Molded nonwovens and articles containing them

Abstract

Three-dimensional nonwoven substrate (10) comprising the following: a first surface (12); a second surface (14); a first side margin (2000); a second side margin (2002); a first final edge (2004); a second end edge (2006); a central transverse axis (CL1); and a central longitudinal axis (CL2) that extends perpendicularly to the central transverse axis (CL1); wherein a line taken in a direction parallel to or perpendicular to the central transverse axis (CL1) of the three-dimensional nonwoven substrate (10) comprises the following: a first visually perceptible zone (110) in the nonwoven substrate (10) that is not provided with openings; and a second visually perceptible zone (120) in the fleece substrate (10); wherein the first visually perceptible zone (110) comprises a pattern of three-dimensional features (20) on the first surface (12) or the second surface (14); wherein at least some of the three-dimensional features (20) define a microzone comprising a first area (300) and a second area (310), and wherein the first area (300) and the second area (310) exhibit a value difference for an intensive size; where the intensive size of the first visually perceptible zone (110) is base weight, thickness or volumetric density; where the base weight, thickness, or volumetric density of each region is greater than zero; and where the second visually perceptible zone (120) defines openings (13), wherein the openings (13) have an effective opening area, according to the opening test herein, in a range of about 0.3 mm 2 up to about 15 mm 2exhibiting and wherein the second visually perceptible zone (120), according to the opening test herein, exhibits an effective open area in a range of about 3% to about 50%.

Description

AREA

[0001] This disclosure relates generally to shaped, three-dimensional nonwovens or substrates, and to articles made from shaped, three-dimensional nonwovens. This disclosure further relates to nonwovens or substrates provided with openings, and to articles containing these openings. BACKGROUND

[0002] Nonwovens are useful for a wide variety of applications, including absorbent personal care products, clothing, medical applications, and cleaning applications. Nonwoven personal care products include infant care items such as diapers, children's care items such as training pants, feminine hygiene items such as sanitary napkins, and adult care items such as incontinence products, pads, and pants. 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, which may include a visual impression of breathability and absorbency. 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 a series of surface features such as openings, protrusions, or both. Nonwovens with openings or protrusions are often referred to as three-dimensionally shaped nonwovens. The openings may be uniformly sized and have circular or oval shapes across their entire surface, and such circular or oval openings may be uniformly spaced relative to each other in the machine transverse direction and / or the machine running direction. The opening patterns may thus allow fluid penetration and / or absorption through their surface. However, in certain types of three-dimensionally shaped nonwovens (e.g.,In nonwovens with variable base weight, the openings are not usually formed due to the variability of the material and concerns about tearing.

[0004] WO 2016 / 073 686 A1, on the other hand, describes a patterned fabric with openings in a specific arrangement.The fabric comprises a nonwoven layer containing a plurality of openings and a plurality of areas without openings, wherein the plurality of openings comprises a first set of openings in a first zone and a second set of openings in a second zone; wherein the first group of openings in the first zone has opening spacings, wherein the opening spacings of the first group of openings have a first distribution with a first mean and a first median, and wherein the first mean is greater than the first median; and wherein the second group of openings in the second zone has opening spacings, wherein the opening spacings of the second group of openings have a second distribution with a second mean and a second median, and wherein the second mean is greater than the second median, and wherein the first and second groups of openings have different patterns.

[0005] US 2014 / 0 296 815 A1 also discloses a fabric with coordinated openings and embossed channels, wherein the fabric has a longitudinal direction, a transverse direction and a depth direction, wherein the fabric has at least one embossed channel with at least two side edges and a first row of openings, wherein the at least one embossed channel has a curved overall shape configuration along either the longitudinal direction, the transverse direction or a combination of longitudinal and transverse directions, and wherein the first row of openings is arranged in an uninterrupted sequence on the fabric laterally adjacent to the at least one embossed channel, such that the first row of openings is configured in the same or a similar overall shape configuration as at least part of the overall shape configuration of the at least one embossed channel.

[0006] Despite previous advances in the field of nonwovens, there remains a need for improved nonwovens with three-dimensional surface features. Furthermore, there remains a need for processes and equipment for manufacturing improved nonwovens with three-dimensional surface features; for articles, including absorbent articles, that utilize improved nonwovens with three-dimensional surface features; and for absorbent articles that utilize nonwovens with three-dimensional surface features and can be packaged in a compressed form while minimizing the loss of three-dimensional surface features upon opening the packaging.In particular, there remains a need for packaging for absorbent products, including soft nonwovens, that offers a reduced stack height compared to conventional absorbent product packaging. This makes the packaging easier for caregivers to handle and store, and allows manufacturers to benefit from lower distribution costs without compromising the aesthetic clarity, absorbency, or softness of the absorbent product as it is immediately after manufacture. Furthermore, there remains a need for absorbent products utilizing soft spunbond nonwovens with three-dimensional surface features that exhibit reduced pilling during use; and for improved nonwovens with three-dimensional surface features and physical integrity combined with softness.In addition, there remains a need for three-dimensionally shaped nonwovens, including nonwovens with variable base weight, which have openings to provide improved fluid uptake and improved visual impression of breathability and absorption capacity, as well as various combinations of perforated surfaces and zones with different intensity properties. SUMMARY

[0007] The present invention relates to a three-dimensional nonwoven substrate. The three-dimensional nonwoven substrate comprises a first surface, a second surface, a first side edge, a second side edge, a first end edge, a second end edge, a central transverse axis, and a central longitudinal axis extending perpendicular to the central transverse axis. A line drawn in a direction parallel to or perpendicular to the central transverse axis of the three-dimensional nonwoven substrate comprises a first visually perceptible zone and a second visually perceptible zone within the nonwoven substrate, both of which are not provided with openings. The first visually perceptible zone comprises a pattern of three-dimensional features on the first surface or the second surface. At least some of the three-dimensional features define a microzone comprising a first region and a second region.The first and second regions exhibit a difference in value for an intensive size, where the intensive size of the first visually perceptible zone is base weight, thickness, or volumetric density, and where the base weight, thickness, or volumetric density of each region is greater than zero. The second visually perceptible zone defines openings. According to the opening test herein, the openings have an effective opening area of ​​approximately 0.3 mm. 2 up to about 15 mm 2 The second visually perceptible zone, according to the opening test herein, has an effective open area in a range of approximately 3% to approximately 50%. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The aforementioned features and advantages of the present revelation, and the manner in which they are achieved, become more apparent, and the revelation itself is better understood, by reference to the following description of non-restrictive forms of revelation in connection with the accompanying drawings, wherein: Fig. 1 is a photographic image of a section of an example of a three-dimensional nonwoven fabric with variable base weight. Fig. 2 a photographic image of a section of an example of a three-dimensional, perforated nonwoven fabric with variable base weight of the present disclosure. Fig. 3 a photographic image of a nonwoven fabric incorporating melt lips or condensed sections surrounding openings of the present disclosure. Fig. 4 is a photographic image of an example of a nonwoven fabric of the present disclosure. Fig. 5 is a photographic image of an example of a nonwoven fabric of the present disclosure. Fig. 6 is a photographic image of an example of a nonwoven fabric of the present disclosure. Fig. 7 a cross-sectional view of a section of the in Fig. The nonwoven fabric shown in section 4 is shown. Fig. Figure 8A is a schematic drawing illustrating the cross-section of a thread produced with a primary component A and a secondary component B in a side-by-side arrangement. Fig. Figure 8B is a schematic drawing illustrating the cross-section of a thread produced with a primary component A and a secondary component B in an eccentric sheath / core arrangement. Fig. Figure 8C is a schematic drawing illustrating the cross-section of a thread produced with a primary component A and a secondary component B in a concentric shell / core arrangement. Fig. 9 is a photographic image that depicts a perspective view of a trilobal two-component fiber. Fig. 10 is a schematic representation of a device for producing a substance of the present disclosure. Fig. 11 is a detail of a section of the device for joining a section of a material of the present disclosure. Fig. 12 is a further detail of a section of the device for joining a section of a substance of the present disclosure. Fig. 13 is a detail of a section of the device for optionally additionally joining a section of a material of the present disclosure. Fig. 14 is a photographic image of an example of a nonwoven fabric of the present disclosure. Fig. 15 a photographic image of a section of a shaping band which is useful for the present disclosure. Fig. 16 a cross-sectional image of a section of the in Fig. The shaping band shown in section 15 is shown. Fig. 17 is an image of a section of a mask used to control the in Fig. To produce the 15 shown shaping band. Fig. 18 is an image of a section of a mask used to make a shaping band which is useful in the present revelation. Fig. 19 a photographic image of a section of a shaping band formed by the mask on which in Fig. Reference was made to 18. Fig. 20 is a picture of a section of a mask used to produce a shaping band useful for the present revelation. Fig. 21 a photographic image of a section of a shaping band formed by the mask on which in Fig. Reference was made to 20. Fig. 22 a photographic image of a section of a shaping band which is useful for the present disclosure. Fig. 23 is an image of a mask used to conceal the in Fig. to produce the 20 shown shaping bands. Fig. 24 a photographic image of a nonwoven fabric of the present disclosure, which is on the in Fig. The shaping band shown in section 22 was produced. Fig. 25 is a perspective schematic view of a shaping band of the present revelation. Fig. 26 is a top view of a nonwoven substrate comprising nonwovens of the present disclosure. Fig. 27 is a top view of a nonwoven substrate incorporating nonwovens of the present disclosure. Fig. 28A is a top view of a substance of the present disclosure from which sections for measuring the local base weight have been removed. Fig. 28B is a top view of a substance of the present disclosure from which sections for measuring the local base weight have been removed. Fig. 29 is a graphical representation of a transverse direction variation of the base weight in a substance of the present disclosure. Fig. 30 is a schematic view of a packaging comprising absorption articles comprising the three-dimensional nonwoven fabric with variable base weight of the present disclosure. Fig. 31 is a schematic representation of an example process for producing a nonwoven fabric provided with openings of the present disclosure. Fig. 32 a perspective view of a track weakening arrangement of Fig. 31 of the present disclosure. Fig. 33 a perspective view of an incremental strain system of the illustrated example procedure of Fig. 31 of the present disclosure. Fig. Figure 34 shows an enlarged view detailing the teeth of the incremental expansion system of Fig. 33 of the present revelation shows. Fig. 35 a perspective view of an exemplary machine transverse tensioning device of the representative example method of Fig. 31 of the present disclosure. Fig. 36 is a schematic representation of a front view of an exemplary machine transverse direction tensioning device with outer longitudinal sections in a non-expanded and non-angled position in relation to a central section of the present disclosure. Fig. 37 a schematic representation of a front view of the machine transverse tensioning device of Fig. 36 is, with the outer longitudinal sections in a position expanded longitudinally in relation to the central section of the present disclosure. Fig. 38 a schematic representation of a front view of the machine transverse tensioning device of Fig. 36 is, with the outer longitudinal sections in an angled and expanded position in relation to the central section of the present disclosure. Fig. 39 is a schematic representation of a front view of a machine transverse direction tensioning device, with outer longitudinal sections fixed in an angled position in relation to a central section of the present disclosure. Fig. 40 is a photographic image of an exemplary opening pattern of the present disclosure. Fig. 41 is a photographic image of an exemplary opening pattern of the present disclosure. Fig. 42 is a schematic representation of an exemplary opening pattern of the present disclosure. Fig. 43 is a schematic representation of an exemplary opening pattern of the present disclosure. Fig. 44 is a schematic representation of an exemplary opening pattern of the present disclosure. Fig. 45 is a schematic representation of an exemplary opening pattern of the present disclosure. Fig. 46 is a schematic representation of another example process for producing a nonwoven fabric provided with openings of the present disclosure. Fig. 47 a perspective view of a roller system of the process of Fig. 46 is. Fig. 48 a photographic image of a highly magnified section of an exemplary aperture pattern obtained by the process of Fig. 46 was manufactured. Fig. 49 is a top view of an example absorption article of the present disclosure. Fig. 50 a cross-sectional view along section 50-50 of Fig. 49 is. Fig. 51 another cross-sectional view along section 50-50 of Fig. 49 is. Fig. 52 is a top view of an absorption article of the present disclosure. Fig. 53 a cross-sectional view along section 53-53 of Fig. 52 is. Fig. 54 is a top view of an absorption article of the present disclosure. Fig. 55 a cross-sectional view along section 55-55 of Fig. 54 is. Fig. 56 a cross-sectional view along section 56-56 of Fig. 54 is. Fig. 57 a photographic image of an example of a nonwoven fabric of the present disclosure. Fig. 58 a photographic image of an example of a nonwoven fabric of the present disclosure. Fig. 59 a photographic image of an example of a nonwoven fabric of the present disclosure. Fig. 60 a photographic image of a cross-section of the in Fig. The example shown is number 59. Fig. 61 is a perspective micro-CT view image of an example of a nonwoven fabric of the present disclosure. Fig. 62 is a perspective micro-CT view image of an example of a nonwoven fabric of the present disclosure. Fig. 63 a micro-CT image of a cross-section of the in Fig. 61 and Fig. The example shown in 62 is... Fig. 64 a micro-CT image of a top view of the in the Fig. 61 and Fig. The example shown in 62 is... Fig. 65 is a graphic illustration of various advantages of the present disclosure. Fig. 66 a photographic image of a section of an example of a nonwoven fabric of the present disclosure. Fig. 67 a photographic image of a section of an example of a nonwoven fabric of the present disclosure. Fig. 68 is a photographic image of a section of an example of a nonwoven fabric of the present disclosure. Fig. 69 is a photographic image of a section of an example of a nonwoven fabric of the present disclosure. Fig. 70 a photographic image of a cross-section of the in the Fig. 68 and Fig. The example shown in 69 is... Fig. 71 is a photographic image of a section of an example of a nonwoven fabric of the present disclosure. Fig. 72 is a photographic image of a section of an example of a nonwoven fabric of the present disclosure. Fig. 73 is a photographic image of a section of an example of a nonwoven fabric of the present disclosure. Fig. 74 is a photographic image of a section of an example of a nonwoven fabric of the present disclosure. Fig. 75 a micro-CT image of a top view of the in Fig. 61 and Fig. The example shown in 62 is after undergoing additional processing. Fig. 76 a graphic representation of various advantages of the in Fig. The present revelation shown in section 75 is. Fig. 77 is a photographic image of a section of an example of a three-dimensional nonwoven fabric with variable base weight. Fig. 78 a photographic image of a section of an example of a three-dimensional, perforated nonwoven fabric with variable base weight of the present disclosure. Fig. 79 is a schematic representation of an example of a nonwoven fabric of the present disclosure. Fig. 80 is a schematic representation of an example of a nonwoven fabric of the present disclosure. Fig. 81 is a schematic representation of an example of a nonwoven fabric of the present disclosure. Fig. 82 is a schematic representation of an example of a nonwoven fabric of the present disclosure. DETAILED DESCRIPTION

[0009] Several non-restrictive forms of the present disclosure are now described to provide an overall understanding of the principles governing the structure, function, manufacture, and use of the shaped nonwovens and articles, including those disclosed herein. One or more examples of these non-restrictive forms are illustrated in the accompanying drawings. Persons skilled in the art will understand that the shaped nonwovens and articles incorporating them, described herein and illustrated in the accompanying drawings, are non-restrictive example forms, and that the scope of protection of the various non-restrictive forms of the present disclosure is defined solely by the claims. The features illustrated or described in connection with a non-restrictive form can be combined with the features of other non-restrictive forms.Such modifications and variations are to be included within the scope of protection of the present disclosure.

[0010] The three-dimensional nonwoven substrates 10 of the present disclosure, as described in the Fig. 1 and Fig. Figure 2, comprising a first surface 12 and a second surface 14, can include at least one first visually perceptible zone 110 without openings, having a pattern of three-dimensional features on the first surface 12 and / or the second surface 14. Fig. 1-2 is the second surface 14 facing the viewer and lies opposite the first surface 12, which is in a cross-section of a Fig. The three-dimensional nonwoven substrates 10 of the present disclosure can comprise at least one second visually perceptible zone 120, which defines a plurality of openings 13, as shown in Figure 7. Fig. 2 shown. In certain examples, the plurality of openings 13 can be organized in one pattern or in a plurality of patterns. The patterns can be the same or different. In certain examples, the nonwoven substrate 10 can comprise a first side edge 2000 and a second side edge 2002, a first end edge 2004 and a second end edge 2006, a central transverse axis CL1 and a central longitudinal axis CL2 extending perpendicular to the central transverse axis CL1, such that a line X drawn in a direction parallel to the central transverse axis CL1 can include each of the first visually perceptible zone 110 and the second visually perceptible zone 120. It is understood that in certain examples, a plurality of openings can define a strip extending in a direction parallel to a central transverse axis (e.g.,CL1) extends such that a line drawn in a direction perpendicular to the central transverse axis can include each of a first visually perceptible zone 110 and a second visually perceptible zone.

[0011] Without being bound to any specific theory, it is suggested that, although openings are not typically incorporated into three-dimensionally shaped nonwovens with variable base weight, openings and patterns thereof can be provided within such nonwovens to offer enhanced fluid absorption and a visual impression of breathability. Furthermore, it is suggested that the three-dimensionally shaped nonwovens may include different combinations of perforated zones and zones of varying intensity sizes to increase the overall effectiveness of a nonwoven substrate or of an article, such as an absorbent product, in which one or more of the nonwoven substrates are used. An example of a nonwoven substrate in an absorbent product is its use as the top layer of a diaper.

[0012] In certain examples, with respect to the first visually perceivable zone 110, at least some of the three-dimensional features can define a microzone comprising a first region and a second region, where the first region and the second region may exhibit a difference in value for one or more intensity quantities. In certain examples, the second visually perceivable zone 120 can comprise a pattern of further three-dimensional features on a first and / or second surface, and at least some of the further three-dimensional features can define a microzone with a third and a fourth region, where the third region and the fourth region may exhibit a difference in value for one or more intensity quantities.In further examples, the nonwoven substrate can also include a third visually perceptible zone 130, which is not perforated, in the direction X parallel to the central transverse axis CL1, wherein the third visually perceptible zone 130 can comprise a pattern of further three-dimensional features on a first and / or second surface, and at least some of the further three-dimensional features can define another microzone with a fifth area and a sixth area, wherein the fifth area and the sixth area can exhibit a difference in values ​​for one or more intensive quantities. Likewise, it is understood that in the examples where a plurality of openings can define a strip extending in a direction parallel to a central transverse axis (e.g.,CL1) extends, a nonwoven substrate may further comprise a third visually perceptible zone without openings, which is made in a line in a direction perpendicular to the central transverse axis or parallel to a central longitudinal axis (e.g. CL2).

[0013] With respect to the first visually perceptible zones 110, at least one intensive quantity is base weight, thickness, or volumetric density, wherein the base weight, thickness, or volumetric density of each zone is greater than zero. With respect to the second or third visually perceptible zones 120 and 130, the one or more intensive quantities may be base weight, thickness, or volumetric density and / or any other suitable intensive quantities described herein, wherein the one or more intensive quantities of the second and / or third perceptible zones 120 and 130 may be greater than zero in certain examples. A difference in the value of the one or more intensive quantities between the first zone and the second zone, or the third zone and the fourth zone, or the fifth zone and the sixth zone, may be of an order of magnitude.In certain examples, the difference in the intensity value between the first area and the second area, or the third area and the fourth area, or the fifth area and the sixth area, can range from about 1.2X to about 10X.

[0014] In certain examples, the second visually perceptible zone 120 can include openings 13 across the entirety of the zone or at least a section of the zone. In certain examples, with respect to the second visually perceptible zone 120, the openings 13 can have an effective opening area in a range of approximately 0.3 mm. 2 up to about 15 mm 2 ; 0.3 mm 2 up to about 14 mm 2 ; 0.4 mm 2 up to about 12 mm 2 ; 0.3 mm 2 up to about 10 mm 2 ; 0.5 mm 2 up to about 8 mm 2 ; or 1.0 mm 2 up to about 8 mm 2 exhibit, explicitly listing all 0.05 mm 2-Increments within the areas specified herein according to the opening test and all areas formed therein or by it. A multitude of the openings 13 in a three-dimensionally shaped nonwoven fabric may differ in effective opening areas. The relative standard deviation of the effective opening areas in a three-dimensionally shaped nonwoven fabric may, for example, be at least about 50%, or at least about 55%, or at least about 60%.

[0015] In certain examples, the second visually perceivable zone 120 may have an effective open area in the range of approximately 5% to approximately 50%; approximately 7% to approximately 50%; approximately 7% to approximately 11%; approximately 8% to approximately 10%; approximately 3% to approximately 50%; approximately 5% to approximately 40%; approximately 10% to approximately 40%; approximately 10% to approximately 35%; approximately 10% to approximately 30%; and approximately 15% to approximately 30%, with the express listing of all 0.1% increments within the ranges specified herein according to the openness test and all ranges formed therein or by it. In one example, the second visually perceivable zone 120 may have an effective open area of ​​approximately 5% to approximately 25% according to the openness test.Without being bound to any theory, it is assumed that perforated three-dimensionally shaped nonwovens of variable base weight with a larger effective open area may be useful as a top layer or absorption layer or system in an absorbent article (functional for the absorption of bodily excretions), while perforated three-dimensionally shaped nonwovens with a smaller effective open area may be useful as an outer layer of an absorbent article (decorative or for purposes of breathability).

[0016] In certain examples, the second visually perceptible zone 120 may encompass two or more distinct aperture patterns. Boundaries between the different zones (e.g., 110, 120, 130) may be linear or non-linear.

[0017] In some examples and with reference to Fig. 3. Sections of the circumferential margins of at least some of the openings may include one or more enamel lips 15 or fused sections. In some examples, sections of the circumferential margins of at least some of the openings may be free of an enamel lip. Therefore, in certain examples, the one or more enamel lips 15 may at least partially or completely surround the openings 13. In one example, the one or more enamel lips 15 may surround approximately 25% to approximately 100% of the circumferential margin of the openings 13. In certain examples, the one or more enamel lips 15 may be formed on lateral sides of the openings 13, and not on leading and / or trailing margins of the openings 13 (see MD and CD arrows for reference in [reference]). Fig. 3) It is assumed that one or more melt lips 15 can be formed during the bonding step and can add strength to a substrate, such as a three-dimensionally shaped nonwoven fabric.

[0018] In certain examples, according to the openness test, at least some of the opennesses may have an aspect ratio greater than 1, greater than 2, greater than 3, greater than 5, or greater than 10, but usually less than 15. In one example, at least some opennesses may have an aspect ratio of approximately 1.5 to approximately 10, with explicit listing of all 0.1 increments within the specified range and all regions formed therein. In certain examples, at least some of the opennesses may have an aspect ratio of less than approximately 1.5. The openness patterns in openness-decorated, three-dimensionally shaped, variable-base-weight nonwovens may include opennesses with more than one aspect ratio, such as two or more distinct populations or with an substantially continuous distribution of aspect ratios with a slope greater than zero.Additionally, the openworked, three-dimensionally shaped, variable-base-weight nonwovens can include openings with more than two effective opening areas, either as two or more distinct populations or as a distribution of opening areas with a slope greater than zero. The relative standard deviation of the opening aspect ratios in an openworked, three-dimensionally shaped, variable-base-weight nonwoven can be at least approximately 30%, at least approximately 40%, or at least approximately 45%.

[0019] At least some of the openwork three-dimensionally shaped nonwovens may, according to the openwork test herein, exhibit an aspect ratio greater than approximately 1.5:1, greater than approximately 1.8:1, greater than approximately 2:1, greater than approximately 2.5:1, greater than approximately 3:1 or in the range of approximately 1.5:1 to 10:1, approximately 2:1 to approximately 6:1, approximately 2:1 to approximately 5:1 or approximately 2:1 to approximately 4:1, with express listing of all 0.1 increments (e.g. 1.6:1, 1.7:1, 1.8:1) within the specified ranges and all areas formed therein or thereby.

[0020] In certain examples, the first visually perceptible zone 110 can be positioned proximal to the first end edge 2004 of the three-dimensional nonwoven substrate 10, and the second visually perceptible zone 120 can be positioned proximal to the second end edge 2006 of the three-dimensional nonwoven substrate 10, as for example in Fig. Figure 81 shows that in further examples, the first visually perceptible zone 110 can be positioned proximal to the second end edge 2006, and the second visually perceptible zone 120 can be positioned proximal to the first end edge 2004. In certain examples with a third visually perceptible zone 130, a portion of the first visually perceptible zone 110 can be positioned proximal to the first side edge 2000, and a portion of the third visually perceptible zone 130 can be positioned proximal to the second side edge 2002. In such examples, the second visually perceptible zone 120 can be positioned intermediately between the first and third visually perceptible zones.In certain examples, a section of the first visually perceptible zone 110 can be positioned proximal to the first page margin 2000, and a section of the third visually perceptible zone 130 can be positioned proximal to the second page margin 2002. Similarly, in certain examples, a section of the first visually perceptible zone 110 can be positioned proximal to the first end margin 2004, and a section of the third visually perceptible zone 130 can be positioned proximal to the second end margin 2006. In some examples, a section of the first visually perceptible zone 110 can be positioned proximal to the first page margin 2000 and the first and / or second end margin 2004, 2006, and a section of the third visually perceptible zone 130 can be positioned proximal to the second end margin 2002 and the first and / or second end margin 2004, 2006.In such examples, the second visually perceptible zone 120 can be completely surrounded by the first and third visually perceptible zones 110 and 130, respectively, with the second visually perceptible zone 120 being of any suitable size and shape, symmetrical or asymmetrical, and positioned centrally or off-center. Similarly, a second visually perceptible zone can be completely surrounded by a first visually perceptible zone 110, or vice versa. It is understood that any number of visually perceptible zones can be present in a substrate, such as more than three, and each of these visually perceptible zones can have a variety of suitable sizes and / or shapes. The different zones can be continuous or discontinuous. Shaped nonwovens

[0021] Shaped nonwovens, including those visually perceptible zones without openings as well as other visually perceptible zones, can be formed directly on a shaped forming belt with continuous spunbond nonwoven yarns in a single forming process before the openings are created. The material of the present disclosure can assume a shape corresponding to the shape of the forming belt. A material 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 additional component layer for a diaper, or as a top layer, bottom layer, absorption layer, distribution layer or additional component layer for a sanitary napkin, or as a top layer, bottom layer, absorption layer, distribution layer or additional component layer for an adult incontinence pad or pants, or as a cushion for a floor cleaning device.

[0022] The advantageous features of the nonwoven fabric are described in some examples herein in connection with a total area of ​​the nonwoven fabric. The total area may be an area determined by dimensions suitable for specific uses where the various features of this disclosure provide advantageous properties.For example, the total surface area of ​​a fabric can be that of a fabric with dimensions that make it suitable for use as a top layer, bottom layer fleece, absorption layer, distribution layer, or additional component layer for a diaper; or as a top layer, bottom layer fleece, absorption layer, distribution layer, or additional component layer for a sanitary napkin; or as a top layer, bottom layer fleece, absorption layer, distribution layer, or additional component layer for an adult incontinence pad or briefs; or as a pad for a floor cleaning device. Thus, the total surface 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 surface areas of 30 cm². 2 up to 500 cm 2The aforementioned areas can, as explicitly stated, include any integer dimension between the area boundaries. For example, the total area in the aforementioned areas is 176 cm². 2 disclosed by a width of 11 cm and a length of 16 cm. As is evident 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 of the present disclosure, each of the formed nonwoven fabrics of the present disclosure having a total area smaller than the area of ​​the web on which it is produced.

[0023] Photographs of representative examples of shaped nonwovens 10 are in Fig. 4-6 shown. As in Fig. 1 and Fig. 2, in Fig. 4-6, the second surface 14 faces the viewer and lies next to the first surface 12, which is in the Fig. Figure 7 is shown opposite. The term “surface” can be 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 may be 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, corresponds respectively to the plane of the machine transverse direction CD and the machine running direction MD, as shown in the Fig. Figures 4-6 show that the length L in the MD and the width W in the CD can determine the total area A for the nonwoven fabric 10. As shown in Fig. Figure 7 shows a cross-section of a section of the in Fig. The three-dimensional features of the shaped nonwoven fabric 10 shown in Figure 4 are described for descriptive purposes as extending outwards from an XY plane of the first surface 16 in a Z direction (see Figure 4). Fig. 7) In one example, 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, where this distance can be measured as the average thickness AC of the nonwoven fabric 10. The average thickness can be determined by non-contact optical means, or it can be determined by devices involving spaced-apart flat plates that measure the thickness of the nonwoven fabric placed between them under a predetermined pressure. It is not necessary for all three-dimensional features to have the same maximum dimension in the Z-direction, but a variety of three-dimensional features can have essentially the same maximum dimension in the Z-direction, determined by the fiber placement process and the properties of the forming tape, as discussed below.

[0024] The in the Fig. The exemplary substances shown in Figures 4-7 (as well as other substances disclosed herein) are fluid-permeable. In one example, the entire substance may be considered fluid-permeable. In another example, areas or zones may be fluid-permeable. “Fluid-permeable,” as used herein in relation to the substance, means that the substance has at least one zone that can allow fluid to pass through it under conditions of use of a consumer product. For example, if the substance is used as a top layer on a disposable diaper, it may have at least one zone that has a degree of fluid permeability that allows urine to pass through to an underlying absorbent core. “Fluid-permeable,” as used herein in relation to an area, means the area that has a porous structure that can allow fluid to pass through it.

[0025] As in Fig. As shown in Figures 4-7, the nonwoven fabric 10 can comprise a regular, repeating pattern 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 Fig. 5 and Fig. Figure 6 shows. For example, the heart-shaped first three-dimensional feature can be found in Figure 20. Fig. 4. The smaller, generally triangular second three-dimensional feature 22 must be recognizably different. The recognizable differences can be visual, such as recognizably different sizes and / or shapes.

[0026] The three-dimensional features of the nonwoven fabric 10 can be formed by depositing fibers directly onto a forming strip with a pattern of corresponding three-dimensional features, such as by carding, air spinning, solution spinning, or melt spinning. In a sense, the nonwoven fabric 10 can be 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 present disclosure 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, garments, medical products, and cleaning agents due to the attributes of the forming strip and the apparatus for forming the fabric.In particular, due to the nature of the forming tape and other device elements as described above, the three-dimensional features of the nonwoven fabric 10 can have significant dimensions that may differ between the first and second regions within a microzone, or from feature to feature, in a manner that provides advantageous properties of the nonwoven fabric 10 when used in personal care products, clothing, medical products, and cleaning agents. For example, the first three-dimensional feature 20 may have a base weight or volumetric density that differs from the base weight or volumetric density of the second three-dimensional feature 22, and both may have a base weight or volumetric density that differs from the base weight or volumetric density of the second three-dimensional feature 22.which differs from that of the third three-dimensional feature 24 and provides favorable aesthetic and functional properties relating to fluid uptake, distribution and / or absorption in diapers or sanitary napkins.

[0027] It is assumed that the difference in intensity 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 and the air permeability of the forming belt and other processing parameters, it is assumed that the fibers in a nonwoven fabric 10 are more stably and permanently shaped.

[0028] As in Fig. 4-6 can be seen and, as can be seen from the description herein, the various three-dimensional features can be delimited by visually perceptible 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. 4 and Fig. 6 and the diamond shape in Fig. 5 and Fig. 6) 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 perceptible areas can be the areas of the nonwoven fabric 10 that are closest to the first surface 12 in the Z-direction, as shown in Fig. 7 shown areas 21, and which lie at least partially in or on the first level 16 when it is in a flattened state. For example, as in Fig. Figure 4 shows the first three-dimensional feature 20, which is heart-shaped, and, as indicated by the 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 every point along its length, where the tangential vector V has both MD and CD components that change values ​​over more than 50% of the length of the linear element of the closed figure. Of course, the figure need not be perfectly 100% closed; the linear element may have breaks that do not diminish the overall impression of a closed figure.As discussed below in connection with the shaping tape, the outlining, visually perceptible 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 fabric 10. In a repeating pattern, the individual shapes (in the case of the first three-dimensional feature in . Fig. 4: a heart shape) resulting in aesthetically pleasing, soft, pillow-like features across the total area OA of the second surface 14 of fabric 10. In an example where 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 superior aesthetic and performance benefits in terms of softness, compression resistance, and fluid absorption. In certain examples, and in examples where opening patterns are provided, the opening patterns can be coordinated with other patterns (e.g., heart or blanket shapes) shown in the nonwoven fabrics described above. That is, in such examples, the opening patterns can be coordinated with patterns in non-opening zones.

[0029] Specifically in the Fig. The regular, repeating patterns of closed, three-dimensional features shown in Figures 4-6 are assumed, without being bound to any theory, to suggest that the dimensions of the various features, the average base weight of the entire fabric 10 over its total area, and other parameters described below, which define the different intensity levels, may contribute to an advantageous 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 return to their original shape once a compressive force is removed.Compression reshaping can be important in top layers, bottom layers, absorption layers, distribution layers, or other component layers of personal care products such as diapers, sanitary napkins, or adult incontinence pads, diapers, or pants, as such products are typically packaged and folded in compressed states. For aesthetic and performance reasons, personal care product manufacturers want to retain most, if not all, of the strength as it was immediately after manufacturing. The three-dimensionality of molded features can be enhanced by the appearance and impression of softness and the appealing look of clear, well-defined shapes, including very small shapes such as those found in [missing information]. Fig. The five small hearts shown provide important aesthetic advantages. The three-dimensional features also offer softness during use, improved absorbency, less leakage, and an overall enhanced user experience. However, the necessary compression during folding, packing, shipping, and storage of personal care products can cause a permanent loss of strength in a top layer, bottom layer nonwoven, absorption layers, distribution layers, or other component layers of the absorbent product, thereby diminishing the functional advantages compared to the state immediately after manufacture. We unexpectedly found that the nonwovens of the present disclosure retain their three-dimensional features to a significant extent, as in the state immediately after manufacture, even after being subjected to compression packing and distribution in a compression-packed state.

[0030] Table 1 below shows compression reshaping data for two examples from the present disclosure. Example 1 corresponds to the one in Fig. 4 shown and produced on a forming belt, nonwoven fabric 10, as with reference to Fig. 15 and Fig. 17 described. Example 2 corresponds to the one in Fig. 5 shown and produced on a forming belt, nonwoven fabric 10, as with reference to Fig. 18 and Fig. 19 described. As can be seen from the data, the materials 10 of the present disclosure 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 features of the present disclosure can have a reduced bag stack height, but still provide the aesthetic advantages and the absorbency and softness benefits of the diaper as in the state immediately after manufacture; or as if it had never been compression-packed.The present disclosure provides packaging with a reduced bag stack height, which allows caregivers to easily handle and store the packaging, while providing manufacturers with reduced shipping costs, both of which are achieved while maintaining the aesthetic clarity, absorbency, or softness performance of the absorbent article as in the state immediately after manufacture. Example 1:

[0031] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, obtained from Dow Chemical Company) and polypropylene core (PH-835, obtained from LyondellBasell) in a trilobal fiber configuration, as shown in Fig. 9, which is a scanning electron micrograph (SEM) showing a cross-section of a bicomponent trilobal fiber, was produced. The nonwoven fabric was formed on a shaping belt with a repeating pattern as shown in Fig. 15 described below with regard to Fig. 10 and Fig. 11 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. 4 shown, spun. Fibers of the fabric were further bound on the first surface 12 by heated compaction rollers 70, 72 (described below) at 130 °C and wound onto a roller at the winder 75. Example 2:

[0032] A bicomponent spunbond nonwoven was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, obtained from Dow Chemical Company) and polypropylene core (PH-835, obtained from LyondellBasell) in a trilobal fiber configuration, as shown in Fig. 9, which shows a scanning electron micrograph of a cross-section of a bicomponent trilobal fiber. The nonwoven fabric was produced on a forming belt with a repeating pattern as shown in Fig. 19 described below with regard to the Fig. 10 and Fig. 11 described, spun under motion at a linear speed of about 25 meters per minute to produce a fabric 10 with an average base weight of 30 grams per square meter with a repeating pattern of diamond shapes, as in Fig. 5 shown, to form. 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 reshaping 3-D-Vlies Roh (Vliesdirekt vonder Walze) 4 KPa (~96 mm IBSH) 14 KPa (~84 mm IBSH) 35 KPa (~68 mm IBSH) Stärke Stärke nachKompression ProzentStärkebeibehaltung (%) Stärke nachKompression ProzentStärkebeibehaltung (%) Stärke nachKompression ProzentStärkebeibehaltung (%) 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

[0033] As can be seen from Table 1, the nonwovens 10 of the present disclosure retain significant amounts of strength after compression at relatively high pressures. For example, the samples of Example 1 and Example 2 retain more than 70% of their original average strength 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 would be exposed to if it were packaged in a high-compression diaper package and subsequently remained in such a state during distribution to a consumer, and the package was then finally opened by a consumer.

[0034] The present disclosure can utilize the melt spinning process. In melt spinning, no mass loss occurs in the extrudate. Melt spinning is distinguished 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.

[0035] Melt spinning can take place at temperatures ranging from approximately 150 °C to approximately 280 °C, or in some cases, from approximately 190 °C to approximately 230 °C. Fiber spinning speeds can exceed 100 meters per minute and can 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. Spinning speeds 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.

[0036] A nonwoven fabric 10 of the present disclosure can comprise continuous multi-component polymer filaments comprising a primary polymer component and a secondary polymer component. The filaments can be continuous bi-component filaments comprising a primary polymer component A and a secondary polymer component B. The bi-component filaments can have a cross-section, a length, and a peripheral surface. 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 can continuously constitute at least a portion of the circumferential surface of the bi-component filaments along their length. 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 available from Hills, Inc., located in Melbourne, Florida. The spinning temperature can range from approximately 180°C to approximately 230°C. The processing temperature can be determined by the chemical nature, molecular weights, and concentration of each component. The spunbond bicomponent fibers can have an average diameter of approximately 6 to approximately 40 micrometers, and preferably approximately 12 to approximately 40 micrometers.

[0037] Components A and B can either be arranged side-by-side, as shown in Fig. 8A shown, or in an eccentric shell / core arrangement, as in Fig. As shown in Figure 8B, components A and B can be arranged to obtain threads that exhibit a natural spiral crimp. Alternatively, components A and B can be arranged in a concentric sheath-core arrangement, as shown in Figure 8B. Fig. 8C shown. Additionally, components A and B can be arranged in a multilobal shell-core configuration, as shown in Fig. Figure 9 shows that further 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, island-in-the-sea configuration, or any combination thereof. The sheath can be continuous or discontinuous around the core. The sheath-to-core weight ratio can range from approximately 5:95 to approximately 95:5. The fibers of this disclosure can have various geometries, including round, elliptical, star-shaped, rectangular, and other eccentricities.

[0038] In certain forms, the nonwoven fabric can comprise one or more layered webs and / or gradient webs. These layered webs and / or gradient webs can differ from one another based on one or more of their surface energy, fiber diameter, and fiber crimp characteristics.

[0039] Methods for extruding multi-component polymer threads into such arrangements are well known to those skilled in the art.

[0040] 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 threads include natural polymers such as starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, chitin, chitosan, 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 comprising monomeric mixtures of propylene and ethylene, and biodegradable or compostable thermoplastic polymers such as polylactic acid threads, polyvinyl alcohol threads, and polycaprolactone threads.In one example, the polymer could be a thermoplastic polymer selected from the group consisting of: polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, styrene-butadiene-styrene block copolymer, styrene-isoprene-styrene block copolymer, polyurethane, and mixtures thereof. In another example, the thermoplastic polymer could be selected from the group consisting of: polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, and mixtures thereof. Alternatively, the polymer could include one derived from bio-based monomers, such as biopolyethylene or biopolypropylene.

[0041] The primary component A and the secondary component B can be selected such that the resulting two-component yarn provides improved nonwoven bonding and substrate softness. The primary polymer component A can have a melting temperature lower than that of the secondary polymer component B.

[0042] 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 can 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 fibers, lower the bonding temperature of the fibers, and improve the wear resistance, strength, and softness of the resulting fabric.

[0043] 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 can include hydrated magnesium silicate, titanium dioxide, calcium carbonate, clay, chalk, boron nitride, limestone, diatomaceous earth, mica quartz, and ceramics.

[0044] The fibers of the present disclosure may also contain a lubricant additive in an amount sufficient to impart the desired haptic quality to the fiber. As used herein, “lubricant additive” or “lubricant” means an external lubricant. Upon melt mixing with the resin, the lubricant may gradually separate or migrate to the surface during cooling or after manufacture, forming a uniform, invisibly thin coating and producing permanent lubricating effects. The lubricant is preferably a fast-curing lubricant and may be a hydrocarbon with one or more functional groups selected from hydroxide, arylenes and substituted arylenes, halogens, alkoxys, carboxylates, esters, carbon unsaturation, acrylates, oxygen, nitrogen, carboxyl, sulfate, and phosphate.

[0045] During manufacturing, in a post-treatment, or even both, the nonwoven fabric of this disclosure can be treated with surfactants or other agents to either hydrophilize or hydrophobize the web. 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.

[0046] Suitable materials for preparing the multi-component threads of the substance of the present disclosure may include PH-835 polypropylene, obtained from LyondellBasell, and Aspun-6850-A polyethylene, obtained from Dow Chemical Company.

[0047] If polyethylene is component A (sheath) and polypropylene is component B (core), then the bicomponent fibers can comprise approximately 5 wt% to approximately 95 wt% polyethylene and approximately 95 wt% to approximately 5 wt% polypropylene. Alternatively, the fibers can comprise approximately 40 wt% to approximately 60 wt% polyethylene and approximately 60 wt% to approximately 40 wt% polypropylene.

[0048] Let us turn Fig. 10, where a representative production line 30 for preparing nonwoven fabric 10 of the present disclosure is disclosed. The production line 30 can be arranged to produce a fabric of bicomponent continuous filaments, but it is understood that the present disclosure includes nonwoven fabrics produced with monocomponent or multicomponent filaments with more than two components. In certain examples, bicomponent filaments can be trilobal.

[0049] Production line 30 can include 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 the respective extruder 32 from a first hopper 36, and polymer component B is fed into the respective 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 experts in the field and are therefore not described in detail here.

[0050] In general terms, the spinning package 48 can comprise a housing that includes 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 can include openings arranged in one or more rows. The spinneret openings can 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 shell / core or side-by-side bicomponent filaments that are extruded in Fig. 8A, Fig. 8B and Fig. 8C illustrates, as well as non-circular fibers, such as trilobal fibers as in Fig. Figure 9 shows. In addition, the fibers can be a single component comprising a polymer component such as polypropylene.

[0051] Production line 30 can also include a quench blower 50, which is positioned adjacent to the curtain of threads extending from the spinneret. Air from the quench blower 50 can quench the threads extending from the spinneret. The quench air can be directed from one side of the thread curtain or from both sides of the thread curtain.

[0052] A damper 52 can be positioned below the spinneret and can collect the quenched fibers. 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 may 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.

[0053] In general terms, the damper 52 can comprise an elongated vertical passage through which the threads are drawn by the suction of air entering from the sides of the passage and flowing downwards through it. A shaped, endless, at least partially perforated forming belt 60 can be positioned below the damper 52 and can receive the continuous threads from the outlet opening of the damper 52. The forming belt 60 can be a belt and can run around the guide rollers 62. A vacuum 64, positioned below the forming belt 60 where the threads are deposited, can draw the threads against the forming surface. Although the forming belt 60 is in Fig. Figure 11 shows a band, but it is understood that the shaping band can also exist in other forms, such as a drum. Details of specific shaped shaping bands are explained below.

[0054] When production line 30 is in operation, hoppers 36 and 38 can be filled with the respective polymer components A and B. The polymer components A and B can be melted and extruded through the respective extruders 32 and 34, through polymer lines 40 and 42, and the spinning pack 48. Although the temperatures of the molten polymers can 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.

[0055] As the extruded filaments extend below the spinneret, an airflow from the quench blower 50 at least partially quenches the filaments and, in certain filaments, induces the crystallization of molten filaments. The quench air can flow in a direction substantially perpendicular to the length of the filaments at a temperature of about 0 °C to about 35 °C and a velocity of about 100 to about 400 feet per minute. The filaments can be sufficiently quenched before being gathered onto the forming belt 60 so that they can be arranged by the compressed air flowing through the filaments and the forming surface. Quenching the filaments can reduce their stickiness, preventing them from sticking too tightly to one another before being joined, and they can be moved or arranged during filament gathering onto the forming belt and web formation.

[0056] After quenching, the threads can be 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.

[0057] The threads can be deposited through the outlet opening of the damper 52 onto the shaped, running forming belt 60. While the threads are in contact with the forming surface of the forming belt 60, the vacuum 64 can draw the air and fibers against the forming belt 60 to form a nonwoven web of continuous threads that assume a shape corresponding to the shape of the forming surface. As described above, because the threads are quenched, they are not too sticky, and the vacuum can move or arrange the threads on the forming belt 60 as the threads are gathered on the forming belt 60 and formed into the fabric 10.

[0058] The production line 30 can further include one or more binding devices, such as the cylindrical compression rollers 70 and 72, which can form a roller gap through which the fabric can be compressed, 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 binding can improve the tensile properties of the fabric 10. The compression rollers 70, 72 can be a pair of smooth-surface stainless steel rollers with independent heating controls. The compression rollers 70, 72 can be heated by electric elements or hot oil circulation.The gap between the compaction rollers 70 and 72 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 example with a forming belt thickness of 1.4 mm and a spunbond nonwoven fabric with a base weight of 30 grams per square meter, the roller gap between the compaction rollers 70 and 72 can be approximately 1.4 mm.

[0059] In one example, the upper compaction roller 70 can be heated sufficiently to melt binding fibers on the first surface 12 of the fabric 10, thus giving the fabric strength so that it can be removed from the forming belt 60 without loss of integrity. As in Fig. 11 and Fig. As shown in Figure 12, 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 heated 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 the nonwoven 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 cores of Fig. 4 and Fig. 15. By adjusting the temperature and residence time, the binding can be primarily limited to fibers that are closest to the first surface 12, or thermal binding to the second surface 14 can be achieved, as in Fig. 14 (which also shows point bindings 90, as discussed in more detail below) and Fig. 66-70 shown. The bond can also be a discontinuous network, for example as point bonds 90, as discussed below.

[0060] The raised elements of the forming strip 60 can be selected to establish various network features of the forming strip and the bonded areas of a nonwoven substrate 11 or nonwoven fabric 10. The network corresponds to the resin that constitutes the raised elements of the forming strip 60 and can include essentially continuous, essentially semi-continuous, discontinuous options, or combinations thereof. These networks can represent the raised elements of the forming strip 60 because they contribute to its appearance or shape in the XY planes of the forming strip 60 or to the three-dimensional features comprising the nonwoven substrate 11 or the nonwoven fabric 10 of the present disclosure.

[0061] An "essentially continuous" network refers to an area within which any two points can be connected by an unbroken line that lies entirely within the area along its length. This means that the essentially continuous network exhibits continuity in all directions parallel to the first plane and terminates only at the edges of this area. The term "essentially" in conjunction with "continuous" indicates that, while absolute continuity can be achieved, minor deviations from absolute continuity may be tolerable, provided these deviations do not noticeably impair the performance of the fiber structure (or forming element) according to its design and planning.

[0062] A “substantially semi-continuous” network refers to an area that exhibits continuity in all, but 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 only in one direction parallel to the first plane. Analogous to the continuous region described above, while absolute continuity in all, but at least one, directions is preferred, slight deviations from such continuity may be tolerable as long as these deviations do not noticeably impair the performance of the fiber structure.

[0063] “Discontinuous” network refers to separate and distinct surfaces that are discontinuous in all directions parallel to the first level.

[0064] After compaction, the material can leave the forming belt 60 and be calendered through a roller gap formed by calender rollers 71, 73, after which the material can be wound onto a roller. 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 84 can include 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" forming 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%. The engraved pattern can be a variety of closely spaced, regular, generally cylindrical pin shapes with generally flat tops, with pin heights ranging from 0.5 mm to 5 mm, and preferably from 1 mm to 3 mm. Pin-bond calender rollers can form 10 closely spaced regular dot bonds 90° in nonwoven fabric, as shown in Fig.14 shown. Further binding can be done, for example, by hot air binding.

[0065] Air-assisted thermal binding can be another approach to producing higher-volume nonwoven structures suitable for this application. Air-assisted thermal binding involves applying hot air to the surface of the nonwoven fabric. The hot air can flow through holes in a plenum positioned 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 plate that carries the nonwoven as it passes through the oven. Drawing the air through the nonwoven can allow for much faster and more uniform heat transfer and minimizes fabric deformation. Beyond conventional air-assisted binding units, it would be conceivable to place the binding unit on top of the 3D belt while applying a vacuum beneath the belt to mimic the air-assisted binding process for this specific application.

[0066] Binders used in air-to-air thermal binding can include crystalline binder fibers, bicomponent binder fibers, and powders. When using crystalline binder fibers or powders, the binder can melt completely, forming molten droplets across the cross-section of the nonwoven fabric. Bonding can occur at these points upon cooling. In the case of sheath / core binder fibers, the sheath can be the binder and the core can be the carrier fiber. For example, a nonwoven fabric could contain sheath / core binder fibers, where the sheath could be polyethylene and the core could be polypropylene.For such a nonwoven fabric, the air-through thermal bonding temperature can range from 110°C to 150°C, and the dwell time can range from 0.5–10 seconds, 5–30 seconds, or 30–60 seconds, as the bonding time will depend on the base weight, the desired strength, and the processing speed. Products manufactured using air-through ovens can tend to be bulky, open, soft, firm, stretchable, breathable, and absorbent.

[0067] Spot bonding, as used herein, is a process of thermally bonding a nonwoven fabric, web, or substrate. This process may involve passing a web through a nip between two rollers, consisting of a heated, raised-patterned or engraved metal roller and a smooth or patterned metal roller. The raised-patterned roller may include a variety of raised, generally cylindrical pins that produce circular spot bonds. The smooth roller may or may not be heated, depending on the application. In a nonwoven fabric production line, the fabric, which may be an unbonded fiber web, may be 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 can depend on process settings such as roll temperatures, web speeds, and roll gap pressures, all of which can be determined by a person skilled in the art to achieve 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 ovals, lines, circles, etc. In one example, spot bonding can produce a pattern of spot bonds that are circles with a diameter of 0.5 mm and a total bond area of ​​10%. Other examples can include bond shapes where the raised pins have a longest dimension across the bond surface of a pin of approximately 0.1 mm to 2.0 mm, and the total bond area ranges from 5% to 30%.

[0068] As in Fig.As shown in Figure 14, the heated compaction roller 70 can form a bonding pattern that is an essentially continuous network bonding pattern 80 (e.g., interconnected heart-shaped bonds) on the first surface 12 of the nonwoven fabric 10 (not shown in Figure 14). Fig.14, since it faces away from the viewer), and the engraved calender roll 73 forms relatively small spot bonds 90 on the second surface 14 of the nonwoven fabric 10. The spot bonds 90 can secure loose fibers that would otherwise be prone to fuzzing or pilling during use of the nonwoven 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 surfaces of the fabric that are pressed by the raised elements of the forming belt 60.This binding can give the nonwoven fabric 10 structural integrity, but may be relatively stiff or rough to a user's skin. Therefore, the first surface 12 of the nonwoven fabric 10 in a diaper or sanitary napkin may be oriented so that it faces the inside of the article, i.e., away from the wearer's body. Likewise, the second surface 14 may, when in use, face the body and be in contact with it. The relatively small dot bindings 90 may be less likely to be perceived visually or tactilely by the user, and the relatively soft three-dimensional features may remain visually free of linting and pilling when in use, while feeling soft to the touch. Further binding may be used instead of, or in addition to, the bindings mentioned above.

[0069] The shaping tape 60 can be manufactured according to the methods and processes described in US 6,610,173 A granted to Lindsay et al. on August 26, 2003, or US 5,514,523 A granted to Trokhan et al. on May 7, 1996, or US 6,398,910 A granted to Burazin et al. on June 4, 2002, or US 2013 / 0199,741 A1 published on behalf of Stage et al. on August 8, 2013, each with the improved features and patterns disclosed herein for the manufacture of spunbond nonwoven webs. The disclosures of Lindsay, Trokhan, Burazin and Stage describe tapes that are representative of papermaking tapes made with hardened resin on a woven reinforcing element, these tapes, with improvements, can be used in the present disclosure as described herein.

[0070] Forming strip 60 with improved three-dimensional features and patterns for producing spunbond nonwoven webs can also be produced by the following methods and processes and / or on the following equipment, including with modifications as desired for structures taught herein: rotary screen processes as taught in US 7,799,382 B2 issued to Payne et al. on September 21, 2010; polymer extrusion as taught in US 2007 / 0170,610 A1 by Payne et al., published on July 26, or US 2005 / 0280,184 A1 by Sayers et al., published on December 22, 2005; resin system grafting as taught in US 7,105,465 B2 issued to Patel et al. on September 12, 2006; Perforated film, as taught in US 8,815,057 B2, issued to Eberhardt et al. on August 26, 2014; successive layer treatment, as taught in US 2006 / 0019567 A1 by Sayers, published January 26, 2006; polymer droplet deposition, as taught in US 7,005,044 B2, issued to Kramer et al. on February 28.2006; Polymer droplet deposition with a sacrificial material, as taught in US 7,014,735 issued to Kramer et al. on March 21, 2006; Air-permeable film technology, as taught by US 8,454,800 B2 issued to Mourad et al. on June 4, 2013, or US 8,822,009 B2 issued to Riviere et al. on September 9, 2014; Multilayer ribbon structures, as taught by US 2016 / 0090692 A1 by Eagles et al., published March 31, 2016; Laser etching, as taught by US 8,758,569 B2 issued to Aberg et al. on June 24, 2014, or US 8,366,878 B2 issued to Klerelid et al. February 5, 2013; Extruded mesh technology as taught in US 2014 / 0 272 269 A1 by Hansen, published September 18, 2014; Nonwoven tapes as described in US 2008 / 0 199 655 A1 by Monnerie et al., published August 21, 2008; and Additive manufacturing methods and processes as taught in US 2015 / 0 102 526 A1 by Ward et al., published April 16, 2015, or US 2016 / 0 159 007 A1 by Miller et al., published June 9, 2016, or WO 2016 / 085704A1 by Burazin et al., published November 17, 2016, or US 2016 / 0185041A1 by Lisagor et al., published June 30, 2016.

[0071] An example of a shaping band 60 of the type useful in the present disclosure and which can be manufactured according to the disclosure of US 5,514,523 A, is shown in Fig. Figure 15 shows that, as taught therein, a reinforcing element 94 (such as a woven band of threads 96) is thoroughly coated with a liquid photosensitive polymeric resin to a pre-selected thickness. A film or negative mask containing the desired repeating elements of the raised element pattern (e.g., Fig.17) incorporated, can be arranged opposite the liquid photosensitive resin. The resin can then be exposed to light of an appropriate wavelength through the film, such as UV light for a UV-curable resin. This exposure to light can cause the resin to cure in the exposed areas (i.e., white sections or unprinted sections in the mask). Uncured resin (resin beneath the opaque sections in the mask) can then be removed from the system, leaving the cured resin, which forms the illustrated pattern, for example, the one shown in Fig. The 15 hardened resin elements shown are shown in Figure 92. Further patterns can also be formed, as discussed herein.

[0072] Fig. Figure 15 shows a section of a shaping band 60, which is used to produce the in Fig.The nonwoven fabric 10 shown is useful. As shown, the shaping tape 60 can comprise 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 be the Fig. exhibit the general structure shown in 15, and can be combined with the elements shown in 15 by using a mask 97. Fig. The dimensions specified in 17 are to be manufactured. As shown in the schematic cross-section in Fig.As shown in Figure 16, cured resin elements 92 can flow around and are cured to “lock” onto 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 overload, 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. 17 represents a section of a mask 97, which defines the design and representative dimensions for a repeating unit of the repeating heart design in the Fig.The nonwoven fabric 10 shown in Figure 4 is shown. The white section 98 can be transparent to UV light and, in the manufacturing process of the tape as described in US 5,514,523 A, can allow UV light to cure an underlying resin layer, which is cured to form the raised elements 92 on the reinforcing element 94. After the uncured resin has been washed away, the shaping tape 60, which has a cured resin design as shown in Figure 4, can be used to form the raised elements 92 on the reinforcing element 94. Fig. Figure 15 shows that the strips are produced by hemming the ends of a length of the strip, the length of which can be determined by the design of the device, as shown in Fig. 10 shown.

[0073] Similarly, Fig. 18 represents a section of a mask 97, which is the design for a repeating unit of the repeating design in the Fig.The nonwoven fabric 10 shown in Figure 5 is shown. The white section 98 can be transparent to UV light and, during the tape manufacturing process, allows UV light to cure an underlying resin layer, which is then cured to form the reinforcing element 94. After the uncured resin has been washed away, the shaping tape 60, which has a cured resin design as shown in Figure 5, can be used to form the reinforcing element 94. Fig. 19 shows that they can be produced by hemming the ends of a length of the strip, the length of which is determined by the design of the device as shown in Fig. 10 can be determined.

[0074] Furthermore, in another non-restrictive example, 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 is shown. The white section 98 is transparent to UV light and allows UV light within the manufacturing process of the tape to cure an underlying resin layer, which is then cured to form the reinforcing element 94. After the uncured resin has been washed away, the shaping tape 60 can be fitted with a cured resin design, as shown in Figure 21. Fig. 21 shown, produced by hemming the ends of a length of nonwoven fabric 10.

[0075] Another example of a section of a shaping band 60 of the kind that is useful in the present disclosure is given in Fig. 22 shown. The section of the shaping band 60, which is in Fig.As shown in Figure 22, a separate tape pattern 61 can be formed, which, corresponding to the length L and width W of the total area OA of the nonwoven fabric 10, can have a length L and a width W. That is, the shaping tape 60 can comprise separate tape patterns 61 (as shown with reference to Figure 22 below). Fig. 25 discussed in more detail), 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. 23 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 24 represents the white section 98, which can be transparent to UV light and, during the tape manufacturing process, allows UV light to cure an underlying resin layer that is cured to form the reinforcing element 94. After the uncured resin has been washed away, the shaping tape 60 can be finished with a cured resin design as shown in Figure 24. Fig. 22 shown are produced by hemming the ends of one length of the ribbon.

[0076] The section of the shaping band that is in Fig. Figure 22 illustrates another advantage of the present disclosure. The section of a shaping band 60, which is shown in Fig. 22, as shown, can be in Fig. Produce the nonwoven fabric shown in section 24. The one in Fig. The nonwoven fabric 10 shown in Figure 24 can have dimensions of a width W and a length L and 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 24, ... total area OA, which makes it suitable, for example, for use as a top layer in a disposable diaper. Fig. 22, as explained by example, differs from that in the Fig.Figures 4-6 show that the pattern of three-dimensional features formed by the separate resin elements 92 on the shaping strip 60 is not present in a regular, repeating pattern across the entire surface. Instead, the pattern of the three-dimensionally raised elements in the separate strip pattern surface DPOA can be described as an irregular pattern enclosing distinct sections, referred to as zones, as described above. The distinction between zones may be visual, i.e., a visually perceptible difference, or the distinction may produce a difference in the average intensive properties, such as base weight or volumetric density, or combinations of visual and intensive properties, within the nonwoven fabric 10.A visually perceptible difference exists if an observer under normal indoor lighting conditions (for example, 20 / 20 visibility, sufficient light for reading) can visually perceive a pattern difference between the zones, such as a first shaping zone 112 and a second shaping zone 122 of the shaping band 60.

[0077] As with reference to Fig. As described in section 2, the nonwoven fabric 10 can also include visually perceptible zones that correspond to the zones of the shaping tape. For example, in Fig.As shown in Figure 24 and described above, the nonwoven fabric 10 can comprise at least two, three, or four visually perceptible zones. The first zone 110, with a first pattern of three-dimensional features and first average intensity sizes, can comprise a first area that is generally located centrally within the total area OA. The second zone 120, with a second pattern of three-dimensional features and second average intensity sizes, can comprise a second area that is generally distributed around the first zone 110 within the total area OA and, in one example, completely surrounds it. The third zone 130, with a third pattern of three-dimensional features and third average intensity sizes, can comprise a third area that is generally distributed around the second zone 120 within the total area OA and, in one example, completely surrounds it.A fourth zone 140 with fourth three-dimensional features and fourth average intensity sizes can include a fourth surface positioned within the total area OA at any location, such as on a front surface of an upper layer, such as the one in . Fig. Figure 24 shows a heart design. In general, there can be n zones, where n is a positive integer. Each of the n zones can comprise an nth pattern of three-dimensional features, an nth area, and nth average intensity sizes. It is understood that the zones can be arranged in a variety of suitable configurations, including, but not limited to, those described herein.

[0078] The visually perceptible zones, as in Fig.Figure 24 shows that these features can include visually perceptible three-dimensional features. These diverse three-dimensional features can be bounded by areas of relatively higher density (relative to the interior of a three-dimensional feature) that take the form of a closed figure, such as the heart shape in the illustrations. Fig. 4 and Fig. 6 and the diamond shape of Fig. 5 and Fig.6. 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, where the first region and the second region are visually distinct, and there is a common intensity magnitude assigned to each of the first and second regions, and a difference in the common intensity magnitude value of the first region and the second region. For example, the three-dimensional features can be defined by a first region and a second region, where the first region is at a higher height (dimension measured in the Z-direction) relative to the plane of the first surface than the second region.In another example, the three-dimensional features can be defined by a first area and a second area, with the first area being on a higher base than the second area.

[0079] It is understood that, instead of having a constant repeating pattern that is uniformly distributed over the entire forming strip, the forming strip 60 of the present disclosure allows the production of a nonwoven fabric which can have repetitions of irregular separate strip patterns 61, each separate strip pattern 61 being like the one in Fig.The separate tape patterns shown in Figure 22 are each 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 rows, and optionally sequentially in parallel webs, each 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 suitable for use as a top layer in disposable absorbent products such as diapers or sanitary napkins.

[0080] In one example, 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 visual appearance and / or in the intensive sizes produced in nonwoven substrates on them. For example, as schematically shown in Fig.Figure 25 shows that the pattern of three-dimensional raised elements in the first forming zone 112 of the separate tape pattern 61A differs from the pattern of three-dimensional raised elements in the first forming zone 112 of the separate tape pattern 61B. The forming tape 60 can therefore offer flexibility in the production of nonwovens 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, with sequential separate tape patterns exhibiting different zone patterns.In one example, the nonwoven pattern of the top or bottom layer for one diaper size can differ from the nonwoven pattern of the top or bottom layer for another diaper size, thus providing a caregiver with a visual cue regarding the diaper size. Similarly, sanitary napkins can utilize a nonwoven fabric 10 for a top layer, with the visual pattern of three-dimensional features indicating the absorbency of the sanitary napkin. In each case, the different patterns of the nonwoven fabrics 10 can be produced on a single tape, with the separate tape patterns manufactured differently as required.

[0081] Therefore, the present disclosure describes, with reference to Fig.25 a forming belt with an axis A parallel to a longitudinal direction, which is a machine direction. The forming belt 60 can comprise a plurality of separate belt patterns 61, which are ordered 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, which is defined in a rectangular pattern by a length L and width W, as specified with reference to the separate belt pattern 61A. Within its total area DPOA, each separate belt pattern can have 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 shaping zone can have a first air permeability value, and the second shaping 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.

[0082] By way of example and with reference to the separate ribbon pattern 61 of the in Fig. 22 shown shaping band 60 and the one in Fig.The following properties were determined for the nonwoven fabric 10 shown in Figure 24. 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 another can be attributed to a difference in the air permeability of the forming tape 60. In the example used to illustrate the Fig.To produce the nonwoven fabric 10 shown in Figure 23, in which 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. Therefore, by varying the air permeability in the zones of the forming strip 60, the intensive values ​​of the average base weight and the average volumetric density in the zones can be simplified across the entire area of ​​the nonwoven fabric 10.

[0083] As can be seen from the description of the in Fig. 25 described shaping band 60 and with reference to Fig.26 can be understood, the nonwoven substrate 11 produced on belt 60 can be described as a nonwoven substrate 11 with a plurality of sections, described herein as ordered in at least one sequential relationship with respect to the longitudinal direction 10, i.e. the machine direction, when produced on the forming belt 60. Fig.Figure 26 is a schematic representation of a spunbond nonwoven substrate 11 showing sequentially arranged 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 sizes, and a first area localized within the total area OA; a second zone 120 with a second pattern of three-dimensional features and second average intensive sizes, with a second area localized 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 size, 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 26, 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 apply to second zones 120A, 120B, and 120C.

[0084] 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 sizes, and visual appearances. A common intensive size is an intensive size shared by more than one zone (with reference to zonal patterns, such as the one in Fig.24 shown) or more than one area (for three-dimensional features, such as the regular, repeating patterns, like the one in Fig. 4 shown). Such intensive quantities of the nonwovens 10 can be average values ​​and can, without restriction, include the volumetric density, the base weight, and the thickness. If, for example, a volumetric density is a common intensive quantity 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) may be identifiable areas that are visually distinguishable from one another and by different intensive quantities averaged within the zone.

[0085] Once produced, the individual nonwoven fabrics 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 flattened orientation in Fig. Figure 30 shows that a nonwoven fabric 10 is cut to the appropriate total area and glued into the diaper 1006 using methods known in the prior art. Nonwoven fabrics 10 can be cut before assembly into a diaper 1006, or the nonwoven substrate 11 can be brought together with other diaper components in web form during the diaper manufacturing process and cut to size after assembly.

[0086] As with reference to Fig.27 can be understood as the nonwoven substrate 11 produced on the forming belt 60 can be described as a nonwoven fabric 10 with a plurality of sections which are described herein as being arranged in at least one sequential relationship with respect to the longitudinal direction, i.e. in the machine direction when produced on the forming belt 60, and in at least one side-by-side relationship, i.e. in the machine transverse direction, when produced on the forming belt 60. Fig. Figure 27 is a schematic representation of a spunbond substrate 11, showing the sequentially ordered nonwovens 10 in adjacent machine-direction production webs 99, wherein the adjacent machine-direction production webs have nonwovens 10 arranged side by side, in Fig.27 are designated as 10D, 10E, and 10F. Each nonwoven fabric 10 can have a total area OA defined in a rectangular pattern by a length L and a width W. Each sequentially arranged nonwoven fabric 10 can have, within its total area OA, at least one first zone 110 with a first pattern of three-dimensional features and first average intensive sizes, and a first area localized within the total area OA; a second zone 120 with a second pattern of three-dimensional features and second average intensive sizes, with a second area localized 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 intensive size, and with a third area within the total area OA.Each nonwoven fabric 10 in side-by-side webs can be substantially identical, or they can differ in size, visual appearance, and / or intensity. Once produced, the nonwoven substrate 11 can be wound into webs for slitting and processing into consumer products, or it can be slit and then wound.

[0087] By using a representative sample to compare base weight differences in a nonwoven fabric 10 produced with a regular, repeating, uniform pattern and a nonwoven fabric 10 produced 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.24 shown are compared and designated as Example 3. Example 3 is a bicomponent spunbond nonwoven fabric produced on the apparatus disclosed herein by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, obtained from Dow Chemical Company) and polypropylene core (PH-835, obtained from LyondellBasell) in a trilobal fiber configuration. The trilobal spunbond bicomponent fibers were formed 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. 22 shown, filed. The second substrate was formed under identical conditions, but had at least one cut with a regular, repeating, uniform pattern on a shaping strip, as shown in Fig.Figure 19 shows the basis weight used to determine the base weight. The fiber spinning conditions, throughput, forming strip line speed, and compaction roller bonding temperature were identical for both substrates. Example 3

[0088] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, obtained from Dow Chemical) and polypropylene core (PH-835, obtained from LyondellBasell) in a trilobal fiber configuration to an average base weight of 30 grams per square meter. A nonwoven fabric was produced as described in reference to Fig. 10 and Fig. 11 described, produced under motion at a linear forming belt speed of approximately 25 meters per minute to produce a fabric with a zonal pattern as in Fig.23 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 roller at the winder 75. Example 4

[0089] A bicomponent spunbond nonwoven fabric produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, obtained from Dow Chemical) and polypropylene core (PH-835, obtained from LyondellBasell) in a trilobal fiber configuration to an average base weight of 30 grams per square meter. A nonwoven fabric was produced as described with reference to Fig. 10 and Fig. 11 described, produced under motion at a linear forming belt speed of approximately 25 meters per minute, to produce a fabric with a repeating (non-zonal) pattern as in Fig.5 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 roller at the winder 75.

[0090] 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 Fig. 28A and Fig. 28B shown, taken from where the dark rectangles are located where a 3 cm 2 The sample was removed for measurement. As can be seen, the fabrics 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 fabric, but also a CD distribution that can be graphically represented in Fig. 29 is shown. Table 2: Measured average base weight distribution in nonwoven fabric 10 in grams per square meter (gsm) area as in Fig. 29 shown Example 3: Zonal base weights 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

[0091] As shown in Table 2, nonwovens 10 produced on forming belts 60 with zones of varying air permeability exhibit significant variation in fiber placement and therefore base weights within the CD of the nonwovens 10, suggesting the ability of fibers to move with air to zones of high permeability. The nonwoven 10 with a non-zonal, repeating pattern exhibits approximately the same base weights within the CD of the fabric.

[0092] In addition to differences in the 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 strength, average softness, average compression resistance and fluid absorption properties.

[0093] Another aspect of the present disclosure relates to commercial spunbond production lines in which multiple beams are used to improve layup, opacity, and uniformity of the fabric. In some cases, the apparatus may include triple spunbond beams (known in the prior art as “SSS”) and may be combined with melt bubbles (M), for example in an apparatus known as an “SSMMS” spunbond production line.

[0094] By calendering the nonwoven fabric 10 to exhibit point binding 90°, pilling can be reduced. Pilling refers to the tendency of fibers to loosen and be removed from the fabric 10. This loosening and removal can occur due to friction with manufacturing equipment during the production of the disposable absorbent product or with another surface, such as a person's skin, that interacts with the nonwoven fabric 10. In some applications, such as for top layers in disposable absorbent products, pilling is a negative consumer phenomenon. However, binding fibers in place can also be negative for consumers, as it can produce roughness on the surface of an otherwise soft nonwoven substrate.As expected, we found that the nonwoven substrates and nonwovens of the present disclosure can withstand an increase in binding (and consequently a decrease in pilling) with minimal loss of softness. Bonding can be achieved by relatively closely spaced spot bonds 90°, the spacing being determined by the desired degree of pilling reduction. Bonding can also be achieved by known methods for chemically or thermally bonding nonwoven fibers, such as thermal bonding, ultrasonic bonding, pressure bonding, latex adhesion bonding, and combinations of these methods. The pilling reduction through bonding is illustrated with reference to Examples 5 and 6 below. Example 5

[0095] A bicomponent spunbond nonwoven fabric was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, obtained from Dow Chemical) and polypropylene core (PH-835, obtained 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 reference to Fig. 10 and Fig. 11 described, produced under motion at a linear speed of about 25 meters per minute, to produce a fabric with the repeating pattern as in Fig. 57 shown to form. Fibers of the material were further bonded on the first surface 12 by compaction rollers 70, 72, with the compaction roller 70 heated to 130 °C, to form essentially continuous bonds 80. Example 6

[0096] A bicomponent spunbond nonwoven fabric was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, obtained from Dow Chemical) and polypropylene core (PH-835, obtained 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 reference to Fig. 10 and Fig. 11 described, produced under motion at a linear speed of about 25 meters per minute, to produce a fabric with the repeating pattern as in relation to Fig.58 described. Fibers of the fabric were further bonded on the first surface 12 by compaction rollers 70, 72, with compaction roller 70 heated to 130 °C, to form substantially continuous bonds 80. Fibers of the fabric were further calendered on calender rollers 71, 73, 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. Roller 73 was heated to 135 °C to form spot bonds 90 on the second side 14 of the nonwoven fabric 10, as described in Fig. 14 shown.

[0097] The nonwovens 10 from Examples 5 and 6 differed solely in the absence or presence of spot ties 90. The second side 14 of the nonwovens 10 were subjected to a pilling test according to the pilling degree test to determine the effectiveness of the spot ties in securing fibers to the surface of the fabric. 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

[0098] 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. The absorbent articles of this disclosure are generally placed in packaging for shipping, storage, and sale. The packaging may include polymer films and / or other materials. Graphics and / or markings relating to properties of the absorbent articles may be formed, printed, positioned, and / or placed on outer sections of the packaging. Each package may contain a variety of absorbent articles.The absorbent products can be packaged under compression to reduce the size of the packages while still providing an adequate quantity of products per package. Packaging the absorbent products under compression makes the packages easier for caregivers to handle and store, while also providing manufacturers with distribution savings due to the smaller package size. Fig. Figure 30 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.

[0099] Packaging of the absorption articles of the present disclosure may have a bag stack height 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, with express listing of all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby, according to the bag stack height test described herein.Alternatively, the packagings of the absorption articles of the present disclosure may have a bag stack height of about 70 mm to about 100 mm, of about 70 mm to about 95 mm, of about 70 mm to about 85 mm, of about 72 mm to about 80 mm or of about 74 mm to about 78 mm, with express listing of all 0.1 mm increments within the specified ranges and all areas formed therein or thereby, according to the bag stack height test described herein. Nonwovens with openings

[0100] Any suitable process for providing openings to the nonwovens described herein may be used. For example, the open-perforated, three-dimensionally shaped nonwovens with variable base weight of the present disclosure may generally be produced by using the process described in US 5,628,097 A; US 5,658,639 A; US 5,916,661 A; US 6,632,504 B1; US ​​6,884,494 B1 and US 7,037,569 B2 and US Patent Publication US 2003 / 0021,951 A1 entitled "High Elongation Apertured Nonwoven Web and Method of Making", published on January 20, 2003.

[0101] With reference to Fig.For example, Figure 31 schematically illustrates a method for forming the openwork, three-dimensionally shaped nonwovens with variable base weight described in this disclosure. First, a precursor material 152 (e.g., the nonwoven described herein) can be supplied as a starting material. The precursor material 152 can be provided as separate webs, e.g., as sheets, patches, etc., for batch processing. However, in commercial processing, the precursor material 152 can be supplied as a roll stock and, as such, can be assumed to have a finite width and an infinite length. In this context, the length can be measured in the machine direction (MD). Correspondingly, the width can be measured in the machine transverse direction (CD).

[0102] The precursor material 152 can comprise the materials for the three-dimensionally formed variable-base nonwovens described herein. The precursor material 152 can be a three-dimensionally formed variable-base nonwoven as one or more layers combined with one or more conventional nonwoven materials and / or films. The precursor material 152 can be sourced from a supplier and shipped to the site where the three-dimensionally formed variable-base nonwovens are formed, or the precursor material 152 can be formed at the same site where the three-dimensionally formed variable-base nonwovens are produced.

[0103] The precursor material 152 can be extensible, elastic, or non-elastic. Furthermore, the precursor material 152 can be a single-layer or multi-layer material. For example, the precursor material 152 can be combined with a polymer film or a conventional nonwoven material to form a laminate.

[0104] The precursor material 152 may comprise or be made from monocomponent fibers, bicomponent fibers, multicomponent mixtures, or multicomponent fibers comprising one or more thermoplastic polymers. In one example, the bicomponent fibers of the present disclosure may be formed from a polypropylene core and a polyethylene sheath. Further details regarding bicomponent or multicomponent fibers and methods for their preparation can be found in the US patent application publications. Nos. US 2009 / 0104831A1, issued April 23, 2009; US 8226625B2, issued July 24, 2012; US 8231595B2, issued July 31, 2012; US 8388594B2, issued March 5, 2013; and US 8226626B2, issued July 24, 2012. The various fibers can be sheath / core, side-by-side, island-in-the-sea, or other known fiber configurations. The fibers can be round, hollow, or shaped, such as...Trilobal, ribbon-like, capillary channel fibers (e.g., 4DG). The fibers may include microfibers or nanofibers.

[0105] In the Fig.In the example shown in Figure 31, the precursor material 152 is shown unwound from a feed roll 154 and moving in a direction indicated by the associated arrows, while the feed roll 154 rotates in the direction indicated by the associated arrows. The precursor material 152 passes through a roll gap 156 of a weakening roll assembly 158 (or overbond) formed by the rolls 160 and 162, thereby forming a weakened precursor material. The weakened precursor material 152 exhibits a pattern of overbonds, or densified and weakened surfaces, after passing through the roll gap 156. At least some, or all, of these overbonds are used to form openings in the precursor material 152. Therefore, the overbonds can generally correlate with patterns of openings produced in the precursor material 152.

[0106] With reference to Fig.32 The precursor material weakening roll assembly 158 can comprise a patterned calender roll 160 and a smooth anvil roll 162. One or both of the patterned calender roll 160 and the smooth anvil roll 162 can be heated, and the pressure between the two rolls can be adjusted by known techniques to provide the desired temperature, if applicable, and pressure to weaken and melt stabilize (i.e., overbond) the precursor material 152 at a plurality of locations 190 simultaneously.The temperature of the calender roll 160 (or sections thereof) and / or the smooth anvil roll 162 (or sections thereof) may be ambient temperature or may be in a range of approximately 100 °C to approximately 300 °C, approximately 100 °C to approximately 250 °C, approximately 100 °C to approximately 200 °C, or approximately 100 °C to approximately 150 °C, with express listing of all 0.5 °C increments within the specified ranges and all ranges formed therein or thereby. The pressure between the calender roll 160 and the smooth anvil roll 162 can be in a range of about 2,000 pli (pounds per linear inch) to about 10,000 pli, about 3,000 pli to about 8,000 pli, or about 4,500 pli to about 6,500 pli, with express listing of all 0.1 pli increments within the specified ranges and all ranges formed therein or thereby.As discussed in more detail below, after the precursor material 152 has passed through the weakening roller arrangement 158, the precursor material 152 in the CD, or more generally in the CD, can be stretched by a transverse tensile force in order to at least partially, or completely, tear the plurality of weakened, melt-stabilized spots 190, thereby producing a plurality of at least partially formed openings in the precursor material 152, coinciding with the plurality of weakened, melt-stabilized spots 190.

[0107] The patterned calender roll 160 can be configured to have a cylindrical surface 164 and a plurality of projections or pattern elements 166 extending outward from the cylindrical surface 164. The pattern elements 166 are illustrated as a simplified example of a patterned calender roll 160, but more detailed patterned calender rolls that can be used to produce three-dimensionally shaped nonwovens of the present disclosure are illustrated in subsequent figures. The projections 166 can be arranged in a predetermined pattern, each projection 166 being configured and arranged to precipitate a weakened melt-stabilized site in the precursor material 152 in order to influence a predetermined pattern of weakened melt-stabilized sites 190 in the precursor material 152.The projections 166 can exhibit a one-to-one correspondence with the pattern of melt-stabilized sites in the precursor material 152. As in . Fig.As shown in Figure 32, the patterned calender roll 160 can comprise a repeating pattern of projections 166 that extends around the entire circumference of the surface 164. Alternatively, the projections 166 can extend around a section or sections of the circumference of the surface 164. Likewise, a single patterned calender roll can comprise a variety of patterns in different zones (i.e., first zone, first pattern; second zone, second pattern). The projections 166 can have a cross-sectional width in the range of approximately 0.1 mm to approximately 10 mm, approximately 0.1 mm to approximately 5 mm, approximately 0.1 mm to approximately 3 mm, approximately 0.15 mm to approximately 2 mm, approximately 0.15 mm to approximately 1.5 mm, approximately 0.1 mm to approximately 1 mm, approximately 0.1 mm to approximately 0.5 mm or approximately 0.2 mm to approximately 0.5 mm, with explicit listing of all 0.05 mm increments within the specified ranges and all areas formed therein and thereby.The projections 166 can have an aspect ratio in the range of approximately 10:1, approximately 9:1, approximately 8:1, approximately 7:1, approximately 6:1, approximately 5:1, approximately 4:1, approximately 3:1, approximately 2:1, approximately 1.5:1, or approximately 1.1:1. Other aspect ratios of the projections 166 are also within the scope of protection of the present disclosure. The projections 166 can be angled in some shapes, with respect to the machine direction on each side, in the range of approximately 60 degrees to approximately 1 degree, approximately 50 degrees to approximately 2 degrees, approximately 45 degrees to approximately 2 degrees, approximately 45 degrees to approximately 5 degrees, approximately 40 degrees to approximately 5 degrees, or approximately 35 degrees to approximately 5 degrees, with express listing of all 0.1-degree increments within the specified ranges and all areas formed therein or thereby.The spacing between adjacent projections 166 in each direction may be more than about 0.5 mm, more than about 0.6 mm, more than about 0.7 mm, more than about 0.8 mm, more than about 0.9 mm, more than about 1 mm, more than about 1.1 mm, more than about 1.2 mm, more than about 1.3 mm, more than about 1.4 mm, more than about 1.5 mm, more than about 2 mm, more than about 3 mm, or may be in the range of about 0.7 mm to about 20 mm or about 0.8 mm to about 15 mm, with express listing of all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby.

[0108] The projections 166 can extend radially outward from the surface 164 and can have distal end surfaces 168. The anvil roller 162 can be a circular cylinder made of steel, rubber, or other material with a smooth surface. The anvil roller 162 and the patterned calender roller 160 can be interchanged in position (i.e., anvil on top) and achieve the same result.

[0109] From the weakening roller arrangement 158, the material 152 can pass through a roller gap 170, which is formed by an incremental expansion system 172 as shown in Fig. 31 and Fig. 33 shown, using opposing pressure applicators with three-dimensional surfaces that are complementary to each other at least to a certain degree.

[0110] Now referring to Fig.Figure 33 shows a fragmentary enlarged view of the incremental expansion system 172, which comprises two incremental expansion rollers 176 and 178. The incremental expansion roller 176 can comprise a plurality of teeth 180 and corresponding grooves 182 extending around the entire circumference of the roller 176. The incremental expansion roller 178 can comprise a plurality of teeth 184 and a plurality of corresponding grooves 186. The teeth 180 on the roller 176 engage with the grooves 186 on the roller 178, while the teeth 184 on the roller 178 engage with the grooves 182 on the roller 176. The spacing and / or distance of the teeth 184 and / or the grooves 186 may match the spacing and / or distance of the plurality of weakened, enamel-stabilized sites 190 in the precursor material 152, or may be smaller or larger.While the precursor material 152 with weakened melt-stabilized sites 202 passes through the incremental strain system 172, the precursor material 152 is subjected to tensile stress in the CD direction, causing the material 152 to expand (or be activated) in the CD, or more generally in the CD. Additionally, the material 152 can be subjected to tensile stress in the MD, or more generally in the MD. The tensile stress force applied to the material 152 is adjusted such that it causes the weakened melt-stabilized sites 190 to rupture at least partially, or completely, thereby creating a plurality of partially formed, or fully formed, openings 192 that coincide with the weakened melt-stabilized sites 190 in the material 152.The bonds of material 152 (in the unbonded areas) can be strong enough that they do not break during tensile stress, thus keeping material 152 in a coherent state, even if the weakened melt-stabilized areas do break. However, it may be desirable to allow some of the bonds to break during stress.

[0111] Referring to Fig.Figure 34 shows a more detailed view of teeth 180 and 184 and grooves 182 and 186 on rollers 176 and 178. The term "distance" refers to the distance between the vertices of adjacent teeth. The distance may be from about 0.02 in to about 0.30 in (about 0.51 mm to about 7.62 mm) or from about 0.05 in to about 0.15 in (about 1.27 mm to about 3.81 mm), expressly listing all 0.001-inch increments within the above-specified ranges and all areas formed therein or by them. The height (or depth) of the teeth may be measured from the base of the tooth to the vertex of the tooth and may or may not be the same for all teeth.

[0112] The height of the teeth may be between approximately 0.010 in (about 0.254 mm) and approximately 0.90 in (about 22.9 mm), or between 0.025 in (about 0.635 mm) and approximately 0.50 in (about 12.7 mm), with express listing of all 0.01-inch increments within the above-specified ranges and all regions formed therein or by them. The teeth 180 in one roller may be offset by about half the distance from the teeth 184 in the other roller, such that the teeth of one roller (e.g., teeth 180) engage with the valley (e.g., groove 186) between the teeth of the counter-roller. The offset permits the two rollers to mesh when the rollers are engaged or in an intermeshing operative position relative to each other. In some examples, the teeth of the respective rollers may only partially interlock.The degree to which the teeth on the opposing rollers engage with each other is referred to here as the "depth of engagement" or "DOE" of the teeth. The DOE can be constant or variable. As in . Fig.As shown in Figure 34, the DOE, denoted as "E", is the distance between a position designated by plane P1, where the tooth apices on the respective rollers lie in the same plane (0% engagement), and a position designated by plane P2, where the tooth apices of one roller extend beyond plane P1 inward toward the groove on the opposite roller. The optimal or effective DOE for particular laminate webs may depend on the tooth height and spacing and / or the material structure. Some example DOEs may be in the range of approximately 0.01 in to approximately 0.5 in, approximately 0.03 in to approximately 0.2 in, approximately 0.04 in to approximately 0.08 in, approximately 0.05 in, or approximately 0.06 in, with the express listing of all 0.001-inch increments within the ranges specified above and all areas formed therein or by them.

[0113] As the material 152 with the weakened, melt-stabilized areas 190 passes through the incremental web stretcher 172, the material 152 can be subjected to a tensile stress in the machine transverse direction or substantially in the machine transverse direction, causing the nonwoven web 152 to elongate in the machine transverse direction. The tensile stress applied to the material 152 can be adjusted by varying the distance, the DOE, or the size of the teeth such that the incremental stretching is sufficient to cause the weakened, melt-stabilized areas 190 to tear at least partially, or completely, thereby producing a plurality of openings 192 that coincide, or partially coincide, with the weakened, melt-stabilized areas 190 in the material 152.

[0114] After the material 152 passes through the incremental web stretching device 172, the web 152 can be advanced to and at least partially around a machine transverse tensioning device 172' (see e.g. Fig. 31 and Fig.35) The machine transverse tensioning device 172' can be offset from the main processing line by, for example, partially guiding the web around two guide rollers 174 and 175 or stationary bars. In other examples, the transverse machine tensioning device 172' can be positioned in line with the main processing line. The machine transverse tensioning device 172' can include a roller comprising at least one outer longitudinal section extending along a longitudinal axis A of the roller relative to a central section of the roller to stretch and / or expand the material 152 in the machine transverse direction.Instead of or in addition to expanding along the longitudinal axis A of the roller, the outer longitudinal section can be angled with respect to the longitudinal axis A of the roller in a direction away from the material 152 being fed over the roller, in order to stretch the material 152 in the machine transverse direction or, more generally, in the machine transverse direction. For example, a roller can comprise two outer longitudinal sections, each of which can expand in opposite directions, generally along the longitudinal axis A of the roller. The two outer sections can both be angled downwards in a direction away from the material 152 being fed over the roller. This movement or positioning of the outer longitudinal sections of the roller generally allows a machine transverse tensile stress on the material 152, causing the plurality of weakened areas 190 to tear and / or further define or form openings 192.

[0115] The outer longitudinal sections of the roller can include a vacuum, a low-tack adhesive, a material or surface with a high coefficient of friction, such as rubber, and / or other mechanisms and / or materials to hold the material 152 against the outer side sections of the roller during the movement of the outer longitudinal section(s) relative to the central section of the roller. The vacuum, the low-tack adhesive, the material or surface with a high coefficient of friction, and / or other mechanisms and / or materials can prevent, or at least inhibit, the held sections of the material 152 from sliding during the stretching of the outer side sections of the material in the machine transverse direction or, more generally, in the machine transverse direction relative to the longitudinal axis A of the roller.

[0116] Fig.Figure 35 is a perspective top view of the exemplary machine transverse tensioning device 172'. The machine transverse tensioning device 172' can comprise a roller that includes a central section 194 and two outer longitudinal sections 196 located at each end of the central section 194. The roller can rotate on a drive shaft 198 about its longitudinal axis A. The roller can rotate relative to the drive shaft 198 or together with the drive shaft 198, as will be recognized by those skilled in the art. The material 152 can be advanced over the entire machine transverse width of the central section 194 and at least portions of the machine transverse widths of the outer longitudinal sections 196. The material 152 can be advanced over at least about 5% to about 80% of the circumference of the roller so that the machine transverse stretching can be carried out.

[0117] Fig.Figure 36 is a schematic representation of a front view of an exemplary machine transverse tensioning device with outer longitudinal sections 196 in relation to the central section 194 in a non-expanded or non-angled position. Fig. Figure 37 is a schematic representation of a front view of the machine's transverse tensioning device. Fig. 33 with the outer longitudinal sections 196 relative to the central section 194 in a longitudinally expanded position. Fig. Figure 38 is a schematic representation of a front view of the machine's transverse tensioning device. Fig. 37 with the outer longitudinal sections 196 relative to the central section 194 in an angled and expanded position. Regarding Fig.38 The outer longitudinal sections 196 can only move or shift in one direction generally perpendicular to the machine running direction of the material running over the roller in order to apply the machine transverse tensile force to the material 152. Fig. Figure 39 is a schematic representation of a front view of a machine transverse tensile clamping device, wherein the outer longitudinal sections 196 are fixed in an angled position relative to the central section 194 in order to apply the machine transverse tensile clamping force to the material 152. In such a design, the central section 194 and each of the outer longitudinal sections 196 can comprise a separate roller.

[0118] Regardless of whether one or both of the outer longitudinal sections 196 are moved, displaced, rotated, fixed, and / or expanded relative to the central section 194, this relative movement or positioning between the outer longitudinal section 196 and the central section 194 can stretch the materials 152 in a machine transverse direction to further tear or define the weakened areas 196 in the material 152 and to create or further form a plurality of openings 198 in the material 152. The machine transverse tensile force applied by the machine transverse tensile clamping device 172' can be, for example, 10-25 grams or 15 grams. In one example, the machine transverse tensile clamping device can be similar to or the same as the incremental stretching device 172 for applying the machine transverse tensile force.In other examples, any suitable machine transverse tensile clamping device can be used to apply the machine transverse tensile clamping force to a material.

[0119] If desired, the incremental stretching step described herein, or the machine transverse stretching step, can be performed at elevated temperatures. For example, the material 152 and / or the rollers can be heated. Utilizing heat in the stretching step can soften the material and may help to elongate the fibers without breaking them.

[0120] Referring again to Fig. 31. The material 152 can be picked up and stored on the winding reel 188. Alternatively, the material 152 can be fed directly to a production line where it can be used to form a section of an absorbent article or another consumer product.

[0121] It is important to note that the in Fig. 31 and Fig. The bonding step illustrated in Figure 32 can be carried out by the material supplier, and the material can then be sent to a consumer product manufacturer to carry out step 172. Indeed, the bonding step in the nonwoven production process can be used to form bondings, which can be done in addition to, or instead of, primary bonds formed in the nonwoven production process. Alternatively, the material supplier can perform the bonding step illustrated in Figure 32. Fig. Complete all 31 illustrated steps and the material can then be sent to the consumer product manufacturer. The consumer product manufacturer can also complete all steps after receiving nonwoven material from a nonwoven material manufacturer. Fig. 31.

[0122] Experts in the field will recognize that it can be advantageous to subject material 152 to several incremental stretching processes, depending on the various desired characteristics of the final product. Both the initial and each subsequent incremental stretching can be performed online or offline. Furthermore, a person skilled in the field will recognize that, depending on the desired end characteristics, the incremental stretching can be performed either across the entire material surface or only in specific areas.

[0123] Examples of opening patterns are in the Fig. Shown in 40-45. Fig. 40 and Fig. 41 openings are shown arranged in 192 different patterns. In the Fig. 42 and Fig.In the 43 patterns shown, opening arrays 193 are separated by continuous, interconnected impact surface patterns 195. In such examples, the impact surface patterns 195 can serve as fluid distribution paths, and the opening arrays 193 can function as fluid “drains,” thereby facilitating fluid access to an underlying absorbent material or core. In certain shapes, the opening arrays 193 can be shaped to enhance their ability to handle fluids such as bodily excretions (i.e., urine, flowing BM, menstrual fluid). In such examples, fluids can move along the impact surface within a concavity, for example, to a point where the concavity ends. At this point, fluids can enter an opening in the direction of the fluid path or those on either side of the concavity if the fluid rotates in any lateral direction.Example opening array shapes with a concavity can include, among other examples, heart shapes, star shapes, some polygons, crescents, and angular indentations. In the... Fig. 44 and Fig. In the 45 patterns shown, openings or arrays thereof can form one or more continuous or semi-continuous patterns 197, resulting in separate “macro” impact surfaces 199. In such examples, the separate macro impact surfaces 199 can function as fluid deposition regions. Fluids moving from the separate macro impact surfaces 199 in any direction can be absorbed into the openings of the continuous or semi-continuous pattern 197. Although the Fig.While Figures 40-45 do not depict the opening patterns applied to three-dimensionally shaped nonwovens with variable base weight, it is understood that such patterns, among other patterns and configurations, can be applied to three-dimensionally shaped nonwovens with variable base weight. Additional opening patterns and configurations are disclosed in US 2016 / 0136014A1.

[0124] As described herein, other suitable methods for providing openings to the nonwovens described herein may be used. For example, the three-dimensionally shaped nonwovens with variable base weight may also be produced by hydroforming carded webs, laser cutting, die-cutting with a structured roller, hot-pinning, or other suitable methods.

[0125] Alternatively, additional methods for creating openings are described in US 9,023,261 B2 or US 8,158,043 B2; US 8,241,543 B2; and US 8,679,391 B2. For example, instead of the rollers 160 and 162 used in the method described here, a pair of interlocking steel rollers 161 and 163 may be used in an opening-creation method as described in Fig. 46, and as described, for example, in US 8,679,391 B2. Each of the rollers 161 and 163 can rotate about an axis A, the axes A being parallel and in the same plane. A precursor material 152 can be taken in through the roller gap 157 and exit as a material with openings.

[0126] As in Fig.As shown in Figure 46, roller 161 can comprise a plurality of combs 165 and corresponding grooves 167 that can extend continuously around the entire circumference of the roller 161. In certain examples, roller 161 can include combs 165 where sections have been removed, such as by etching, milling, or other machining processes, so that some or all of the combs 165 do not extend continuously around the circumference but have interruptions or gaps. The interruptions or gaps can be arranged to form a pattern, including simple geometric patterns such as circles or diamonds, but also complex patterns such as logos and trademarks. In one example, the roller 161 can comprise teeth, similar to the teeth 169 on roller 163 described below. In this way, it is possible to have three-dimensional openings with sections that extend outward on both sides of an openingd material.

[0127] Roller 163 can comprise a plurality of rows of circumferentially extending combs, which have been modified to be rows of circumferentially spaced teeth 169 that extend in a spaced relationship around at least one section of the roller 163. The individual rows of teeth 169 of roller 163 can be separated by corresponding grooves 171. In operation, rollers 161 and 163 can interlock, so that the combs 165 of roller 161 can extend into the grooves 171 of roller 163 and the teeth 169 of roller 163 can extend into the grooves 167 of roller 161. Either one or both of the rollers 161 or 163 can be heated by means known in the prior art, such as by incorporating rollers filled with hot oil or electrically heated rollers. Alternatively, one or both of the rollers 161 or 163 can be heated by surface convection or by surface irradiation.

[0128] The teeth 169 can be joined to a base of the roller 163 by any method known to the prior art, such as welding, press fit or integral fastening, whereby excess material can be removed from a roller. Fig. Figure 47 shows a section of the roller 163 with a plurality of teeth 169, which are useful in a process for creating openings. A tooth tip 173 can generally be pointed, blunt-pointed, or otherwise shaped to stretch and / or pierce the precursor material 152. A representative opened material is shown in Fig. 48 shown, wherein openings 192 were formed by the action of teeth 169 on the heated roller 163, which were stretched and pressed through the precursor material 152 to permanently deform the precursor material 152 to form a plurality of separate, spaced volcano-like structures 191 extending outwards from it.

[0129] The openings described above can also have an opening density, according to the opening test, of, for example, at least approximately 150, at least approximately 175, at least approximately 200 or at least approximately 300.

[0130] At least some of the openings described above may furthermore exhibit absolute Feret angles, according to the opening test herein, of at least about 10 degrees, at least about 15 degrees, at least about 20 degrees, at least about 25 degrees, at least about 30 degrees, at least about 35 degrees, at least about 40 degrees, at least about 45 degrees, or be in the range of about 10 degrees to about 45 degrees or about 15 degrees to about 35 degrees, with express listing of all 0.1 degree increments within the specified ranges and all ranges formed therein or thereby.

[0131] The patterned openings can further comprise a first plurality of patterned openings and a second plurality of patterned openings. The central longitudinal axes of the first plurality of patterned openings can extend in a first direction relative to the machine direction of travel. The central longitudinal axes of the second plurality of openings can extend in a second, different direction relative to the machine direction of travel.The second different direction may differ from the first direction by at least approximately 5 degrees, at least approximately 10 degrees, at least approximately 15 degrees, at least approximately 20 degrees, at least approximately 30 degrees, at least approximately 40 degrees, at least approximately 50 degrees, at least approximately 60 degrees, at least approximately 70 degrees, at least approximately 80 degrees, at least approximately 90 degrees, or in the range of approximately 10 degrees to approximately 90 degrees or approximately 20 degrees to approximately 70 degrees, with express listing of all 0.1-degree increments within the ranges specified above and all ranges formed therein or by them. In certain examples, the first direction may have a positive slope relative to the machine's direction of travel, and the second direction may have a negative slope relative to the machine's direction of travel. In other examples, the first direction and the second direction may both have a positive slope, or both may have a negative slope.At least some of the multiple bonds may form a diamond-shaped or diamond-like pattern in the web. Impact surfaces may be formed at least partially around at least some of the multiple bonds or patterned openings, or completely around them. At least some of the patterned openings, such as two or more, three or more, or four or more, may be non-homogeneous, such that, according to the opening test herein, they may have different sizes, shapes, absolute Feret angles, and / or aspect ratios.

[0132] The three-dimensionally shaped nonwovens or layers thereof may have openings which, according to the opening test herein, have an average inter-opening distance of less than approximately 3.5 mm, less than approximately 3 mm, less than approximately 2.5 mm, less than approximately 2 mm, less than approximately 1.5 mm, less than approximately 1 mm, in the range of approximately 1 mm to approximately 3.5 mm, in the range of approximately 1 mm to approximately 3 mm, in the range of approximately 1 mm to approximately 2.5 mm or in the range of approximately 3.5 mm to approximately 10 mm, with express listing of all 0.1 mm increments within the ranges specified above and all areas formed therein or thereby.

[0133] A three-dimensionally shaped nonwoven fabric may have open spacings, which can also be calculated according to the openness test herein. The open spacings may have a distribution with a mean and a median. The mean may be greater than, different from, or less than the median. For example, the mean may be greater than, different from, or less than the median in the range of approximately 3% to approximately 25%, approximately 4% to approximately 25%, approximately 5% to approximately 20%, approximately 8% to approximately 20%, or approximately 4% to approximately 15%, in particular repeating every 0.1% increment within the ranges specified above and all ranges specified herein or by it. A first zone of a three-dimensionally shaped nonwoven fabric may have open spacings. The open spacings of the first zone may have a first distribution with a first mean and a first median.The first median may be greater than, different from, or less than the first median by the ranges set out above in this paragraph. A second zone of the three-dimensionally shaped nonwoven fabric may have inter-opening spacings. The inter-opening spacings of the second zone may exhibit a second distribution with a second mean and a second median. The second mean may be greater than, less than, or different from the second median by the ranges set out above in this paragraph. A third zone of the three-dimensionally shaped nonwoven fabric may have inter-opening spacings. The inter-opening spacings of the third zone may exhibit a third distribution with a third mean and a third median. The third mean may be greater than, less than, or different from the third median by the ranges set out above in this paragraph.The first, second, and third means may be the same or different. The first, second, and third medians may be the same or different. The first, second, and third zones may be located in an upper layer, an upper layer layer, an absorption layer, an outer sheath, an outer sheath layer, or any other component of an absorbent article or other consumer product.

[0134] In further examples, a first section of an absorbent article or other consumer product may comprise a first three-dimensionally shaped nonwoven fabric which, according to the opening test, exhibits inter-opening distances. The inter-opening distances of the first section exhibit a first distribution. A second section of an absorbent article or other consumer product may comprise a second three-dimensionally shaped nonwoven fabric which, according to the opening test, exhibits inter-opening distances. The inter-opening distances of the second section exhibit a second distribution. A third section of an absorbent article or other consumer product may comprise a third three-dimensionally shaped nonwoven fabric which, according to the opening test, exhibits inter-opening distances. The inter-opening distances of the third section exhibit a third distribution.The first, second, and third distributions may be the same or different. The first distribution may have a first mean and a first median. The first mean may be greater than, less than, or different from the first median by, for example, approximately 3% to approximately 25%, approximately 4% to approximately 25%, approximately 5% to approximately 20%, approximately 8% to approximately 20%, or approximately 4% to approximately 15%, with explicit mention of all 0.1% increments within the ranges specified above and all ranges formed therein or by them. The second distribution may have a second mean and a second median. The second mean may be greater than, different from, or less than the second median by the ranges set forth above in this paragraph. The third distribution may have a second mean and a second median.The second mean may be larger, different, or smaller than the second median by the ranges set out above in this paragraph. The first, second, and third means may be the same or different. The first, second, and third medians may be the same or different. The relative standard deviation of the inter-hole spacing of a three-dimensionally shaped nonwoven fabric may be at least approximately 50% or at least approximately 55%. The maximum inter-hole spacing in a given three-dimensionally shaped nonwoven fabric may, for example, be at least approximately 8 mm or at least approximately 10 mm.

[0135] A three-dimensionally shaped nonwoven fabric may, according to the opening test herein, have one or more openings with an absolute Ferret angle of at least about 15 degrees, at least about 18 degrees, at least about 20 degrees, at least about 22 degrees, at least about 25 degrees, at least about 30 degrees, at least about 35 degrees, at least about 40 degrees, in the range of about 15 degrees to about 80 degrees, in the range of about 20 degrees to about 75 degrees, in the range of about 20 degrees to about 70 degrees or in the range of about 25 degrees to about 65 degrees, with express listing of all 0.1 degree increments within the above-specified ranges and all areas formed therein or thereby.

[0136] A three-dimensionally formed nonwoven fabric may, according to the opening test herein, exhibit a plurality of openings with an average absolute Ferret angle of at least approximately 15 degrees, at least approximately 18 degrees, at least approximately 20 degrees, at least approximately 22 degrees, at least approximately 25 degrees, at least approximately 30 degrees, at least approximately 35 degrees, at least approximately 40 degrees, in the range of approximately 15 degrees to approximately 80 degrees, in the range of approximately 20 degrees to approximately 75 degrees, in the range of approximately 20 degrees to approximately 70 degrees, or in the range of approximately 25 degrees to approximately 65 degrees, with the express listing of all 0.1-degree increments within the above-specified ranges and all areas formed therein or thereby. These openings may all be present within a single repeating unit of the three-dimensionally formed nonwoven fabric.The relative standard deviation of the absolute Feret angles in a three-dimensionally shaped nonwoven fabric can be at least approximately 30%, or at least approximately 40%, or at least approximately 50%. A repeating unit is an area in a three-dimensionally shaped nonwoven fabric that can be identified as having a complete opening pattern or array. Multiple repeating units can be present in a three-dimensionally shaped nonwoven fabric, with each repeating unit having a complete opening pattern or array.

[0137] At least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine, or at least ten openings in a three-dimensionally shaped nonwoven fabric or a repeating unit of a three-dimensionally shaped nonwoven fabric may, according to the opening test therein, each exhibit a different absolute Feret angle. In other examples, some of the openings may have the same absolute Feret angles, while others may have different absolute Feret angles. In addition to exhibiting different absolute Feret angles, the at least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine, or at least ten openings may have different sizes and / or shapes.At least some of the at least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine, or at least ten openings may have the same size and / or shape while exhibiting different absolute Feret angles. For example, the absolute Feret angles of at least some of the openings in a repeating unit may differ by at least approximately 5 degrees, at least approximately 10 degrees, at least approximately 15 degrees, at least approximately 20 degrees, at least approximately 25 degrees, or at least approximately 30 degrees.

[0138] Some of the three-dimensionally shaped nonwovens may have impact area widths of at least approximately 4 mm, at least approximately 5 mm, at least approximately 6 mm, at least approximately 7 mm, at least approximately 8 mm, at least approximately 9 mm, at least approximately 10 mm or in the range of approximately 4 mm to approximately 15 mm, with explicit listing of all 0.1 mm increments within the specified range and all areas formed therein. General description of an absorption article

[0139] An absorbent article can comprise a fluid-permeable material, including perforated, three-dimensionally shaped nonwovens with variable base weight, as described above; a fluid-impermeable material; and an absorbent core containing an absorbent material, wherein the absorbent core is positioned at least partially between the fluid-permeable material and the fluid-impermeable material. That is to say, in certain examples, the three-dimensional nonwovens 10 of the present disclosure, as well as the perforated material 152 described above, can be used as a component of absorbent articles such as diapers, children's care products such as training pants, feminine care products such as sanitary napkins, and adult care products such as incontinence products, pads, and pants.

[0140] An example of an absorbent product in the form of a diaper (size 220) is in the Fig.49-51 shown. Fig. Figure 49 is a top view of the example diaper 220 in a flat, spread-out state, with sections of the structure cropped to more clearly illustrate the construction of the diaper 220. The carrier-side surface of diaper 220 of Fig. Figure 49 faces the viewer. This diaper 220 is shown solely for illustrative purposes, 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 each case, the three-dimensional nonwoven materials of the present disclosure can be liquid-permeable, as described above.

[0141] The absorbent article 220 can comprise a fluid-permeable material or top layer 224, a fluid-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 leg cuffs 234. The absorbent article can also comprise an ADS 250, which in the illustrated example comprises a distribution layer 254 and an absorption layer 252, which are discussed further below. The absorbent article 220 can also comprise elasticized sealing cuffs 232, comprising rubber bands 233, which are joined to an outer skin of the absorbent article, usually over the top layer and / or bottom layer, and substantially planar to the outer skin of the diaper.

[0142] Fig. 49 and Fig.Figure 52 also shows common adhesive-backed components, such as a fastening system having tabs 242 that are attached towards the rear edge of the article and interact with an impact 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 barrier cuffs, and / or a lotion application.

[0143] The absorption article 220 can comprise a front waistband 210, a rear waistband 212 longitudinally opposite the front waistband 210, a first sideband 203, and a second sideband 204 longitudinally opposite the first sideband 203. The front waistband 210 can be the edge of the article intended to be placed toward the front of the user when worn, and the rear waistband 212 can be the opposite edge. The absorption article 220 can 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 relative to the longitudinal axis 280 when the article is laid flat and positioned as shown in Figure 220. Fig.49 viewed from above. 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 can 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 can 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.

[0144] 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 heat stamping.

[0145] 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.% superabsorbent polymers, and a core wrapping encloses the superabsorbent polymers. The core wrapping 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 include one or more channels that are in Fig. Figure 49 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.

[0146] These and other components of the example absorption article will now be discussed in more detail. upper class

[0147] 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 fluids) can be formed from a section of, or the entirety of, one or more of the three-dimensional nonwoven materials described herein and / or comprise one or more of the nonwoven materials positioned thereon and / or joined thereto, 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 exclusively form a central CD surface of the top layer.The central CD area can extend over the full MD length of the top layer or less than the full MD length of the top layer.

[0148] The upper layer 224 can be joined with the lower layer 225, the absorption core 228, and / or any further layers, as is known to those skilled in the art. Normally, the upper layer 224 and the lower layer 225 are joined directly to one another at some locations (e.g., at or near the perimeter of the absorption article) and are joined indirectly at other locations by being joined directly to one or more further elements of the article 220.

[0149] The top layer 224 can be adapted to the wearer's skin, feel soft, and be non-irritating. Furthermore, at least one section, or the entirety, of the top layer 224 can be fluid-permeable, allowing liquids to readily penetrate its thickness. Additionally, a section, or the entirety, of the 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 a skin care composition, as is generally disclosed in the prior art. The top layer 224 can also include or be treated with antibacterial agents. lower class

[0150] The underlayer 225 is generally the section of the absorbent article 220 that is positioned adjacent to the garment-side surface of the absorbent core 228 and prevents, or at least inhibits, the bodily excretions absorbed and retained therein from soiling articles such as bed sheets and underwear. The underlayer 225 can typically be impermeable, or at least substantially impermeable, to fluids (e.g., urine). The underlayer can, for example, be or comprise a thin plastic film, such as a thermoplastic film with a thickness of about 0.012 mm to about 0.051 mm. Other suitable underlayer materials can include breathable materials that allow vapors to escape from the absorbent article 220 while still preventing, or at least inhibiting, fluids from passing through the underlayer 225.

[0151] The lower layer 225 can be joined 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 field.

[0152] The absorbent article may comprise a sublayer comprising an outer sheath or an outer sheath nonwoven. An outer sheath or an outer sheath 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 sheath or the outer sheath nonwoven may be formed from the high-volume, three-dimensional nonwoven materials described herein. Alternatively, the outer sheath or the outer sheath nonwoven may comprise one or more known outer sheath materials. If the outer sheath comprises one of the three-dimensional nonwoven materials of this disclosure, the three-dimensional nonwoven material of the outer sheath may or may not correspond to a three-dimensional nonwoven material used as the top layer or the top layer and the absorbent layer of the absorbent article (e.g., same material, same pattern).In other examples, the outer sheath 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 sheath may be joined to at least one section of the underlayer 225 by mechanical bonding, ultrasonic bonding, thermal bonding, adhesive bonding, or another suitable fastening method. Absorption core

[0153] 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 absorption 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.

[0154] The absorption core 228 may comprise an absorption material with a large quantity of superabsorbent polymers (hereinafter referred to as "SAP") enclosed within the core wrapping. The SAP content may be 70%–100%, or at least 70%, 75%, 80%, 85%, 90%, 95%, 99%, or 100%, based on the weight of the absorption material contained within the core wrapping. The core wrapping 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.

[0155] The term "absorbent material" refers to a material that exhibits certain absorption or liquid retention 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 within the core wrapping. This air-felt-free core is relatively thin compared to a conventional core, which typically contains 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.

[0156] As previously stated, air-felt-free cores with very little or no natural, cellulosic, and / or synthetic fibers are quite thin compared to conventional cores, making the overall absorbency product thinner than absorbency products with cores containing a blend of SAP and cellulose fibers (e.g., 40%–60% cellulose fibers). This core thickness can lead consumers to perceive reduced absorption and performance, although this is not technically the case. Currently, these thin cores are commonly used with essentially flat top sheets. Furthermore, absorbency products with these thin air-felt-free cores have reduced capillary voids due to the lack of natural, cellulosic, 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.

[0157] 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 an example, the absorbency and performance perceived by the consumer are enhanced by 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 as the top layer and absorption layer laminate, the three-dimensional nonwoven materials add capillary voids to the absorbent article while still allowing a minimal stack height, thereby passing on cost savings to consumers and manufacturers.Accordingly, 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 the top layer, or the top layer and the absorbent layer laminate, can provide consumers with an aesthetically pleasing top layer relative to a flat top layer with increased thickness, thus enhancing consumer perceptions of absorbency and performance.

[0158] The example absorption core 228 of the absorption article 220 of the Fig. 52 and Fig. 53 is in Fig.Figures 42-44 show the absorption core 228 in isolation. The absorption core 228 can comprise a front face 480, a back face 282, and two longitudinal sides 284, 286 joining the front face 480 and the back face 282. The absorption core 228 can also comprise a generally flat top and a generally flat bottom. The front face 480 of the core can be the side of the core that is to be placed toward 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 planar view as in Fig.49 seen from above. The absorption material may be distributed in larger quantities towards the front 480 than towards the rear 282, since greater absorption capacity may be required at the front of the particular absorption article. 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 wrapping 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 wrapping 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 wrapping of the absorption article. The first material, substrate or fleece 216 can at least partially surround the second material, substrate or fleece 216', as in Fig. Figure 55 illustrates how to form the core wrapping. The first material 216 can surround a section of the second material 216' proximal to the first and second side edges 284 and 286.

[0159] The absorption core may incorporate adhesive to help immobilize the SAP within the core wrap and / or to ensure the integrity of the core wrap, particularly when the core wrap is made from two or more substrates. The adhesive may be a hot-melt adhesive, such as that supplied by HB Fuller. The core wrap may extend over an area larger than strictly necessary to accommodate the absorption material within it.

[0160] The absorption material can be a continuous layer present within the core wrapping. Alternatively, the absorption material can also consist of individual pockets or strips of absorption material enclosed within the core wrapping. 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 absorption layers with discontinuous absorption material application patterns, the resulting layer being substantially continuously distributed over the polymer particle absorption material surface, as disclosed, for example, in US 2008 / 0312622A1 (Hundorf). The absorption core 228 can comprise a first absorption layer and a second absorption layer.The first absorption layer can comprise the first material 216 and a first layer 261 of absorption material, which may be 100% or less SAP. The second absorption layer can comprise the second material 216' and a second layer 262 of absorption material, which may also be 100% or less SAP. The absorption core 228 can also include a fiber-containing thermoplastic adhesive material 251 that at least partially bonds each layer of the absorption material 261, 262 to the respective material 216 or 216'. This is shown as an example in [reference]. Fig. 55 and Fig.Figure 56 illustrates that, prior to combination, the first and second SAP layers are applied as transverse strips or "impact surfaces" of the same width as the desired absorption material deposition area on their respective substrates. The strips can contain varying amounts of absorption 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 wrapping.

[0161] The fiber-containing thermoplastic adhesive material 251 can be in at least partial contact with the absorption material 261, 262 in the impact surfaces, and it can be in at least partial contact with the materials 216 and 216' in the bonding surfaces. This can give the fiber-containing layer of thermoplastic adhesive material 251, which in itself can be essentially a two-dimensional structure of relatively small thickness, an essentially three-dimensional structure compared to its dimensions in the longitudinal and lateral directions. This allows the fiber-containing thermoplastic adhesive material to provide cavities to cover the absorption material in the impact surfaces, thereby immobilizing this absorption material, which can be 100% or less SAP.

[0162] 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 stretch while the SAP swells. Superabsorbent polymer (SAP)

[0163] The SAP that is useful with the present disclosure can comprise a variety of water-insoluble but water-swellable polymers that are able to absorb large quantities of fluids.

[0164] 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 copolymer, cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and starch-grafted polyacrylonitrile copolymer.

[0165] SAP can take on numerous forms. The term "particle" refers to granules, fibers, flakes, spheres, powders, platelets, and other shapes and forms known to experts in the field of superabsorbent polymer particles. SAP particles can be in the form of fibers, i.e., they can be elongated, needle-shaped superabsorbent polymer particles. The fibers can also be in the form of a long thread that can be woven. SAP can also be spherical particles. The absorption core can comprise one or more types of SAP.

[0166] For most absorbent articles, fluid discharge from a wearer occurs 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 placed at a distance of half a unit 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 distributed in the rear half. Alternatively, the SAP distribution may be uniform throughout the core or may exhibit other suitable distributions.

[0167] The total amount of SAP present in the absorbent core can also vary according to 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 within (or at least one, if multiple are present) 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 the absorption material deposition area 8 are derived from the absorption material deposition area to calculate this average base weight. Core wrapping

[0168] The core wrapping 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 nonwovens bonded together. Common bonding methods include the so-called C-wrapping and / or sandwich wrapping. In a C-wrapping, as in Fig. 50 and Fig. As illustrated in Figure 55, the longitudinal and / or transverse edges of one of the substrates can be folded over the other substrate to form flaps. These flaps are then bound to the outer surface of the other substrate, usually by gluing.

[0169] The core wrapping can be made of any material suitable for receiving and holding the absorption material. Common substrate materials used in the manufacture of conventional cores can be employed, in particular paper, woven fabrics, films, textiles or nonwovens, or laminates or composites of any of these.

[0170] The substrates can also be air-permeable (in addition to being liquid- or fluid-permeable). Films useful in this respect can therefore incorporate micropores.

[0171] The core wrapping 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% of absorption material escapes from the core wrapping. The term "sealing" is to be understood in a broad sense. The seal need not be continuous along the entire circumference of the core wrapping, but may be discontinuous along a portion or over its entirety, as formed by a series of sealing points spaced apart in a line. A seal can be formed by gluing and / or thermal bonding.

[0172] When the core wrapping is formed by two substrates 216, 216', four seals can be used to enclose the absorption material 260 within the core wrapping. For example, a first substrate 216 can be placed on one side of the core (the top, as in Fig.(Figures 54-56) are positioned 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-wrapping construction can offer advantages such as improved resistance to bursting in a wet-loaded condition compared to a sandwich wrapping. The front and back surfaces of the core wrapping can then also be sealed by bonding the first and second substrates together to provide complete encapsulation 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 construction for these edges. In this sandwich construction, the first and second substrates can extend outwards on all sides of the core and be sealed flat, or substantially flat, along the entire or part of the core's perimeter, usually by bonding and / or heat / pressure joining. In one example, neither the first nor the second substrate needs to be shaped to allow for rectangular cutting to facilitate production; however, other shapes are also within the scope of protection of this disclosure.

[0173] The core wrapping can also be formed from a single substrate that can enclose the absorption material as in a package wrapping and that can be sealed along the front and back of the core and a longitudinal seal. SAP separation area

[0174] The absorbent material deposition area 208 can be defined by the circumferential edge of the layer formed by the absorbent material 260 within the core wrapping, 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 exhibits a taper 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 face of the core, which is intended for placement in the step region of the absorbent article, as shown in Fig. 49 illustrates this. This can provide better wearing comfort. The absorption material deposition area 8 can also be generally rectangular, as for example in Fig.Figures 52-54 show that other deposition surfaces, such as rectangular, "T", "Y", "hourglass", or "dogbone" shapes, are also within the scope of protection of this disclosure. The absorption material can be deposited using any suitable technique that allows for relatively accurate deposition of SAP at a relatively high rate. Channels

[0175] The absorption material deposition area 208 can comprise at least one channel 226 which is oriented at least partially in the longitudinal direction of the article 280 (i.e., has a longitudinal vector component), as shown in the Fig. 49 and Fig.Figure 50 shows that further channels may be oriented at least partially in the transverse direction (i.e., having a lateral vector component) 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, which may be 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 free from, absorption material, particularly 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 wrapping to the bottom of the core wrapping through the absorption material deposition area 208. The channels can be continuous, but it is also conceivable that the channels could be discontinuous. The absorption distribution system or 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.

[0176] In some examples, the channels may be present at least at the same height in the longitudinal direction as step point C or the transverse axis 260 in the absorption article, as in Fig. Figure 49 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.

[0177] The absorption core 228 can also include 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.49 shown in the direction of the front of the article. The channels may comprise one or more pairs of channels arranged symmetrically or otherwise with respect to the longitudinal axis 280.

[0178] 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.

[0179] The channels can be oriented 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.

[0180] To reduce the risk of fluid leakage, the main channels may not extend longitudinally to one 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 minimum distance between a channel and the nearest edge of the absorbent material deposition area 208 may be at least 5 mm.

[0181] 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 can be considered to be the width of the material-free zone, disregarding the possible presence of the core wrapping within the channels. If the channels are not formed by absorption material-free zones, for example, mainly by binding the core wrapping through the absorption material zone, the width of the channels can be the width of this bond.

[0182] At least some or all of the channels can be permanent channels, meaning that their integrity is maintained, at least partially, in both dry and wet conditions. Permanent channels can be obtained by providing one or more adhesive materials, for example, 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 tying together the top and bottom sides of the core wrapping (e.g., the first substrate 216 and the second substrate 216') and / or the top layer 224 with the bottom layer 225 through the channels.Typically, an adhesive can be used to bond both sides of the core wrapping or the top layer and bottom layer through the channels, but it is also possible to bond via other known processes, such as pressure bonding, ultrasonic bonding, heat bonding, or a combination thereof. The core wrapping or the 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 fluid. 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 winding to itself or the top layer to the bottom layer through the channels can be advantageous. cuff

[0183] The absorbent article may comprise a pair of leg cuffs 234. Each leg cuff may be formed by a piece of material connected to the absorbent article so that it extends upward from a carrier-side surface of the absorbent article and provides enhanced containment of fluids and other bodily excretions approximately at the junction of the carrier's torso and legs. The leg cuffs may be bounded by a proximal rim 264, which is directly or indirectly joined to the top layer 224 and / or the bottom layer 225, and by a free terminal rim 266, which is intended to come into contact with and seal against the carrier's skin.The leg cuffs 234 can extend at least partially between the front waist edge 210 and the rear waist edge 212 of the absorbent article on opposite sides of the longitudinal axis 280 and are present at least at the level of the crotch point (C) or crotch area. The leg cuffs can be joined to the outer skin of the article at the proximal edge 264 by a bond 265, which may be produced by gluing, melt bonding, or a combination of other suitable bonding processes. The bond 265 at the proximal edge 264 can be continuous or discontinuous. The bond 265 closest to the raised section of the leg cuffs defines the proximal edge 264 of the upright section of the leg cuffs.

[0184] The leg cuffs can be integrated into the top layer 224 or the bottom layer 225, or they can be a separate material bonded to the outer skin of the article. Each leg cuff 234 can include one, two, or more elastic cords 235 near the free terminal edge 266 to provide a better seal.

[0185] In addition to the leg cuffs 234, the article may include sealing cuffs 232, which are fused to the outer skin of the absorbent article, in particular to the top layer 224 and / or the bottom layer 225, and are positioned externally relative to the leg cuffs. The sealing cuffs 232 may provide a better seal around the wearer's thighs. Each leg cuff sealing cuff may include one or more elastic cords or elastic elements 233 in the outer skin of the absorbent article between the top layer 224 and the bottom layer 225 in the area of ​​the leg openings. All or a section of the leg cuff sealing cuffs and / or sealing cuffs may be treated with a lotion or other skin care composition. Intake distribution system

[0186] 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, but the present disclosure is not limited thereto.

[0187] In one example, the high-volume, 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 side of the top layer / receiving layer laminate. carrier layer

[0188] In an example where the high-volume, three-dimensional nonwoven materials of the present disclosure enclose a top layer and a receiving layer laminate, the distribution layer may need to be supported by a carrier layer (not illustrated), 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

[0189] The distribution layer of the ADS can comprise at least 50 wt.% cross-linked cellulose fibers. The cross-linked cellulose fibers can be crimped, twisted, or wound, or a combination thereof, including crimped, twisted, and wound. This type of material is disclosed in US 2008 / 0 312 622 A1 (Hundorf). The cross-linked cellulose fibers provide greater elasticity and thus greater resistance of the first absorption layer to compression in product packaging or under conditions of use, e.g., under the weight of a carrier. This can provide the core with a higher void volume, permeability, and liquid absorption, and thus with reduced leakage and improved dryness.

[0190] The distribution layer comprising the cross-linked cellulose fibers of the present disclosure may include further 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.%, based on the layer, cross-linked cellulose fibers (including the cross-linking agents). Receptive layer

[0191] If a three-dimensional nonwoven material of the present disclosure is provided solely as the top layer of an absorbent article, the ADS 250 may comprise an absorption layer 252. The absorption layer may be located between the distribution layer 254 and the top layer 224. In such an example, the absorption layer 252 may be or comprise a nonwoven material, such as a hydrophilic SMS or SMMS material comprising a spunbond nonwoven, a meltblown, and another spunbond nonwoven layer, or alternatively, a carded, chemically bonded staple fiber nonwoven. The nonwoven material may be latex-bonded. fastening system

[0192] 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 with adhesive-backed diapers. This fastening system may not be necessary for exercise pants articles, as the waist area of ​​these articles is already tied. The fastening system may include a fastening element such as adhesive side flaps, hook-and-loop fasteners, form-fitting fasteners such as side flaps and slots, buckles, buttons, snap fasteners, and / or hybrid fastening elements, although any other suitable fastening mechanisms are also within the scope of protection of this disclosure.An impact zone 244 is normally provided on the garment-side surface of the front waist area 205 so that the fastening element can be detachably attached to it. Front and rear lateral lobes

[0193] The absorption article can comprise anterior side lobes 246 and posterior side lobes 240. The side lobes can be an integrated part of the outer skin, as formed from the upper layer 224 and / or the lower layer 226 as side panels. Alternatively, as in Fig.As shown in Figure 49, the side flaps are separate elements attached by gluing, heat 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-backed diapers in place around the wearer's waist. The rear side flaps 240 can be elastic or extendable to provide a more comfortable fit that better conforms to the body's contours by adapting the absorbent article to the wearer and maintaining this fit throughout the wearing period, long after the absorbent article has become saturated with fluids or other bodily excretions, as the elasticized side flaps allow the sides of the absorbent article to expand and contract. Elastic waist feature

[0194] The absorbent article 220 may also include at least one elastic waist feature (not shown) that helps to provide improved fit and retention. The elastic waist feature may generally be designed to expand and contract elastically to dynamically adapt to the wearer's waist. The elastic waist feature may extend outward from at least one waist edge of the absorbent core 228, at least longitudinally, and may generally form 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 positioned in the back waist area. Color signals

[0195] In one form, the absorbent articles of the present disclosure may have different colors in different layers or sections thereof (e.g., the top layer and the absorption layer, the top layer and the nonwoven core sheath, a first section and a second section of 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 approximately 1.5 to 10, approximately 2 to 8, or approximately 2 to 6. Other Delta E ranges are also within the scope of protection of the present disclosure.

[0196] In one example, different layers of the absorbent material can be joined together using a colored adhesive. The colored adhesive can be applied to each 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 examples, the colored adhesive could be blue.

[0197] In other examples, each of the layers can include markings, such as printed ink, to support the appearance, depth impression, absorption impression, or quality impression of the absorption articles.

[0198] In further examples, the colors can 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 visually distinct patterns of three-dimensional features can also have color printed on it to emphasize, highlight, contrast with, or otherwise modify the change in the visual appearance of the nonwoven fabric 10. The color enhancements can be advantageous in communicating certain functional characteristics of the nonwoven fabric 10 to a user of an absorbent article during use. The color can therefore be used in combination with structural, three-dimensional features in a component, or in combinations of components, to provide a visually distinguishable absorbent article.For example, a second top layer or absorption layer may have a printed pattern of color or colors that complements the pattern of three-dimensional features of a nonwoven fabric 10 used as a top layer in an absorbent article. Another example is an absorbent article comprising: 1) an absorbent core comprising a channel, 2) a top layer with a three-dimensional pattern that is registered with or highlights the channel or channels in the core, and 3) a graphic, colored component, printed ink, or markings visible from the top layer view (body-side contact surface) or the bottom layer view (garment-side surface) to further emphasize the functional features of the core channel or channels and the overall performance of the absorbent article.

[0199] A further characterization of the novel aspects of the present disclosure can be achieved by focusing on the three-dimensional features within a visually perceptible zone. Each zone discussed above, such as zones 110, 120, and 130, can be further described in terms of the microzones. As described above, a microzone is a section of the nonwoven fabric 10 within a zone, which may have at least two visually perceptible areas, and where there may be a difference in the common intensity levels between these two areas. A microzone may comprise a section of the nonwoven fabric 10 that may cross two or more zone boundaries, which has at least two visually perceptible areas, and where there may be a difference in the common intensity levels between these two areas.

[0200] The advantage of including microzones in the present disclosure is to illustrate that, in addition to the differences in average intensity sizes 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 sizes 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 belt used to produce the materials. The difference in intensity sizes between areas of the three-dimensional features provides additional visual and functional advantages. The sharp visual contrast between areas can provide extremely fine, visually distinguishable designs within 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 of the zones. Therefore, the present disclosure provides an unexpected combination of differences in the average intensity sizes between zones and, simultaneously, differences in the intensity sizes of the areas that constitute a microzone.

[0201] Areas defined by three-dimensional features can be described with reference to Fig. 59 and Fig. 60 can be understood. Fig. Figure 59 shows a light microscope image of a section of a substance 10 according to the present disclosure, and Fig. Figure 60 is a scanning electron micrograph (SEM) of a cross-section of the in Fig. 59 shown section of fabric. Therefore, the Fig. 59 and Fig.60 a section of a nonwoven fabric 10, which has been enlarged to more accurately describe the otherwise visually perceptible characteristics of the fabric. The section of the nonwoven fabric 10, which is in Fig. 59, is approximately 36 mm in the CD and exhibits sections of at least three visually distinct zones, as discussed below.

[0202] In the Fig. 59 and Fig. 60, which shows a section of a pattern of a nonwoven fabric 10, is a first zone 110 (on the left side of Fig.50) generally characterized by 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 and 310. In one example, a three-dimensional feature is a section of the nonwoven fabric 10 formed between or around a raised element of the forming tape, 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 size with the first region 300 and, in one example, has relatively lower thickness values, i.e., a smaller dimension in the Z-direction.The relative dimensions in the Z-direction with respect to a plane of the first surface 16, as described above, can be found in . Fig. 51 can be seen. Absolute dimensions are not critical; however, the dimensional differences can be visually perceived on the nonwoven fabric 10 even without magnification.

[0203] The present disclosure permits advantageous features that are best expressed with reference to the areas defined by three-dimensional features in microzones. For example, as shown in Fig.Figure 59 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 can exist in the nonwoven fabric 10 without magnification; the magnified views used herein are for clarity. Any area extending beyond the boundary between the first region 300 and the second region 310 such that a difference in their respective intensity levels can be determined within the area can be a microzone. Additionally, light microscopy or micro-CT imaging of a structure can also be used to locate regions and the area of ​​a microzone.

[0204] The in Fig.Section 59 of the nonwoven fabric 10 further illustrates another advantageous characteristic of the nonwoven fabric 10 insofar as the differences in intensity sizes between adjacent areas can be differences across zones. Therefore, a microzone can be identified spanning an area that encompasses the second area 310 of zone 120 and the first area 300 of the third zone 130. In certain examples, including the one in Fig. 59 and Fig. In the case of the nonwoven fabric shown in Figure 60, the difference in the intensity sizes exhibited by the areas in microzones may mean that a zone boundary may be significantly different in size from the differences between intensity sizes exhibited by areas within a zone.

[0205] Regardless of which zone or zonal boundary encloses a particular microzone, the three-dimensional features can be characterized by the differences between the intensity magnitudes of the regions they define. In general, the nonwoven fabric of the present disclosure can be a spunbond nonwoven with a first surface defining a plane. The fabric can comprise a variety of three-dimensional features, each defining a first region and a second region, the regions sharing a common intensity magnitude that differs between them. For example, the first region can be distinguished as being located at a higher elevation relative to the plane of the first surface than the second region, thus exhibiting a difference in the common intensity magnitude of the thickness of each region.The two regions can also be distinguished by their different base weights and / or volumetric densities. That is, the two regions within a microzone of the spunbond nonwoven can be differentiated with respect to common intensive properties, including characteristics such as thickness, base weight, and volumetric density. In one example, one or both regions of a microzone may be fluid-permeable. In another example, the higher-density region of a microzone may be fluid-permeable.

[0206] Within the first zone 110 of the in Fig. In the fabric section shown in Figure 59, for example, there can be three-dimensional features 20 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 in Fig.59 shown first zone 110 can each be 274 micrometers, 1 gram per square meter and 0.437 g / cm² 3 be.

[0207] Similarly, within zone 130 of the in Fig. In the material section shown in Figure 59, for example, three-dimensional features 20 may be present, defining 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 in Fig. 59. Zone 130 shown can each contain 2083 micrometers, 116 grams per square meter and 0.462 g / cm². 3 be.

[0208] Additionally, 120 of the [units] can be [units] within the second zone. Fig.In the material section shown in Figure 59, for example, three-dimensional features 20 may be present, defining 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 59] is [the following text appears to be a fragment and cannot be translated accurately]. Fig. The fabric section shown in section 59 can each be 204 micrometers, 20 grams per square meter, and / or 0.53 g / cm². 3 in the example shown, the second zone 120 forms something that appears in an unmagnified view of nonwoven fabric 10 as a sewn border between the first and third zones 110, 130.

[0209] Furthermore, in a zone which forms the border between the second and third zones 120, 130 of the in Fig.The material section shown in Figure 59 comprises, for example, at least two areas: a first area 300 in the third zone 130 and a second area 310 in the second zone 120. The difference in thickness, base weight, and volumetric density between the first and second areas for the [material] shown in Figure 59 is [amount]. Fig. The fabric section shown in section 59 can each measure 2027 micrometers, 58 grams per square meter and 0.525 g / cm². 3 be.

[0210] The microzones are discussed in more detail with reference to Fig. 61-63 and those in Fig. The data shown in the 65 images is discussed. Fig. Figures 61-63 are micro-CT scans of a section of a nonwoven fabric 10, which in the pattern corresponds to that of the in Fig. The nonwoven fabric shown in Figure 59 resembles Figure 10. The micro-CT scan allows the description of the same features as in Figure 59. Fig. 59 shown, in a slightly different way and in a manner that allows a very precise measurement of the intensive quantities.

[0211] As in Fig. As shown in Figure 61, zones 110, 120, and 130 with their respective three-dimensional features are clearly visible. As in the Fig. 61 and Fig. Figure 62 shows that 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 colored sections are the second area 310 for the three-dimensional feature 20.

[0212] The micro-CT scan allows the image to be "sliced" and divided cross-sectionally, as shown by the section plane 450 in Fig. 62 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 render the cross-sectional image in Fig. to result in 63.

[0213] Micro-CT technology allows for precise and direct measurement of large quantities. Thickness measurements can be taken directly from imaged cross-sections, such as the one in Fig. The cross-section shown in Figure 63 is based on the scale magnification. Furthermore, 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 micro-CT methodology is explained below in the section "Test Procedures".

[0214] Fig. Figure 64 is a micro-CT scan image of the section of nonwoven fabric 10 that is in Fig. 61 and Fig. Figure 63 shows the use of specific first and second areas, shown as numbered sections of the nonwoven fabric 10, which can then be analyzed. Fig.64 specific areas were manually selected and analyzed to measure thickness, base weight, and volumetric density, and the data are presented in Fig. 65 reproduced.

[0215] Fig. Figure 65 shows data for the grouping of measurements from the first and second areas within the in Fig. The three zones shown in the diagram are 65. The x-axis is the range where the numbers correspond to the numbered areas in the diagram. Fig.64. Measurements of the first range are designated Fn (e.g., F1), and measurements of the second ranges are designated Sn (e.g., S1). Therefore, 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, first ranges F2 are ranges 16–20 in the second zone 120, and ranges 11–15 and 21–25 are second ranges S2 in the second zone 120. Finally, ranges 31–35 are first ranges F3 in the third zone 130, and ranges 26–30 are second ranges S2 in the third zone 130. The numbered ranges are across all three graphs of Fig. 56 are shown continuously, however, for the sake of simplicity, zones 110, 120 and 130 are shown exclusively on the thickness map.

[0216] The in Fig.The graphs shown in Figure 65 graphically represent the magnitude of the difference in intensity between the first and second regions within each zone and can be used to graphically visualize the difference in intensity for pairs of regions that form a microzone. For example, it can be seen that in the first zone 110, the base weight may be essentially the same between the two regions, but the thickness may vary from about 400 micrometers in the first regions to about 40 micrometers in the second regions, or by a difference of about 10 times. The volumetric density in the first zone 110 may range from about 0.1 g / cm³. 3 up to approximately 0.6 g / cm³ 3 They vary. Similar quantifiable distinctions can be understood for each of the zones shown.

[0217] Therefore, with reference to Fig. 64 and Fig.65 together a further characterization of the advantageous structure of a nonwoven fabric 10 of the present disclosure. The nonwoven fabric 10 can be described as having at least two visually distinct zones, e.g., first and second zones 110, 120, wherein each of the zones has a pattern of three-dimensional features, each of the three-dimensional features defining a microzone, comprising first and second areas, e.g., areas 300, 310, and wherein the difference in value for at least one of the microzones in the first zone 110 is quantifiably different from the difference in value for at least one of the microzones in the second zone 120. For example, in Fig.64 Two representative microzones 400 in the third zone 130 are designated as the pair of areas marked as surfaces 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 one microzone. Likewise, two representative microzones 400 in the second zone 120 are designated as the pair of areas marked as surfaces 19 and 24 and 17 and 22. Starting from Fig. 65. Tables 4-7 can be filled out as shown: Table 4: Illustrative examples of differences in thickness 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 Basis 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 levels within different zones: Thickness (micrometers) Thickness differences Basis weights (grams per square meter) Base weight differences Volumetric density (g / cm³) 3 ) Volumetric density differences Zone 130ErsterBereich 32 2147 2118 149 135 0,069 0,423 Zone 110ZweiterBereich 8 29 14 0,492

[0218] The four representative microzones from two zones are shown in Tables 4-6 for illustration. It is understood, however, that each pair of first and second areas in Fig. 64 could be quantified in the same way to fill 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 that define microzones, the intensive sizes can be measured and, as here with reference to Fig. 64 and Fig. 65 illustrates, in tables, to understand both the differences in values ​​for intensive quantities within a zone and the differences in values ​​of intensive quantities between an area of ​​the first zone and another area in a second zone.

[0219] A microzone spanning two zones, such as the first and second zones 110 and 130, can exhibit an even greater difference in intensity compared to a microzone within a single zone. For example, when considering the data for a microzone spanning a first region of the third zone 130 (e.g., first region 32) and a second region of the first zone 110 (e.g., second region 8), the microzone shows dramatic differences in thickness, base weight, and volumetric density. The thickness of first region 32 of the third zone 130 is approximately 2100 micrometers, while the thickness of second region 8 of the first 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 the first 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 the third zone 130 can be approximately 0.069 g / cm³. 3 The volumetric density of the second area is 8, while the volumetric density of the first zone is 110 0.492 g / cm³. 3 , or a difference value of approximately 7X.

[0220] For each parameter of the measured intensity 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 intensity of microzone regions, so that comparisons of the differences and ratios of regions, as described herein, can be dimensioned.

[0221] A further characterization of a nonwoven fabric 10 can be given with reference to Fig. 66-70, in which SEMs show certain aspects of the nonwoven fabric 10 and areas within it in more detail. Fig. 66-70 are photographs of enlarged sections of the first Zone 110 of the in Fig. 59 shown fabric. The one in Fig. Nonwoven fabric 10 shown in section 59 was produced according to the procedure described above with reference to Fig. 10 produced in which the material was processed through a roller gap formed by compression rollers 70 and 72, wherein the roller 72, which comes into contact with the first side 12, is heated to cause partial binding of fibers in the second areas 301. Fig. 66 (facing the belt) and 67 (facing the heated compaction roller) are each SEMs of a section of the second surface 14 and first surface 12, magnified to 20X. Fig. Figures 68 (facing the belt) and 69 (facing the heated compaction roller) are each photographs of a section of the second surface 14 and first surface 12, enlarged to 90X, and show in detail the advantageous structural characteristics of the partial bonding of fibers formed by the compaction rollers 70 and 72.

[0222] How best to Fig. 68 and Fig. 69 can be seen, as well as in the cross-sectional view of Fig. 70, the heated compaction rollers can induce thermal bonding of fibers to varying degrees, with a beneficial effect on the entire nonwoven fabric 10. As illustrated, the fibers in contact with a heated roller, e.g., roller 70 in contact with the first surface 12 of the nonwoven fabric 10, can be melt-bonded, such that the first surface 12 experiences relatively more fiber-to-fiber bonding than the second surface 14. In one example, the bonded fibers 80 of the first surface can be essentially completely 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 a disposable absorbent product, e.g.,such as an upper layer, to maintain physical integrity during manufacturing and use, as well as relative softness on one side, which may be the user-side, skin-contacting side.

[0223] Even in the microzones with the greatest thickness difference, this "bond thinning" effect serves the purpose of maintaining web integrity, while softness or other advantageous properties such as fluid handling characteristics are not significantly affected. As with reference to Fig. As can be understood from 71-74, the difference in the extent of thermal fiber bonding can be such that the fibers on the first surface 12 may be completely or substantially completely bonded in a second area 310, while the extent of thermal fiber bonding on the second surface 14 in a first area 300 may have minimal to no thermal bonding.

[0224] Fig. Figure 71 again shows the section of nonwoven fabric 10, which is in Fig. 59 is shown. Fig. Images 72-74 show enlarged images of a microzone located in Fig. 61 is indicated as a first area 300 and a second area 310, which visually appears to be a hole or opening. Fig. 72 and Fig. Figure 73 shows the microzone as it appears on the second surface 14, magnified to 40X and 200X respectively. Fig. Figure 74 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 illustrated structure is that a microzone can function as a fluid-permeable opening, while the bound regions of the second region 310 simultaneously function to maintain the physical integrity of the nonwoven fabric 10.

[0225] Microzones therefore play a significant role in the overall physical structure and function of a nonwoven fabric 10 of the present disclosure. By producing relatively closely spaced, precisely designed three-dimensional features, activated by the shaping band of the present disclosure, a nonwoven fabric 10 can exhibit visually distinct zones, microzones, and three-dimensional features that provide functional superiority in the areas of, at least, softness and fluid 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 both form and function.

[0226] Fig. Figure 75 is a micro-CT scan image of the section of nonwoven fabric 10, similar to the one in Fig. 61 and Fig. Figure 62, which, however, was 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 Fig. 64 and Fig. 65 can be analyzed for specific spot-bonding microzones 400, first and second areas, which are shown as numbered sections of the nonwoven fabric 10, and comprise areas of spot bonds, specifically in the numbered areas 31-35. For example, adjacent areas 32 and 26 form a microzone 400 in the third zone 130. Fig. 75 specific areas were visually distinguished to identify areas containing the added point binding areas and analyzed to measure thickness, base weight, and volumetric density, and the data are presented in Fig. 76 reproduced, quantifying and comparing the thickness, base weight and volumetric density of all areas, including the point bonding areas.

[0227] Fig. Figure 76 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 75. The x-axis represents the range, with the numbers corresponding to the numbered areas in the diagram. Fig. 64. Measurements of the first range are designated Fn (e.g., F1), and measurements of the second ranges are designated Sn (e.g., S1). Therefore, 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, first ranges F2 are ranges 16–20 in the second zone 120, and ranges 11–15 and 21–25 are second ranges S2 in the second zone 120. Finally, ranges 31–35 are second ranges, but are point bindings 90, which are in Fig. 76 are designated as B1 to distinguish them in this revelation as being formed by a point-binding process. First regions F3 in the third zone 130 are regions 26-30 and 36-40, while regions 41-44 are second regions S2 in the third zone 130. The numbered regions are across all three graphs of Fig. The entire 76 area is shown, however, for the sake of simplicity, zones 110, 120 and 130 are shown exclusively on the thickness map.

[0228] The in Fig. The graphs shown graphically represent the magnitude of the difference in intensive values ​​between first and second regions within any zone of a fabric that has undergone a calender spot-bonding step, and can be used to graphically see the difference in intensive values ​​for pairs of regions that form a microzone. For example, it can be seen that in first zone 110, the base weight between the two regions can vary within a narrower range than the thickness or volumetric density. For example, the thickness can vary from about 325 micrometers in the first regions to about 29 micrometers in the second regions of first zone 110, or a difference of about 10 times. The volumetric density in first zone 110 can vary from about 0.08 g / cm³. 3 up to approximately 0.39 g / cm³ 3They vary. Similar quantifiable distinctions can be understood for each of the zones shown.

[0229] In general, areas within a microzone can exhibit widely varying values ​​for base weight, thickness, and volumetric density.

[0230] Therefore, with reference to Fig. 75 and Fig. 76 together a further characterization of the advantageous structure of a nonwoven fabric 10 of the present disclosure, in particular with regard to the thermal calender spot bonds 90. For the purpose of description focusing on the third zone 130, three-dimensional features defining a microzone, which includes the first and second areas that are spot-bonded areas, can be identified and the values ​​of intensive quantities can be quantified. For example, in Fig. 75 a representative point-binding microzone 400 in the third zone 130 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.

[0231] The differences in certain intensity sizes for point-binding microzones can be found in Fig. 67. For example, considering the two point-binding microzones 400 described above, e.g., the two point-binding 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 about 55 to about 60 grams per square meter, but the same areas have a significant difference in thickness from about 430 micrometers to about 460 micrometers to about 125 micrometers and a significant difference in volumetric density of about 0.13–0.14 g / cm³. 3 up to approximately 0.41-0.48 g / cm³ 3 further differences in intensity levels can be observed with reference to Fig. 66 were observed.

[0232] Bonding points 90 can play a significant role in the overall physical structure and function of a nonwoven fabric 10 of the present disclosure. By adding bonding points 90 to the nonwoven fabric 10, which comprise relatively closely spaced, precisely designed three-dimensional features activated by the shaping band of the present disclosure, a nonwoven fabric 10 can be further enhanced to exhibit an unexpected combination of visually distinct zones, microzones, and three-dimensional features, providing functional superiority in the high-performance combination of softness, strength, low pilling, and fluid handling, as well as visually appealing aesthetic designs.The bonding point feature provides a nonwoven fabric 10 designed for the highest combined performance of strength, softness, fluid handling and visual aesthetics, especially considering both form and function.

[0233] Fig. Figure 77 shows an example of a three-dimensional, shaped nonwoven fabric 520 with variable base weight, as described herein, but without any openings. Fig. Figure 78 shows an exemplary, perforated, three-dimensionally shaped nonwoven fabric 520 with variable base weight, as described herein. As in Fig. As shown in Figure 78, the perforated, three-dimensionally shaped nonwoven fabric 520 with variable base weight comprises a plurality of perforations 521 in one of the central zones, where the plurality of perforations 521 were formed as a result of over-bonding and stretching in the CD to break the over-bonds, as described herein. It is assumed that such perforations 521 can facilitate fluid uptake and provide a visual impression of breathability and absorbency when used as a component (e.g., top layer, outer sheath nonwoven) in an absorbent article.

[0234] Fig. Figures 79-82 show additional exemplary configurations for zones in a three-dimensionally shaped nonwoven fabric or substrate 10 with variable base weight. For example, as in Fig. 79 and Fig. As shown in Figure 80 and described herein, a section of the first visually perceptible zone 110 can be positioned proximal to the first side margin 2000, and a section of the third visually perceptible zone 130 can be positioned proximal to the second side margin 2002. The second visually perceptible zone 120 can be positioned between the first visually perceptible zone 110 and the third visually perceptible zone 130. As shown in Fig. As shown in 80, the second visually perceptible zone 120 can comprise an area with a first opening pattern 2010 and an area with a second opening pattern 2012.

[0235] In Fig. 81 The first visually perceivable zone 110 can be positioned proximal to the first end edge 2004 of the three-dimensional nonwoven or substrate 10, and the second visually perceivable zone 120 can be positioned proximal to the second end edge 2006. It is understood that, in an example, a first visually perceivable zone can be positioned proximal to a second end edge of a three-dimensional nonwoven substrate, and a second visually perceivable zone can be positioned proximal to a first end edge. As described herein, the second visually perceivable zone 120 can be surrounded by one or more visually perceivable zones that do not have openings. For example, and as in Fig. As shown in Figure 82, the second visually perceptible zone 120 can be surrounded by the first visually perceptible zone 110 and the third visually perceptible zone 100. A section of the first visually perceptible zone 110 can be positioned proximal to the first side edge 2000, and a section of the third visually perceptible zone 130 can be positioned proximal to the second side edge 2002. A fourth visually perceptible zone 140 and a fifth visually perceptible zone 150 can be provided. A section of the fourth visually perceptible zone 140 can be positioned proximal to the first end edge 2004, and a section of the fifth visually perceptible zone 150 can be positioned proximal to the second end edge 2006. In such examples, zones without openings (e.g. 110, 130) can stretch and expand together with zones with openings (e.g. 120).It is understood, however, that the zones described herein can be arranged in a variety of configurations. Test procedure: Compression aging test

[0236] Initial strength measurement: • Cut out five 3-inch by 3-inch samples for each nonwoven fabric to be measured. • Number each sample from 1 to 5. • Measure the thickness at 0.5 kPa with the 65 mm standard foot using a Thwing Albert thickness gauge according to standard procedure. • Report the initial strength for each of the five samples. • Represent the average thickness of the five samples. Aging compression method 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 in an aluminium sample holder, with an appropriate weight on top of the samples (4 kPa, 14 kPa or 35 kPa). • Place the stacked samples, weighed down, in an oven at 40 °C for 15 hours. • Remove the weight after 15 hours, separate the samples and measure the thickness of each sample at 0.5 kPa using the 65 mm standard foot and a Thwing Albert thickness gauge according to standard procedure. • Display the aged strength value for each of the five samples. • Represent the average aged strength of the five samples.

[0237] Analysis reports: • Represent average initial and aged strengths through the position number • Strength Recovery Index: (Average aged strength / average initial strength) * 100 Localized base weight

[0238] The localized base weight of the nonwoven fabric can be determined by several available techniques, but a simple representative technique involves a die-cutting die with an area of ​​3.0 cm². 2 This method is used to cut a sample of the web from the selected 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

[0239] The linting degree test is used to determine the quantity of fibers from a nonwoven material under an abrasive force (i.e., the linting degree).

[0240] 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 preparation

[0241] 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

[0242] 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 of 11 cm MD and 4 cm CD within the covered area. Test 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. Attach the metal plate and the 2-pound weight to 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 be attached 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 release belts. 10. The lint weight is given as the average of 10 measurements. calculations

[0243] 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 area. Air permeability test

[0244] The air permeability test is used to determine the rate 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 determine variations in air permeability across the strip. Test 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 distance: 0.8 inches 3. Position the 20.7 mm opening plate on the top side of the forming strip (the side with the three-dimensional protrusions) at the point 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. Bag stack height check

[0245] The stack height of bags in a package of absorbent products is determined as follows: equipment

[0246] A thickness gauge with a flat, rigid, horizontal sliding plate is used. The thickness gauge is configured so 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. 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 plate exerts a downward force of 850 ± 1 gram force (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 additional weight is 850 ± 1 gram. Test procedure

[0247] Absorption article packaging is equilibrated at 23 ± 2 °C and 50 ± 5 % relative humidity before measurement.

[0248] The horizontal sliding plate is raised and an absorbent packaging is placed centrally under the horizontal sliding plate in such a way that the absorbent materials inside the packaging are in a horizontal orientation (see Fig.30) Any handle or other packaging feature on the packaging surfaces that would come into contact with one of the plates is folded flat against the packaging surface to minimize its effect on the measurement. The horizontal sliding plate is lowered slowly until it makes contact with the top surface 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 absorbable items) are measured, and the arithmetic mean is recorded as the package width.

[0249] The “bag stack height” = (packaging width / count of absorbents per stack) × 10 is calculated and reproduced to ± 0.5 mm. Methods for micro-CT measurement of intensive quantities

[0250] The micro-CT measurement technique for intensive quantities measures the base weight, thickness, and volumetric density values ​​within visually 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 scanner 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, with some of the X-rays being attenuated. The degree of attenuation correlates with the mass 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 reconstructed into a single 3D image. The device is connected via an interface to computer-running software for controlling image acquisition and storing the raw data. The 3D image is then analyzed using image analysis software (suitable image analysis software is MATLAB, available from The MathWorks, Inc., Natick, MA, or equivalent) to measure intensive parameters such as base weight, thickness, and volumetric density of regions within the sample. Rehearsal preparation:

[0251] 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.

[0252] 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 rigid, flat surface in a planar configuration. Carefully separate the individual substrate layer from the absorbent article. A scalpel and / or cryogenic spray (such as Cyto-Freeze, Control Company, Houston, TX) may be used to remove a substrate layer from any additional underlying layers, if necessary, to avoid any longitudinal and lateral expansion of the material. Once the substrate layer has been removed from the article, the sample is punched as described above.

[0253] 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. Remove 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.

[0254] A sample can be cut from any location containing the visually perceptible 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 visually perceptible areas. A zone, a three-dimensional feature, or a microzone may be visually perceptible 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 creases, wrinkles, or tears when selecting a sampling location. Image capture:

[0255] 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 allows the central section of the sample to lie horizontally and be scanned without any other materials directly adjacent to the upper and lower surfaces. Measurements should be taken in this area. The 3D image field of view is approximately 35 mm on each side in the xy-plane, with a resolution of approximately 5000 by 5000 pixels and with 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. The 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 produce 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:

[0256] 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 retains the signal from the sample fibers within the substrate.

[0257] Three 2D images with intensive sizes are generated from the threshold 3D image. The first is the base weight 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 cumulative signal across the entire sample.

[0258] 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 exhibits a uniform base weight. Follow the procedures described above to obtain at least ten replica samples of the calibration curve substrate. Accurately measure the base weight 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, and calculate the average to the nearest 0.01 grams per square meter. Following the procedures described above, acquire a micro-CT image of a single layer of the calibration sample substrate.Following the procedure described above, the micro-CT image is processed and a base weight image containing 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 calibration substrate layers is acquired. A raw base weight image of both layers together is generated, the actual base weight of which is twice the average base weight value measured in the calibration samples.Repeat this procedure 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 value is equal to the number of layers multiplied by the average base weight value 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 performing a linear regression of the raw data against 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.

[0259] The second 2D image of significant size is the thickness image. To generate this image, the top and bottom surfaces of the sample are identified, and the distance between these surfaces is calculated, yielding the sample thickness. The top surface of the sample is identified by starting at the uppermost 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 bottom 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 top and bottom 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.

[0260] The third 2D image of significant size 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 parameters of micro-CT base weight, thickness, and volumetric density:

[0261] 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 visually perceptible areas. A zone, three-dimensional feature, or microzone may be visually perceptible 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 visually discerning differences in intensity compared to other areas within the sample. For example, an area boundary may be identified based on visually perceiving a difference in thickness when compared to another area in the sample.Each of the intensity sizes can be used to distinguish area boundaries on either the physical sample itself or any of the micro-CT images of intensity size. Once the area boundary has been identified, draw an oval or round "area of ​​interest" (ROI) within the interior of the area. The ROI should have an area of ​​at least 0.1 mm. 2 The images are selected to measure an area with values ​​of high intensity that is representative of the identified region. From each of the three high-intensity images, the average base weight, average thickness, and average volumetric density within the region of interest (ROI) are calculated. These values ​​are then adjusted as follows: the base weight of the region to the nearest 0.01 grams per square meter, the thickness to the nearest 0.1 micrometers, and the volumetric density to the nearest 0.0001 g / cm³. 3 record. Opening test

[0262] Aperture dimensions, effective aperture area, % effective open area, inter-aperture distance measurements, among other measurements, are obtained from sample images captured using a flatbed scanner. The scanner is capable of scanning in reflection mode at a resolution of 6400 dpi and 8-bit grayscale (a suitable scanner is an Epson Perfection V750 Pro from Epson America Inc., Long Beach, CA, or equivalent). The scanner is connected to a computer running image analysis software (a suitable program is ImageJ v. 1.47 or equivalent, National Institutes of Health, USA). The sample images are distance-calibrated against a captured image of a ruler certified by NIST. A steel frame is used to mount the pattern, which is then secured with a black glass tile (P / N 11-0050-30, available from HunterLab, Reston, VA) before taking the pattern image.The resulting image is then compared to a threshold value, separating open opening areas from sample material areas and analyzing them using image analysis software. All tests are performed in a climate-controlled room maintained at approximately 23 ± 2 °C and approximately 50 ± 2% relative humidity. Rehearsal preparation:

[0263] To obtain a sample, an absorbent material is glued to a rigid, flat surface in a planar configuration. Any leg elastic bands can be cut to facilitate flattening of the material. A straight steel frame (100 mm) 2 , 1.5 mm thick with an opening of 60 mm 2The steel frame is used to mount the pattern. Take the steel frame and apply double-sided adhesive tape to the lower surface surrounding the inner opening. Remove the release paper from the tape and adhere the steel frame to the perforated layer of the article. Align the frame so that it is parallel and perpendicular to one machine direction (MD) and one cross direction (CD) of the perforated layer. Using a razor blade, cut the perforated layer away from the underlying layers of the article around the perimeter of the frame. Carefully remove the pattern, preserving its longitudinal and cross extensions to avoid distortion of the openings. A cryogenic spray (such as Cyto-Freeze, Control Company, Houston, TX) can be used to remove the top-layer pattern from the underlying layers, if necessary.Five replicates obtained from five substantially similar articles are prepared for analysis. If the perforated layer of interest is too small to accommodate the steel frame, the frame dimensions are reduced accordingly to achieve the objectives of sample removal without distortion of the perforations, while leaving a sufficient-sized perforation to allow scanning of a substantial portion of the perforated layer. A perforated substrate raw material is prepared for testing by elongating or activating it under the same process conditions and to the same extent as it would be used on the absorption article, and then attaching it to the steel frame in its elongated state as described above for testing. Pre-test samples are conditioned at approximately 23 ± 2 °C and approximately 50 ± 2% relative humidity for 2 hours. Image capture:

[0264] Place the ruler on the scanner bed, oriented parallel to the sides of the scanner glass, and close the lid. Capture a calibration image of the ruler in reflection mode at a resolution of 6400 dpi (approximately 252 pixels per mm) and 8-bit grayscale, with the field of view corresponding to the dimensions of one interior space of the steel frame. Save the calibration image as an uncompressed TIFF file. Lift the lid and remove the ruler. Once the calibration image is obtained, scan all patterns under identical conditions and measure them based on the same calibration file. Next, place the framed pattern flat on the center of the scanner bed, with the outward-facing surface of the pattern facing the scanner glass.Align the pattern so that the sides of the frame are parallel to and perpendicular to the sides of the scanner's glass surface, ensuring the resulting pattern image displays the MD vertically from top to bottom. Place the black glass tile on the frame covering the pattern, close the lid, and take a scan. Scan the remaining four replicas in the same way. If necessary, crop all images to a rectangular field of view that outlines the area with openings and save the files again. Calculation of % effective open area:

[0265] Open the calibration image file in the image analysis program and perform a linear distance calibration using the ruler shown. This distance calibration scale is applied to all subsequent sample images before analysis. Open a sample image in the image analysis program and set the distance scale. View the 8-bit histogram (0 to 255, with one bin per GL) and identify the grayscale value (GL) for the minimum population located between the dark pixel peak of the aperture holes and the lighter pixel peak of the fleece. Set the image threshold at the minimum grayscale value to generate a binary image. In the binary image, the apertures appear black, with a GL value of 255, and the patterns appear white, with a GL value of 0.

[0266] Analyze each of the separate aperture areas using the image analysis program. Measure and record all individual aperture areas, including partial apertures, to the nearest 0.01 mm. 2 along the edges of the image. Any openings with an area smaller than 0.3 mm. 2 Discard as "ineffective". Sum the remaining opening areas (including whole and partial openings) and divide by the total area enclosed in the image, then multiply by 100. Plot this as the % effective open area to the nearest 0.01%.

[0267] Analyze the four remaining sample images accordingly. Calculate and reproduce the average % effective open area values ​​to the nearest 0.01% for the five replicates. Effective opening dimension measurements:

[0268] Open the calibration image file (containing the ruler) in the image analysis program. Change the resolution of the original image from 6400 dpi to 640 dpi (approximately 25.2 pixels per mm) using bicubic interpolation. Perform a linear distance calibration using the ruler shown. This distance calibration scale will be applied to all subsequent sample images before analysis. Open a sample image in the image analysis program. Change the resolution of the original image from 6400 dpi to 640 dpi (approximately 25.2 pixels per mm) using bicubic interpolation. Set the distance scale. View the 8-bit histogram (0 to 255, with one bin per GL) and identify the grayscale value (GL) for the minimum population located between the dark pixel peak of the aperture holes and the lighter pixel peak of the fleece.Set the image threshold at the minimum grayscale value to generate a binary image. In the binary image, the apertures appear black, with a GL value of 255, and patterns appear white, with a GL value of 0. Next, two morphological operations are performed on the binary image. First, a closing operation (a dilation operation followed by an erosion operation, iterations = 1, pixel count = 1) removes stray fibers within an aperture. Second, an opening operation (an erosion operation followed by a dilation operation, iterations = 1, pixel count = 1) removes isolated black pixels. Pad the edges of the image during the erosion step to ensure that black border pixels are preserved during the operation. Finally, fill any remaining voids enclosed within the black aperture areas.

[0269] Using image analysis software, analyze each of the separate aperture areas. During the analysis, exclude measurements of partial apertures along the edges of the image so that only entire apertures are measured. Measure and record all of the individual effective aperture areas, circumferential edges, Feret diameters (length of the apertures) along with their corresponding orientation angle in degrees from 0 to 180, and minimum Feret diameters (width of the apertures). Record the measurements for each of the areas of the individual elements to the nearest 0.01 mm. 2 The circumferential margins and Feret diameters (length and width) are specified to the nearest 0.01 mm, and angles to the nearest 0.01 degrees. Any openings with an area smaller than 0.3 mm² 2Discard as "ineffective". Record the number of remaining apertures, divide by the image area, and record as the aperture density value. The orientation angle for an aperture aligned with the MD (vertical in the image) will be 90 degrees. Apertures with a positive slope increasing from left to right will have an angle between zero and 90 degrees. Apertures with a negative slope decreasing from left to right will have an angle between 90 and 180 degrees. Using the individual aperture angles, calculate an absolute Feret angle by subtracting 90 degrees from the original orientation angle and taking its absolute value. In addition to these measurements, calculate an aspect ratio value for each individual aperture by dividing the aperture length by its width. Repeat this analysis for each of the remaining four replica images.Calculate and report the statistical mean and standard deviation for each of the effective aperture dimensions, absolute Feret angle, and aspect ratio measurements using all aperture values ​​recorded from the replicas. Record the average of the individual absolute Feret angle measurements as the average absolute Feret angle value. Calculate and report the % relative standard deviation (RSD) for each of the aperture dimensions, absolute Feret angle, and aspect ratio measurements by dividing the standard deviation by the mean and multiplying by 100. Measurements of the inter-opening distances:

[0270] The mean, standard deviation, median, and maximum distance between the apertures can be measured by further analyzing the binary image that was used for the aperture dimension measurements. First, obtain a duplicate copy of the resized binary image after the morphological operations and, using image analysis software, perform a Voronoi operation. This produces an image of cells bounded by lines of pixels equidistant from the boundaries of the two nearest pattern apertures, where the pixel values ​​are outputs from a Euclidean distance map (EDM) of the binary image. An EDM is created by replacing each intermediate aperture pixel in the binary image with a value equal to that pixel's distance from the nearest pattern aperture. Next, the background zero values ​​are removed to allow for statistical analysis of the distance values.This is achieved by using the image calculator to divide the Voronoi cell image by itself to produce a 32-bit floating-point image, where all the cell lines have a value of one and the remaining parts of the image are identified as not a number (NaN). Next, using the image calculator, this image is multiplied by the original Voronoi cell image to produce a 32-bit floating-point image where the spacing values ​​along the cell lines remain, and all zero values ​​have been replaced by NaN. Finally, the pixel spacing values ​​are converted into actual aperture spacings by multiplying the values ​​in the image by the image's pixel resolution (approximately 0.04 mm per pixel), and then the image is multiplied by 2 again, since the values ​​represent the center-to-center distance between apertures.

[0271] Measure and record the mean, standard deviation, median, and maximum interfocal distances for the image to the nearest 0.01 mm. Repeat this procedure for all replica images. Calculate the % relative standard deviation (RSD) for the interfocal distance by dividing the standard deviation by the mean and multiplying by 100.

[0272] The dimensions and values ​​disclosed herein shall not be understood as being strictly limited to the exact numerical values ​​quoted. Instead, unless otherwise specified, each such dimension shall mean both the quoted value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" shall mean "about 40 mm".

[0273] 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, alone or in combination with other referenced sources, it teaches, suggests, or discloses such invention. 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.

[0274] Although certain embodiments of the present disclosure have been presented and described, it is obvious to those skilled in the art that various further changes and modifications can be made without departing from the spirit and scope of protection of the invention. Therefore, the appended claims are intended to cover all such changes and modifications that fall within the scope of protection of this invention.

Claims

[1] Three-dimensional nonwoven substrate (10) comprising the following: a first surface (12); a second surface (14); a first side margin (2000); a second side margin (2002); a first final edge (2004); a second end edge (2006); a central transverse axis (CL1); and a central longitudinal axis (CL2) that extends perpendicularly to the central transverse axis (CL1); wherein a line taken in a direction parallel to or perpendicular to the central transverse axis (CL1) of the three-dimensional nonwoven substrate (10) comprises the following: a first visually perceptible zone (110) in the nonwoven substrate (10) that is not provided with openings; and a second visually perceptible zone (120) in the fleece substrate (10); wherein the first visually perceptible zone (110) comprises a pattern of three-dimensional features (20) on the first surface (12) or the second surface (14); wherein at least some of the three-dimensional features (20) define a microzone comprising a first area (300) and a second area (310), and wherein the first area (300) and the second area (310) exhibit a value difference for an intensive size; where the intensive size of the first visually perceptible zone (110) is base weight, thickness or volumetric density; where the base weight, thickness, or volumetric density of each region is greater than zero; and where the second visually perceptible zone (120) defines openings (13), wherein the openings (13) have an effective opening area, according to the opening test herein, in a range of about 0.3 mm 2 up to about 15 mm 2exhibiting and wherein the second visually perceptible zone (120), according to the opening test herein, exhibits an effective open area in a range of about 3% to about 50%. [2] Nonwoven substrate (10) according to claim 1, wherein the second visually perceptible zone (120) comprises a pattern of second three-dimensional features (20) on the first surface (12) or the second surface (14), wherein at least some of the second three-dimensional features (20) define a second microzone comprising a third area and a fourth area, and wherein the third area and the fourth area exhibit a value difference for an intensive size. [3] Nonwoven substrate (10) according to claim 1 or 2, wherein the openings (13) have an effective opening area, according to the opening test herein, in a range of about 0.5 mm 2 up to about 8 mm 2exhibiting and wherein the second zone exhibits an effective open area, according to the opening test herein, in a range of about 5% to about 25%. [4] Nonwoven substrate (10) according to one of the preceding claims, wherein the first visually perceptible zone (110) is positioned proximal to the first end edge (2004) and wherein the second visually perceptible zone (120) is positioned proximal to the second end edge (2006). [5] Nonwoven substrate (10) according to one of claims 1-3, wherein the first visually perceptible zone (110) is positioned proximal to the second end edge (2006) and wherein the second visually perceptible zone (120) is positioned proximal to the first end edge (2004). [6] Nonwoven substrate (10) according to one of the preceding claims, wherein sections of circumferential edges of at least some of the openings (13) comprise one or more melt lips (15). [7] Nonwoven substrate (10) according to one of claims 1-5, wherein circumferential edges of at least some of the openings (13) are free of melt lips (15). [8] Nonwoven substrate (10) according to one of the preceding claims, wherein at least some of the openings (13) have an aspect ratio in a range of about 1.5 to about 10. [9] Nonwoven substrate (10) according to one of claims 1-7, wherein at least some of the openings (13) have an aspect ratio of less than about 1.

5. [10] Nonwoven substrate (10) according to one of claims 1-9, wherein the difference in value for the intensive size between the first area (300) and the second area (310) is of an order of magnitude, preferably about 1.2X to 10X. [11] Nonwoven substrate (10) according to one of the preceding claims, wherein the line taken in the direction parallel to or perpendicular to the central transverse axis (CL1) of the three-dimensional nonwoven substrate (10) comprises: a third visually perceptible zone (130) in the nonwoven substrate (10) that is not provided with openings; and wherein the third visually perceptible zone (130) comprises a pattern of third three-dimensional features (20) on the first surface (12) or the second surface (14); wherein at least some of the third three-dimensional features (20) in the third perceivable zone (130) define a microzone comprising a fifth area and a sixth area, and wherein the fifth area and the sixth area exhibit a value difference for an intensive quantity; and where the second visually perceptible zone (120) is positioned between the first visually perceptible zone (110) and the third visually perceptible zone (130). [12] Nonwoven substrate (10) according to claim 11, wherein a section of the first visually perceptible zone (110) is positioned proximal to the first side edge (2000) and wherein a section of the third visually perceptible zone (130) is positioned proximal to the second side edge (2002). [13] Nonwoven substrate (10) according to claim 11, wherein a section of the first visually perceptible zone (110) is positioned proximal to the first end edge (2004) and wherein a section of the third visually perceptible zone (130) is positioned proximal to the second end edge (2006). [14] Nonwoven substrate (10) according to any of the preceding claims, wherein the nonwoven substrate (10) is a spunbond nonwoven substrate (11). [15] Absorption articles (220), comprising: a liquid-permeable material (224) comprising the three-dimensional nonwoven substrate (10) according to one of the preceding claims; a liquid-impermeable material (225); and an absorption core (228) comprising an absorption material, wherein the absorption core (228) is positioned between the liquid-permeable material (224) and the liquid-impermeable material (225).

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