas and record this value as the contact angle to the next 0.1 degrees.

[0246] Time-to-wick is defined as the time it takes for the contact angle of a droplet absorbed into the test sample to decrease to a contact angle of < 10°. Time-to-wick is measured by identifying the first image in a given series where the contact angle has decreased to < 10°, and then calculating and recording the time elapsed since time zero based on this image. Time-to-wick is recorded as 60 seconds if a contact angle of less than 10° is not reached within 60 seconds. Repeat this procedure for the five replicated test areas. Calculate the arithmetic mean of the time-to-wick for the five replicated test areas and record this value to the next 0.1 milliseconds.

[0247] The revelation includes the combinations described in the following paragraphs: A. A spunbond nonwoven fabric comprising the following: a. a first surface and a second surface and at least a first and a second optically detectable zone on at least one of the first and the second surface, wherein each of the first and the second zone has a pattern of three-dimensional features, wherein each of the three-dimensional features defines a microzone comprising a first area and a second area, wherein the first and the second area exhibit a value difference for an intensive property; and b. wherein the difference in value for an intensive property for at least one of the microzones in the first zone differs from the difference in value for the intensive property for at least one of the microzones in the second zone; wherein in at least one of the microzones the first area has a contact angle greater than about 90 degrees, as measured by the contact angle test method described in detail herein. B. The spunbond nonwoven fabric according to paragraph A, wherein the contact angle is between about 90 degrees and about 140 degrees, as measured by the contact angle test method detailed herein. C. The spunbond nonwoven fabric according to paragraphs AB, wherein the contact angle is between about 110 degrees and about 135 degrees, as measured by the contact angle test method detailed herein. D. The spunbond nonwoven fabric according to paragraphs AC, wherein the contact angle is between about 125 degrees and about 135 degrees, as measured by the contact angle test method detailed herein. E. The spunbond nonwoven fabric according to paragraphs AD, wherein the first area has both a contact angle of more than about 90 degrees and a time-to-wick of more than about 10 seconds, as measured by the time-to-wick test method detailed herein. F. The spunbond nonwoven fabric according to paragraphs AE, wherein time-to-wick is between about 10 seconds and about 60 seconds, as measured by the time-to-wick test method detailed herein. G. The spunbond nonwoven fabric according to paragraphs AF, wherein the difference in value for the intensive property for one of the microzones in the first zone is of an order of magnitude that differs from the difference in value for the intensive property for at least one of the microzones in the second zone. H. The spunbond nonwoven fabric according to paragraphs AG, wherein the difference in value for the intensive property for one of the microzones in the first zone differs by approximately 1.2X to approximately 10X from the difference in value for the intensive property for at least one of the microzones in the second zone. I. The spunbond nonwoven fabric according to paragraphs AH, wherein the intensive property is thickness and the thickness of each region is greater than zero. J. The spunbond nonwoven fabric according to paragraphs AI, wherein the difference in thickness in the first zone is greater than about 25 micrometers. K. The spunbond nonwoven fabric according to paragraphs AJ, wherein the intensive property is a base weight and the base weight is greater than zero in every area. L. The spunbond nonwoven fabric according to paragraphs AK, wherein the difference in base weight in the first zone is greater than approximately 5 grams per square meter. M. The spunbond nonwoven fabric according to paragraphs AL, wherein the intensive property is the volumetric density and the volumetric density of each region is greater than zero. N. The spunbond nonwoven according to paragraphs AM, wherein the difference in volumetric density in the first zone is greater than approximately 0.042 g / cm³ 3 is. O. The spunbond nonwoven according to paragraphs AN, further comprising a third zone with a pattern of three-dimensional features, each defining a microzone comprising a first area and a second area, wherein a value difference for an intensive property for one of the microzones in the third zone differs a) from the value difference for the intensive property for at least one of the microzones in the first zone and b) from the value difference for the intensive property for at least one of the microzones in the second zone. P. The spunbond nonwoven according to paragraphs AO, wherein at least one of the surfaces has a TS7 value of less than about 15 dB V 2 exhibits rms. Q. The spunbond nonwoven according to paragraph P, wherein the first surface has a TS7 value of approximately 2 to approximately 12 dB V 2 rms and the second surface has a TS7 value that differs from the TS7 value of the first surface. R. The spunbond nonwoven according to paragraph Q, wherein the second surface has a TS7 value that is lower than the TS7 value of the first surface. S. The spunbond nonwoven according to paragraph P, wherein the second surface has a TS7 value of approximately 3 to approximately 8 dB V 2 rms and the first surface has a TS7 value that differs from the TS7 value of the second surface. T. The spunbond nonwoven according to paragraph S, wherein the first surface has a TS7 value that is higher than the TS7 value of the second surface. U. An absorption article comprising a spunbond nonwoven fabric as described in paragraphs AT. Y. A packaging of absorbent articles, wherein each absorbent article comprises a spunbond nonwoven fabric as described in paragraphs AU. W. The packaging according to paragraph V, wherein the packaging has a stacking height in the bag of between about 70 mm and about 100 mm, according to the test of the stacking height in the bag described herein. X. A spunbond nonwoven fabric comprising the following: a. a first surface and a second surface and at least a first and a second optically detectable zone on at least one of the first and the second surface, wherein each of the first and the second zone has a pattern of three-dimensional features, wherein each of the three-dimensional features defines a microzone comprising a first area and a second area, wherein the first and the second area exhibit a value difference for an intensive property; and b. wherein the difference in value for an intensive property for at least one of the microzones in the first zone differs from the difference in value for the intensive property for at least one of the microzones in the second zone; wherein in at least one of the microzones the second area has a time-to-wick of less than about 10 seconds, as measured by the time-to-wick test procedure described in detail herein. Y. The spunbond nonwoven fabric according to paragraph X, wherein time-to-wick is less than 5 seconds, as measured by the time-to-wick test method detailed herein. Z. The spunbond nonwoven fabric according to paragraphs XY, wherein time-to-wick is less than 2.5 seconds, as measured by the time-to-wick test method detailed herein. AA. The spunbond nonwoven fabric according to paragraphs XZ, wherein time-to-wick is less than 0.5 seconds, as measured by the time-to-wick test method detailed herein. BB. The spunbond nonwoven according to paragraphs X-AA, wherein the difference in value for the intensive property for one of the microzones in the first zone is of an order of magnitude that differs from the difference in value for the intensive property for at least one of the microzones in the second zone. CC. The spunbond nonwoven fabric according to paragraphs X-BB, wherein the difference in values ​​for the intensive property for one of the microzones in the first zone differs by approximately 1.2X to approximately 10X from the difference in values ​​for the intensive property for at least one of the microzones in the second zone. DD. The spunbond nonwoven fabric according to paragraphs X-CC, where the intensive property is thickness and the thickness of each region is greater than zero. EE. The spunbond nonwoven fabric according to paragraphs X-DD, wherein the difference in thickness in the first zone is greater than approximately 25 micrometers. FF. The spunbond nonwoven fabric according to paragraphs X-EE, wherein the intensive property is a base weight and the base weight is greater than zero in every area. GG. The spunbond nonwoven fabric according to paragraphs X-FF, wherein the difference in base weight in the first zone is greater than approximately 5 grams per square meter. HH. The spunbond nonwoven according to paragraphs X-GG, wherein the intensive property is the volumetric density and the volumetric density of each region is greater than zero. II. The spunbond nonwoven according to paragraphs X-HH, wherein the difference in volumetric density in the first zone is greater than about 0.042 g / cm³ 3 is. JJ. The spunbond nonwoven according to paragraphs X-II, further comprising a third zone with a pattern of three-dimensional features, each defining a microzone comprising a first area and a second area, wherein a difference in value for an intensive property for one of the microzones in the third zone differs a) from the difference in value for the intensive property for at least one of the microzones in the first zone and b) from the difference in value for the intensive property for at least one of the microzones in the second zone. KK. The spunbond nonwoven according to paragraphs X-JJ, wherein at least one of the surfaces has a TS7 value of less than about 15 dB V 2 exhibits rms. LL. The spunbond nonwoven according to paragraph KK, wherein the first surface has a TS7 value of approximately 2 to approximately 12 dB V 2 rms and the second surface has a TS7 value that differs from the TS7 value of the first surface. MM. The spunbond nonwoven according to paragraph LL, wherein the second surface has a TS7 value that is lower than the TS7 value of the first surface. NN. The spunbond nonwoven according to paragraph LL, wherein the second surface has a TS7 value of approximately 3 to approximately 8 dB V 2 rms and the first surface has a TS7 value that differs from the TS7 value of the second surface. OO. The spunbond nonwoven according to paragraph NN, wherein the first surface has a TS7 value that is higher than the TS7 value of the second surface. PP. An absorbent article comprising a spunbond nonwoven fabric as described in paragraphs X-OO. QQ. A packaging of absorbent articles, wherein each absorbent article comprises a spunbond nonwoven fabric as described in paragraphs X-PP. RR. The packaging according to paragraph QQ, wherein the packaging has a stacking height in the bag between approximately 70 mm and approximately 100 mm, according to the test of the stacking height in the bag described herein. SS. Spunbond nonwoven fabric comprising the following: a. a first surface and a second surface and at least a first and a second optically detectable zone on at least one of the first and the second surface, wherein each of the first and the second zone has a pattern of three-dimensional features, wherein each of the three-dimensional features defines a microzone comprising a first area and a second area, wherein the first and the second area exhibit a value difference for an intensive property; and b. wherein the difference in value for an intensive property for at least one of the microzones in the first zone differs from the difference in value for the intensive property for at least one of the microzones in the second zone; wherein in at least one of the microzones the first area has a contact angle greater than about 90 degrees, as measured by the contact angle test method detailed herein, and wherein the second area has a time-to-wick of less than about 10 seconds, as measured by the time-to-wick test method detailed herein. TT. The spunbond nonwoven fabric according to paragraph SS, wherein the contact angle for the first area is between about 90 degrees and about 140 degrees, as measured by the contact angle test method detailed herein. UU. The spunbond nonwoven fabric according to paragraph SS-TT, wherein the contact angle for the first area is between about 110 degrees and about 135 degrees, as measured by the contact angle test method detailed herein. VV. The spunbond nonwoven fabric according to paragraph SS-UU, wherein the contact angle for the first area is between about 125 degrees and about 135 degrees, as measured by the contact angle test method detailed herein. WW. The spunbond nonwoven fabric according to paragraphs SS-VV, wherein the first area has a contact angle greater than about 90 degrees, as measured by the contact angle test method detailed herein, and wherein a time-to-wick is more than about 10 seconds, as measured by the time-to-wick test method detailed herein. XX. The spunbond nonwoven fabric according to paragraphs SS-WW, wherein the time-to-wick for the first range is between about 10 seconds and about 60 seconds, as measured by the time-to-wick test method detailed herein. YY. The spunbond nonwoven fabric according to paragraphs SS-XX, wherein the time-to-wick for the second area is less than 5 seconds, as measured by the time-to-wick test method detailed herein. ZZ. The spunbond nonwoven fabric according to paragraphs SS-YY, wherein the time-to-wick for the second area is less than 2.5 seconds, as measured by the time-to-wick test method detailed herein. AAA. The spunbond nonwoven fabric according to paragraphs SS-ZZ, wherein the time-to-wick for the second area is less than 1 second, as measured by the time-to-wick test method detailed herein. BBB. The spunbond nonwoven according to paragraphs SS-AAA, wherein the difference in value for the intensive property for one of the microzones in the first zone is of an order of magnitude that differs from the difference in value for the intensive property for at least one of the microzones in the second zone. CCC. The spunbond nonwoven fabric according to paragraphs SS-BBB, wherein the difference in values ​​for the intensive property for one of the microzones in the first zone differs by approximately 1.2X to approximately 10X from the difference in values ​​for the intensive property for at least one of the microzones in the second zone. DDD. The spunbond nonwoven fabric according to paragraphs SS-CCC, where the intensive property is thickness and the thickness of each region is greater than zero. EEE. The spunbond nonwoven fabric according to paragraphs SS-DDD, wherein the difference in thickness in the first zone is greater than approximately 25 micrometers. FFF. The spunbond nonwoven fabric according to paragraphs SS-EEE, wherein the intensive property is a base weight and the base weight is greater than zero in every area. GGG. The spunbond nonwoven fabric according to paragraphs SS-FFF, wherein the difference in base weight in the first zone is greater than approximately 5 grams per square meter. HHH. The spunbond nonwoven according to paragraphs SS-GGG, where the intensive property is the volumetric density and the volumetric density of each region is greater than zero. III. The spunbond nonwoven according to paragraphs SS-HHH, wherein the difference in volumetric density in the first zone is greater than approximately 0.042 g / cm³ 3 is. JJJ. The spunbond nonwoven according to paragraphs SS-III, further comprising a third zone with a pattern of three-dimensional features, each defining a microzone comprising a first area and a second area, wherein a value difference for an intensive property for one of the microzones in the third zone differs a) from the value difference for the intensive property for at least one of the microzones in the first zone and b) from the value difference for the intensive property for at least one of the microzones in the second zone. KKK. The spunbond nonwoven fabric according to paragraphs SS-JJJ, wherein at least one of the surfaces has a TS7 value of less than about 15 dB V 2 exhibits rms. LLL. The spunbond nonwoven fabric according to paragraph KKK, wherein the first surface has a TS7 value of approximately 2 to approximately 12 dB V 2 rms and the second surface has a TS7 value that differs from the TS7 value of the first surface. MMM. The spunbond nonwoven according to paragraph LLL, wherein the second surface has a TS7 value that is lower than the TS7 value of the first surface. NNN. The spunbond nonwoven fabric according to paragraph KKK, wherein the second surface has a TS7 value of approximately 3 to approximately 8 dB V 2 rms and the first surface has a TS7 value that differs from the TS7 value of the second surface. OOO. The spunbond nonwoven fabric according to paragraph NNN, wherein the first surface has a TS7 value that is higher than the TS7 value of the second surface. PPP. An absorption article comprising a spunbond nonwoven fabric, as described in paragraphs SS-PPP. QQQ. A package of absorbent articles, each absorbent article comprising a spunbond nonwoven fabric as described in paragraphs SS-PPP. RRR. The packaging according to paragraph QQQ, wherein the packaging has a stacking height in the bag between approximately 70 mm and approximately 100 mm, according to the test of the stacking height in the bag described herein. SSS. A nonwoven fabric having a first surface and a second surface and an optically detectable pattern of three-dimensional features on one of the first or second surfaces, wherein each of the three-dimensional features defines a microzone having a first area and a second area, wherein the first and second areas exhibit a value difference in an intensive property, wherein the intensive property is one or more of: a. Thickness, b. Base weight and c. volumetric density; and wherein in at least one of the microzones the first area has a contact angle greater than about 90 degrees, as measured by the contact angle test method detailed herein, and wherein the second area has a time-to-wick of less than about 10 seconds, as measured by the time-to-wick test method detailed herein. TTT. The spunbond nonwoven fabric according to paragraph SSS, wherein the difference in value for the intensive property for one of the microzones in a first zone is of an order of magnitude that differs from the difference in value for the intensive property for at least one of the microzones in a second zone. UUU. The spunbond nonwoven according to paragraphs SSS-TTT, wherein the difference in values ​​for the intensive property for one of the microzones in the first zone differs by approximately 1.2X to approximately 10X from the difference in values ​​for the intensive property for at least one of the microzones in the second zone. VVV. The nonwoven fabric according to paragraphs SSS-UUU, where the intensive property is thickness and the thickness of each region is greater than zero. WWW. The nonwoven fabric of the paragraphs SSS-VVV, wherein the difference in thickness in the first zone is greater than approximately 25 micrometers. XXX. The nonwoven fabric according to paragraphs SSS-WWW, wherein the intensive property is a base weight and the base weight is greater than zero in each area. YYY. The nonwoven fabric according to paragraphs SSS-XXX, wherein the difference in base weight in the first zone is greater than approximately 5 grams per square meter. ZZZ. The nonwoven fabric according to paragraphs SSS-YYY, where the intensive property is the volumetric density and the volumetric density of each region is greater than zero. AAAA. The nonwoven fabric according to paragraphs SSS-ZZZ, wherein the difference in volumetric density in the first zone is greater than approximately 0.042 g / cm³ 3 is. BBBB. The nonwoven fabric according to paragraphs SSS-AAAA, wherein at least one of the surfaces has a TS7 value of less than approximately 15 dB V. 2 exhibits rms. CCCC. The nonwoven fabric according to paragraph BBBB, wherein the first surface has a TS7 value of approximately 2 to approximately 12 dB V2 rms and the second surface has a TS7 value that differs from the TS7 value of the first surface. DDDD. The nonwoven fabric according to paragraph CCCC, wherein the second surface has a TS7 value that is lower than the TS7 value of the first surface. EEEE. The nonwoven fabric according to paragraph BBBB, wherein the second surface has a TS7 value of approximately 3 to approximately 8 dB V 2 rms and the first surface has a TS7 value that differs from the TS7 value of the second surface. FFFF. The nonwoven fabric according to paragraph EEEE, wherein the first surface has a TS7 value that is higher than the TS7 value of the second surface. GGGG. An absorbent article comprising a nonwoven fabric as described in one of paragraphs SSS-FFFF. HHHH. A packaging of absorbent articles, wherein each absorbent article comprises a nonwoven fabric, as described in paragraphs SSS-GGGG. IIII. The packaging in accordance with paragraphs SSS-HHHH, wherein the packaging has a stacking height in the bag of between about 70 mm and about 100 mm, according to the test of the stacking height in the bag described herein. YYYY. The nonwoven fabric according to paragraph IIII, wherein the nonwoven fabric is a spunbond nonwoven construction.

[0248] The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​stated. Instead, unless otherwise specified, each of these dimensions should have the meaning of the stated value and a functionally appropriate range surrounding that value. For example, a dimension disclosed as "40 mm" should mean "about 40 mm".

[0249] Every document referenced herein, including any cross-references or related patents or applications, and any patent application or patent to which this application claims priority or benefit, is hereby incorporated herein by reference in its entirety, unless expressly excluded or otherwise limited. The citation of a document does not imply that it is recognized as prior art for any embodiment disclosed or claimed herein, or that it teaches, suggests, or discloses such embodiment, either alone or in combination with other referenced literature. Furthermore, should any meaning or definition of a term in this document conflict with any meaning or definition of the same term in any document incorporated by reference, the meaning or definition assigned to the term in this document shall prevail.

[0250] Although certain embodiments of the present invention have been presented and described, it is obvious to the person skilled in the art that various further changes and modifications can be made without deviating from the basic concept and scope of protection of the present invention. Therefore, the appended claims are intended to cover all such changes and modifications that fall within the scope of protection of the invention.

Claims

[1] Spunbonded nonwoven fabric (10) comprising the following: a. a first surface (12) and a second surface (14) and at least a first and a second optically detectable zone (110, 120) on at least one of the first and the second surface (12, 14), wherein each of the first and the second zone (110, 120) has a pattern of three-dimensional features (20, 22, 24), wherein each of the three-dimensional features (20, 22, 24) defines a microzone comprising a first region (300) and a second region (310), wherein the first and the second region (300, 310) exhibit a value difference for an intensive property, wherein the intensive property is one or more of thickness, base weight, and volumetric density; and b. wherein the difference in value for the intensive property for at least one of the microzones in the first zone (110) differs from the difference in value for the intensive property for at least one of the microzones in the second zone (120); wherein in at least one of the microzones the first area (300) has a contact angle of more than 90 degrees, as measured by the contact angle test method described in detail herein. [2] Spunbond nonwoven fabric (10) according to claim 1, wherein the contact angle is between 90 degrees and 140 degrees, as measured by the contact angle test method described in detail herein. [3] Spunbond nonwoven fabric (10) according to any of the preceding claims, wherein the contact angle is between 110 degrees and 135 degrees, as measured by the contact angle test method described in detail herein. [4] Spunbond nonwoven fabric (10) according to any of the preceding claims, wherein the contact angle is between 125 degrees and 135 degrees, as measured by the contact angle test method described in detail herein. [5] Spunbond nonwoven fabric (10) according to any of the preceding claims, wherein the first area (300) has both a contact angle of more than 90 degrees and a time-to-wick of more than 10 seconds, as measured by the time-to-wick test method described in detail herein. [6] Spunbond nonwoven fabric (10) according to claim 5, wherein the time-to-wick is between 10 seconds and 60 seconds, as measured by the time-to-wick test method described in detail herein. [7] Spunbond nonwoven fabric (10) according to one of the preceding claims, wherein the difference in value for the intensive property for one of the microzones in the first zone (110) differs by 1.2X to 10X from the difference in value for the intensive property for at least one of the microzones in the second zone (120). [8] Spunbond nonwoven fabric (10) according to one of the preceding claims, wherein the intensive property is thickness and the thickness of each region (300, 310) is greater than zero and the difference in thickness in the first zone (110) is greater than 25 micrometers. [9] Spunbond nonwoven fabric (10) according to one of the preceding claims, wherein the intensive property is base weight and the base weight of each area (300, 310) is greater than zero and the difference in base weight in the first zone (110) is greater than 5 grams per square meter. [10] Spunbond nonwoven fabric (10) according to one of the preceding claims, wherein the intensive property is volumetric density and the volumetric density of each region (300, 310) is greater than zero and the difference in volumetric density in the first zone (110) is greater than 0.042 g / cm³ 3 is. [11] Spunbond nonwoven fabric (10) according to one of the preceding claims, further comprising a third zone (130) with a pattern of three-dimensional features, each defining a microzone comprising a first area (300) and a second area (310), wherein a difference in the value of the intensive property for one of the microzones in the third zone (130) differs a) from the difference in the value of the intensive property for at least one of the microzones in the first zone (110) and b) from the difference in the value of the intensive property for at least one of the microzones in the second zone (120). [12] Spunbond nonwoven fabric (10) according to any of the preceding claims, wherein at least one of the surfaces (12, 14) has a TS7 value of less than 15 dB V 2 exhibits rms. [13] Spunbond nonwoven fabric (10) according to claim 12, wherein the first surface (12) has a TS7 value of 2 to 12 dB V 2 rms and the second surface (14) has a TS7 value that differs from the TS7 value of the first surface (12). [14] Spunbond nonwoven fabric (10) according to claim 12, wherein the second surface (14) has a TS7 value of 3 to 8 dB V 2 rms and the first surface (12) has a TS7 value that differs from the TS7 value of the second surface (14). [15] Absorbent article comprising a spunbond nonwoven (10) according to any one of the preceding claims.

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