Molded fleece

Abstract

Nonwoven fabric (10) comprising a first surface (12) and a second surface (14) and an optically detectable pattern of three-dimensional features (20, 22, 24) on one of the first or second surface (12, 14), wherein each of the three-dimensional features (20, 22, 24) defines a microzone having a first region (300) and a second region, wherein the first and second regions (300, 310) exhibit a difference in value with respect to an intensive property, wherein the intensive property is one or more of: a. thickness, b. base weight and c. volumetric density, and wherein in at least one of the microzones the first region (300) is hydrophobic and the second region (310) is hydrophilic, wherein the hydrophilic second region (310) was obtained by the targeted addition of a surfactant or hydrophilizing material.

Description

FIELD OF TECHNOLOGY

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

[0002] Nonwoven fabrics are useful for a wide variety of applications, including absorbent personal care products, garments, medical applications, and cleaning applications. Nonwoven personal care products include infant care items such as diapers, child care items such as training pants, feminine care items such as sanitary napkins, and adult care items such as incontinence products, pads and pants. Nonwoven garments include protective workwear and medical garments such as surgical gowns. Other nonwoven medical applications include nonwoven wound dressings and surgical dressings. Cleaning applications for nonwoven fabrics include towels and wipes. Still other uses of nonwoven fabrics are well known. The above list is not considered exhaustive.

[0003] Different properties of nonwovens determine the suitability of nonwovens for different applications. Nonwoven fabrics can be designed to have different combinations of properties to suit different needs. Variable properties of nonwoven fabrics include liquid handling properties such as wettability, distribution, and absorbency, strength properties such as tensile and tear strength, softness properties, durability properties such as abrasion resistance, and aesthetic properties. The physical form of a nonwoven also affects the functionality and aesthetic properties of the nonwoven. Nonwoven fabrics are initially manufactured in webs which, when laid on a flat surface, may have a substantially planar, featureless surface, or they may have a series of surface features such as apertures or protrusions, or both. Nonwoven fabrics with openings or projections are often referred to as three-dimensionally shaped nonwoven fabrics. The present disclosure relates to three-dimensionally shaped nonwoven fabrics.

[0004] Despite previous advances in the nonwoven art, there remains a need for improved nonwoven fabrics having three-dimensional surface characteristics.

[0005] Furthermore, there remains a need for methods and apparatus for making improved nonwoven fabrics having three-dimensional surface characteristics.

[0006] Furthermore, there remains a need for articles, including absorbent articles, that utilize improved nonwoven fabrics with three-dimensional surface characteristics.

[0007] Furthermore, there remains a need for absorbent articles that utilize nonwoven fabrics with three-dimensional surface features and that can be packaged in a compressed form while at the same time minimizing the loss of the three-dimensional surface features upon opening the package.

[0008] Furthermore, there remains a need for absorbent articles that utilize soft spunbonded nonwoven fabrics with three-dimensional surface features that exhibit reduced in-use lint properties.

[0009] Furthermore, there remains a need for improved nonwoven fabrics having three-dimensional surface characteristics and physical integrity combined with softness as measured by a tissue softness analyzer sold by Emtec Electronic GmbH.

[0010] Furthermore, there remains a need for improved nonwoven fabrics having microzoned three-dimensional surface features and physical integrity combined with at least one region of the microzone that is hydrophobic and another region of the same microzone that is hydrophilic.

[0011] In addition, there remains a need for absorbent article packaging that includes soft nonwoven materials that have a reduced bag stack height compared to conventional absorbent article packaging, so that the packaging is convenient for caregivers to handle and store, and so that manufacturers can achieve low distribution costs without sacrificing aesthetics clarity, absorbency or softness of the manufactured absorbent article. SUMMARY OF THE INVENTION

[0012] A nonwoven fabric is disclosed. The nonwoven fabric may include a first surface and a second surface and an optically recognizable pattern of three-dimensional features on one of the first and second surfaces. Each of the three-dimensional features can define a micro-zone that includes a first area and a second area. The first and second regions may have a difference in value for an intense property, where the intense property is one or more of caliper, basis weight or volumetric density and where in at least one of the microzones the first region is hydrophobic and the second region is hydrophilic is. character list figure 1 is a photograph of an example of the present disclosure. figure 2 is a photograph of an example of the present disclosure. figure 3 is a photograph of an example of the present disclosure. figure 4 is a cross section of a portion of a fabric of the present disclosure as disclosed in FIG figure 1 is shown. figure 5A is a schematic representation showing the cross section of a filament formed with a primary component A and a secondary component B was manufactured in a side-by-side arrangement. figure 5B is a schematic representation showing the cross section of a filament formed with a primary component A and a secondary component B was fabricated in an eccentric sheath / core arrangement. figure 5C is a schematic showing the cross-section of a filament formed with a primary component A and a secondary component B is depicted in a concentric sheath / core arrangement. figure 6 is a photograph of a perspective view of a bicomponent trilobal fiber. figure 7 is a schematic representation of an apparatus for making a fabric of the present disclosure. figure 8 is a detail of a portion of the apparatus for joining a portion of fabric of the present disclosure. figure 9 is further detail of a portion of the apparatus for joining a portion of fabric of the present disclosure. figure 10 is a detail of a portion of the apparatus for selectively additionally joining a portion of a fabric of the present disclosure. figure 11 is a photograph of an example of the present disclosure. figure 12 is a photograph of a portion of a forming belt useful with the present disclosure. figure 13 is a cross-sectional view of a portion of the figure 12 forming bands. figure 14 is an image of a portion of a mask used to create the in figure 12 to produce the shaping band shown. figure 15 is an image of a portion of a mask used to create the in figure 16 to produce the shaping band shown. figure 16 is a photograph of a portion of a forming belt useful with the present disclosure. figure 17 is an image of a portion of a mask used to define the in figure 18 to produce the shaping band shown. figure 18 is a photograph of a portion of a forming belt useful with the present disclosure. figure19 is a photograph of a portion of a forming belt useful with the present disclosure. figure 20 is an image of a mask used to create the in figure 19 to produce the forming band shown. figure 21 is a photograph of a substance of the present disclosure found on the in figure 19 is made. figure 22 is a perspective schematic view of a forming belt of the present disclosure. figure 23 is a plan view of a nonwoven substrate containing nonwoven fabrics of the present disclosure. figure 24 is a plan view of a nonwoven substrate containing nonwoven fabrics of the present disclosure. figure 25A is a plan view of a fabric of the present disclosure with local basis weight measurement portions removed. figure 25B is a plan view of a fabric of the present disclosure with local basis weight measurement portions removed. figure 26 is a graphical representation of a cross-directional variation in basis weight in a fabric of the present disclosure. figure 27 is a schematic view of a package of the present invention. figure 28 is a plan view of an absorbent article of the present disclosure. figure 29 is a plan view of an absorbent article of the present invention. figure 30 is a cross-sectional view of the portion 29-29 from figure 28 figure 31 is a plan view of an absorbent article of the present disclosure. figure 32 is a cross-sectional view of the portion 32-32 from figure 31 figure 33 is a plan view of an absorbent article of the present disclosure. figure 34 is a cross-sectional view of the portion 34-34 from figure 33 figure 35 is a cross-sectional view of the portion 35-35 from figure 33 figure 36 is a photograph of an example of the present disclosure. figure 37 is a photograph of an example of the present disclosure. figure 38 is a photograph of an example of the present disclosure. figure 39 is a photograph of a cross section of the in figure 38 example shown. figure 40 is a micro-CT perspective view image of an example of the present disclosure. figure 41 is a micro-CT perspective view image of an example of the present disclosure. figure 42 is a micro-CT image of a cross section of FIG figure 40 and figure 41 illustrated example. figure 43 is a micro-CT image of a top view of the FIG figure 40 and figure 41 illustrated example. figure 44 is a graphical representation of various advantages of the invention of the present disclosure. figure 45 is a photographic view image of a portion of an example of the present disclosure. figure 46 is a photographic view image of a portion of an example of the invention of the present disclosure. figure 47 is a photographic view image of a portion of an example of the invention of the present disclosure. figure 48 is a photographic view image of a portion of an example of the invention of the present disclosure. figure 49 is a photograph of a cross section of the in FIGS figure 47 and figure 48 illustrated example. figure 50 is a photographic view image of a portion of an example of the invention of the present disclosure. figure 51 is a photographic view image of a portion of an example of the invention of the present disclosure. figure 52 is a photographic view image of a portion of an example of the invention of the present disclosure. figure53 is a photographic view image of a portion of an example of the invention of the present disclosure. figure 54 is a micro-CT image of a top view of the in FIGS figure 40 and figure 41 after undergoing additional processing. figure 55 is a graphical representation of various advantages of the in figure 54 of the present disclosure. figure 56 is a schematic representation of an apparatus for making a fabric of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0013] The present disclosure provides a shaped nonwoven fabric formed directly on a shaped forming belt with continuous spunbond filaments in a single conversion process. The fabric of the present disclosure may take a form that conforms to the shape of the forming belt. A fabric of the present disclosure made on a forming belt of the present disclosure in a method of the present disclosure may be particularly advantageous for use in personal care products, garments, medical products, and cleaning products. The formed nonwoven fabric can be used as a topsheet, backsheet nonwoven, acquisition layer, distribution layer or other component layer for a diaper, or as a topsheet, backsheet nonwoven, acquisition layer, distribution layer or other component layer for a sanitary napkin, or as a topsheet, backsheet nonwoven, acquisition layer, distribution layer or a other component layer for an adult incontinence pad or panty, or as a pad for a floor cleaning device.

[0014] The beneficial features of the nonwoven fabric, in some embodiments herein, are described in the context of an overall area of ​​the nonwoven fabric. The total range may be a range determined by dimensions suitable for particular applications where the various features of the invention offer beneficial properties. For example, the total area of ​​a fabric can be that of a fabric with dimensions that make it suitable for use as a topsheet, backsheet, acquisition layer, distribution layer, or other component layer for a diaper, or as a topsheet, backsheet, acquisition layer, distribution layer, or other component layer for a sanitary napkin , or as a topsheet, backsheet nonwoven, acquisition layer, distribution layer or other component layer for an adult incontinence pad or panty, or as a pad for a floor cleaning appliance. Thus, the total area can be based on width and length dimensions ranging from 3 cm wide to 50 cm wide and from 10 cm long to 100 cm long, resulting in total areas of 30 cm 2 up to 500 cm 2 leads.

[0015] Explicitly speaking, the aforementioned ranges include every integer dimension between the range boundaries. For example, in the above areas, a total area of ​​176 cm 2 revealed by a width of 11 cm and a length of 16 cm. As is apparent from the description herein, the total area of ​​a formed nonwoven web can be an area less than the area of ​​the nonwoven web of which it is a part when commercially manufactured. That is, in a given commercial nonwoven web of material, there may be a plurality of nonwoven webs formed according to the invention, each of the formed nonwoven webs of the invention having a total area that is less than the area of ​​the web from which it is formed.

[0016] Photographs of representative examples of formed nonwoven fabrics 10 are in the figure 1-3 pictured. The shaped non-woven fabric 10 can be a nonwoven spunbond substrate having a first surface 12 and a second surface 14 be. Both figure 1-3 is the second surface 14 faces the viewer and lies on the first surface 12 opposite that in the figure 1-3 is invisible, but in figure4 is shown. The term "surface" is widely used to refer to either side of a web for descriptive purposes and is not intended to imply any required flatness or smoothness. Although the molded non-woven fabric 10 being soft and flexible, it is described in a flattened state in the context of one or more X-Y planes parallel to the flattened state, and corresponds to each plane in the cross-machine direction in web-making technology CD , and the machine direction, md , as in the figure 1-3 shown. The length L in the md and the width W in the CD determine the total area A for the nonwoven 10 . As in figure 4, which is a cross section of a portion of the in figure 1 non-woven fabric shown 10 is, for descriptive purposes, the three-dimensional features of the formed nonwoven fabric will be described as extending in a Z-direction from an X-Y plane of the first surface 16 extend outwards (see figure 4). In one embodiment, a maximum dimension of three-dimensional features in the z-direction may be the maximum distance between the plane of the first surface 16 and an X-Y plane of the second surface 18 define this distance as the average thickness AC of the non-woven fabric 10 can be measured. The average caliper can be determined by optical, non-contacting means, or it can be determined by spaced flat plate devices which determine the caliper of the web placed therebetween at a given pressure. It is not necessary that all three-dimensional features have the same maximum dimension in Z -direction, however, a variety of three-dimensional features may have substantially the same maximum dimension in Z -direction determined by the fiber lay-up process and the properties of the forming belt, as discussed below.

[0017] The in the figure 1-4 (as well as other fabrics disclosed herein) are liquid permeable. In one embodiment, the entire fabric can be considered liquid permeable. In one embodiment, areas or zones (described below) may be liquid permeable. By liquid pervious, as used herein in relation to the fabric, it is meant that the fabric has at least one zone that allows liquid to pass therethrough under conditions of use of a consumer product. For example, when used as a topsheet on a disposable diaper, the fabric can have at least one zone that has a level of liquid permeability that allows urine, liquid stool, menses, or any other bodily exudates to penetrate to an underlying absorbent core . By "liquid permeable" as used herein in relation to a region, it is meant that the region has a porous structure that allows liquid to pass therethrough.

[0018] As in the figure 1-4 shown, the non-woven fabric can 10 exhibit a regular, repeating pattern of a plurality of separate, recognizably distinct three-dimensional features, including a first three-dimensional feature 20 and a second three-dimensional feature 22 , and a third three-dimensional feature 24 , as in the figure 2 and figure 3 shown. For example, this differs in figure 1 heart-shaped first three-dimensional feature shown 20 recognizable by the smaller, substantially triangular shaped second three dimensional feature 22 . The discernible differences can be visual, such as discernibly different sizes and / or shapes.

[0019] The three-dimensional characteristics of the non-woven fabric 10can be formed by depositing fibers, such as by carding, air spinning, solution spinning, or melt spinning, directly onto a forming belt with a pattern of corresponding three-dimensional features. In a sense, the non-woven fabric 10 molded onto a shaping belt that shapes the three-dimensional features of fabric 10 definitely. However, as described herein, it is important that the apparatus and method of the invention protect the nonwoven 10 be manufactured in such a way that, in addition to accepting the shape of the forming belt, it is given advantageous properties for use in sanitary articles, clothing, medical products and detergents due to the properties of the forming belt and the apparatus for the forming process. More specifically, due to the nature of the forming belt and other device elements, as described below, the three-dimensional characteristics of the nonwoven fabric 10 exhibit intense properties that may differ between the first and second regions within a microzone (described in more detail below), or from feature to feature, in a manner that benefits the nonwoven fabric 10 for use in personal hygiene products, clothing, medical products and cleaning products. For example, the first three-dimensional feature 20 have a basis weight or density that differs from the basis weight or density of the second three-dimensional feature 22 differs and both may have a basis weight or density different from that of the third three-dimensional feature 24 distinguishes and provides favorable aesthetic and functional properties related to fluid intake, distribution and / or absorption in diapers or sanitary napkins.

[0020] It is believed that the difference in the intensive properties between the various three-dimensional features of the nonwoven fabric 10 is based on the fiber distribution and densification resulting from the apparatus and method described below. Fiber distribution occurs in the fiber laydown process, as opposed to, for example, a post-processing process such as hydrojetting or embossing processes. Since the fibers are free to move during a process such as a melt spinning process, 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 believed that the fibers in a nonwoven fabric 10 are more stable and permanently formed.

[0021] As in the figure 1-3, and as will be apparent from the present description, the various three-dimensional features may be delimited by optically recognizable regions (related to the interior of a three-dimensional feature) drawn in the form of a closed figure (such as the heart shape in Figures figure 1 and figure 3 and the diamond shape in the figure 2 and figure 3) may exist. The closed figure can be a curvilinear closed figure like the heart shape in the figure 1 and figure be 3 The delineated, visually recognizable areas can be the areas of the non-woven fabric 10 be closest to the first face in the z-direction 12 adjoin, such as those in figure 4 areas shown 21 , and which are at least partly in or on the first level 16 lying when in a flattened state. For example, as in figure 1, the first three-dimensional feature 20 heart-shaped, and like this as an exemplary first three-dimensional feature 20A is represented, it is defined by a curvilinear closed heart-shaped element. A curvilinear element can be understood to mean a linear element that has a tangent vector anywhere along its length V has, where the closed figure can be such that the tangential vector Vhas both MD and CD components that change values ​​greater than 50% of the length of the linear element of the closed figure. Of course, the figure does not have to be 100% closed, but the linear element can also have interruptions that do not spoil the overall impression of a closed figure. As discussed below in connection with the forming belt, the outlining optically discernible curvilinear closed heart-shaped element is formed by a corresponding closed heart-shaped raised element on the ridge on the forming belt to form the closed figure of a heart on fabric 10 to build. In a repeating pattern, the individual shapes (in the case of the first three-dimensional feature in figure 1: a heart shape) to aesthetically pleasing soft fluffy features throughout the area OA the second surface 14 of fabric 10 lead away. In an embodiment in which the nonwoven 10 used as a topsheet for a diaper or sanitary napkin, the second surface 14 of the non-woven fabric 10 body side to deliver better aesthetic and performance benefits in terms of softness, compression resistance and fluid absorption.

[0022] More specifically, the regular, repeating pattern of closed, three-dimensional features, as in figure 1-3, it is assumed, without being bound by theory, that the dimensions of the various features represent the average basis weight of the entire fabric 10 over its entire area, and other parameters as described below, which define the various intensive properties, contribute to a beneficial improvement in compression resilience. It is believed that the plurality of relatively closely spaced, relatively small, and relatively soft three-dimensional features can act as springs to resist compression and to spring back once a compressive force is removed. Compression recovery is important in the topsheets, backsheet nonwovens, acquisition layers, distribution layers, or other component layers of personal care articles such as diapers, sanitary napkins, or adult incontinence pads, diapers, or pants, since such articles are typically packaged and folded into a compressed state. Manufacturers of personal care products want to retain most, if not all, of the manufactured thickness for aesthetic and performance reasons. The three-dimensional form of molded features offers important aesthetic benefits due to the soft look and feel and pleasing appearance of clear, well-defined shapes, including very small shapes like the one in figure 2 little hearts shown. The three-dimensional features also provide softness during use, improved absorbency, less leakage and overall improved application. However, the necessary compression during the folding, packaging, shipping, and storage of the personal care articles can cause a permanent loss of thickness of a topsheet, nonwoven backsheet, acquisition layers, distribution layers, or other component layers of the absorbent article, thereby detracting from the functional benefits produced. We have unexpectedly found that the nonwoven fabrics of the present disclosure retain their original three-dimensional characteristics to a significant extent, even after undergoing compression packaging and distribution in a compression-packed state.

[0023] Table 1 below presents compression resiliency data for two embodiments of the present disclosure. Example 1 corresponds to that in figure 1 non-woven fabric shown 10 and is made on a forming line as with reference to FIG figure 12 and figure 14 described. Example 2 corresponds to that in figure 2 non-woven fabric shown 10 and is made on a forming line as with reference to FIG figure 15 and figure16 described. As can be seen from the data, the fabrics of this invention 10 exhibit a significant benefit in terms of compression recovery when measured by the compression aging test. In one form, packages of absorbent articles with the compression resiliency properties of the present disclosure can have a reduced bag stack height, yet provide the aesthetic benefits and the absorbency and softness benefits of the diaper just made, or as if it had never been compression packed. This invention provides packages with reduced stack height in the pouch and allows caregivers to easily handle and store the packages while also offering manufacturers reduced distribution costs, both of which are achieved while maintaining the original aesthetic clarity, absorbency, or softness of the absorbent article are maintained. Example 1:

[0024] A bicomponent spunbonded nonwoven fabric made by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration as described in figure 6, which is a scanning electron micrograph (SEM) of a cross-section of a bicomponent trilobal fiber. The web was placed on a forming belt with a repeating pattern as in figure 12 as described below with respect to FIG figure 7 and figure 8, moving at a linear speed of about 25 meters per minute, to an average basis weight of 30 grams per square meter, with a repeating pattern of heart shapes, as in figure 1 pictured. The fibers of the fabric were compressed on the first side 12 by heated compaction rolls 70 , 72 (described below) further bonded at 130°C and at the winder 75 wound up on a roll. Example 2:

[0025] A bicomponent spunbonded nonwoven fabric made by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration as described in figure 6, which is a scanning electron micrograph of a cross-section of a bicomponent trilobal fiber. The web was placed on a forming belt with a repeating pattern as in figure 16 as described below with respect to FIG figure 7 and figure 8, moving at a linear speed of about 25 meters per minute, around a fabric 10 with an average basis weight of 30 grams per square meter, with a repeating pattern of heart shapes, as in figure 2 shown. The fibers of the fabric were on the first surface 12 by heated compaction rollers 70 , 72 (described below) at 130°C. Table 1: Compression Resilience 3D fleece Raw (nonwoven straight from the roll) 4KPa (-96mm IBSH) 14KPa (-84mm IBSH) 35KPa (-68mm IBSH) thickness thickness after compression Percent Thickness Retention (%) thickness after compression Percent Thickness Retention (%) thickness after compression Percent Thickness Retention (%) example 1 0,45 0,38 84,44 0,35 77,78 0,34 75,56 example 2 0,43 0,36 83,72 0,36 83,72 0,31 72,09

[0026] As can be seen from Table 1, the substances according to the invention retain 10 contribute significant amounts to their thickness after compression at relatively high pressures. For example, the samples of Example 1 and Example 2 retain more than 70% of their original average thickness after being tested by the compression aging test at a pressure of 35 KPa. The compression aging test is a simulation of the conditions a nonwoven fabric would experience if packaged in a high compression diaper package and then remained in such condition during distribution to a consumer and then the package was ultimately opened by a consumer.

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

[0028] The melt spinning can occur at about 150°C to about 280°C, or in some embodiments at about 190°C to about 230°C. Fiber spinning speeds can be greater than 100 meters / minute and can be from about 1000 to about 10,000 meters / minute and can be from about 2000 to about 7000 meters / minute and can be from about 2500 to about 5000 meters / minute. Spinning speeds can affect the brittleness of the spun fiber, and generally the higher the spinning speed, the less brittle the fiber. Continuous fibers can be made by spunbond processes or meltblown processes.

[0029] A nonwoven fabric according to the invention 10 may comprise continuous multicomponent polymeric filaments comprising a primary polymeric component and a secondary polymeric component. The filaments may be continuous bicomponent filaments having a primary A polymer component and a secondary B polymer component. The bicomponent filaments have a cross section, a length, and a circumferential area. Components A and B may be located in substantially distinct zones across the cross section of the bicomponent filaments and may extend continuously along the length of the bicomponent filaments. The secondary component B forms at least a portion of the peripheral surface of the conjugate filaments in a continuous manner along the length of the conjugate filaments. Polymer components A and B can be melt spun into multicomponent fibers on conventional melt spinning equipment. The devices are selected based on the desired configuration of the multi-component. Commercially available melt spinning equipment is available from Hills, Inc. located in Melbourne, Florida. The spinning temperature ranges from about 180°C to about 230°C.

[0030] The processing temperature is determined by the chemical nature, molecular weights and concentration of each component. The spunbonded bicomponent filaments can have an average diameter of from about 6 to about 40 microns, and preferably from about 12 to about 40 microns.

[0031] The components A and B can either be in a side-by-side arrangement, as in figure 5A, or in an eccentric sheath / core arrangement as shown in FIG figure 5B to obtain filaments that have a natural helical crimp. Alternatively, the components A and B be arranged in a concentric sheath-core arrangement, as in figure 5C. In addition, the components A and B be arranged in a multilobal mantle / core arrangement, as in figure 6 shown. Other multicomponent fibers can be made using the compositions and methods of the present disclosure. The bicomponent and multicomponent fibers may be in a pie slice, ribbon, sea island configuration, or any combination thereof. The cladding may or may not be continuous around the core. The shell to core weight ratio is from about 5:95 to about 95:5. The fibers of the present disclosure can have different geometries, including round, elliptical, star-shaped, rectangular, and other miscellaneous eccentricities.

[0032] Methods for extruding multicomponent polymeric filaments into such configurations are well known to those skilled in the art.

[0033] 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-limiting examples of polymeric materials that can be spun into filaments include natural polymers such as starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, chitin, chitosan and, polyisoprene (cis and trans), peptides, polyhydroxyalkanoates, and synthetic polymers, inclusive , but not limited to, thermoplastic polymers such as polyesters, nylons, polyolefins such as polypropylene, polyethylene, polyvinyl alcohol and polyvinyl alcohol derivatives, sodium polyacrylate (absorbent gel material), and copolymers of polyolefins such as polyethylene-octene or polymers with monomeric mixtures of propylene and ethylene, and biodegradable and compostable thermoplastic polymers such as polylactic acid filaments, polyvinyl alcohol filaments, and polycaprolactone filaments. In one example, the thermoplastic polymer is selected from the group consisting of: polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, styrene-butadiene-styrene block copolymer, polyurethane, and mixtures thereof. In another example, the thermoplastic polymer is selected from the group consisting of: polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, and mixtures thereof. Alternatively, the polymer may comprise one derived from monomers that are bio-based, such as bio-polyethylene or bio-polypropylene.

[0034] The primary component A and the secondary component B can be selected such that the resulting conjugate filament provides improved nonwoven bonding and substrate softness. The primary polymer component A has a melting temperature lower than the melting temperature of the secondary polymer component B .

[0035] The primary polymer component A may comprise polyethylene or random copolymer of propylene and ethylene. The secondary polymer component B can comprise polypropylene or random copolymer of propylene and ethylene. Polyethylenes include linear low density polyethylene and high density polyethylene. In addition, the secondary polymer component B can include additives to increase the natural helical crimp of the filaments, lower the bonding temperature of the filaments, and improve the abrasion resistance, strength, and softness of the resulting fabric.

[0036] Inorganic fillers such as the oxides of magnesium, aluminum, silicon and titanium can be added as inexpensive fillers or processing aids. Other inorganic materials include hydrous magnesium silicate, titanium dioxide, calcium carbonate, clay, chalk, boron nitride, limestone, diatomaceous earth, micaceous silica and ceramics.

[0037] The filaments of the present invention also contain a slip additive in an amount sufficient to impart the desired feel to the fiber. As used herein, "lubricant" or "lubricant" means an external lubricant. When melted with the resin, the lubricant gradually exudes or migrates to the surface during cooling or after manufacture, forming a uniform, invisibly thin coating, providing permanent lubrication. The lubricant is preferably a fast bloom lubricant and can be a hydrocarbon having one or more functional groups selected from hydroxide, aryl and substituted aryls, halogens, alkoxys, carboxylates, esters, unsaturated carbons, acrylates, oxygen, nitrogen, carboxyl, sulfate and phosphate be.

[0038] During manufacture or in a post-treatment, or both, the nonwoven fabric of the present invention may be treated with surfactants or other agents to render the web either hydrophilic or hydrophobic. This is standard practice for nonwovens used in absorbent articles. For example, a nonwoven fabric used for a topsheet can be treated with a hydrophilizing material or surfactant to make it permeable to body exudates such as urine. For other absorbent articles, the topsheet can remain in its natural hydrophobic state or can be made even more hydrophobic by the addition of a hydrophobicizing material or surfactant.

[0039] Suitable materials for making the multicomponent filaments of the fabric of the present disclosure include PH-835 polypropylene available from LyondellBasell and Aspun-6850-A polyethylene available from Dow Chemical Company.

[0040] If polyethylene is the component A (sheath) and polypropylene is component B (core), the bicomponent filaments may comprise from about 5% to about 95% by weight polyethylene and from about 95% to about 5% by weight polypropylene. The filaments may comprise from about 40% to about 60% by weight polyethylene and from about 60% to about 40% by weight polypropylene.

[0041] Let's turn figure 7 to where a representative production line 30 for making fabric 10 disclosed in the present disclosure. The production line 30 is arranged to produce a web of bicomponent continuous filaments, but it should be understood that the present disclosure encompasses nonwoven webs made with mono- or multicomponent filaments having more than two components. Bicomponent filaments can be trilobal.

[0042] The production line 30 includes a pair of extruders 32 and 34 , each through the extruder drives 31 and 33 be driven to the primary polymer component A and the secondary polymer component B to extrude separately. The polymer component A is in the respective extruder 32 from a first funnel 36 fed, and the polymer component B is in the respective extruder 34 from a second funnel 38 fed. The polymer components A and B can from the extruders 32 and 34 through respective polymer lines 40 and 42 into the filters 44 and 45 and melt pumps 46 and 47 are fed, which the polymer into a spin pack 48 pump. Spinnerets for extruding bicomponent filaments are well known to those skilled in the art and are therefore not described in detail here.

[0043] Generally described, the spin pack comprises 48 a housing enclosing a plurality of plates stacked one on top of the other with a pattern of openings arranged to create flow paths for the separate passage of polymer components A and B through the spinneret. The Spin Pack 48 has openings arranged in one or more rows. The spinneret orifices form a downwardly extending curtain of filaments as the polymers are extruded through the spinneret. For the purposes of the present disclosure, the spinnerets may be arranged to form sheath / core or side-by-side bicomponent filaments which are in the figure 5A, figure 5B and figure 5C, as well as non-round fibers such as trilobal fibers as in figure 6 pictured. Additionally, the fibers can be a monocomponent that includes a polymer component such as polypropylene.

[0044] The production line 30 also includes a quench fan 50 one positioned adjacent to the curtain of filaments extending from the spinneret. Air from the quench air blower 50 quenches the filaments extending from the spinneret. The quench air can be directed from one side of the filament curtain or from both sides of the filament curtain.

[0045] A damper52 is positioned under the spinneret and takes up the quenched filaments. Fiber draw units or aspirators for use as dampers in melt spun polymers are well known. Suitable fiber draw units for use in the method of the present disclosure include a linear fiber attenuator of the type disclosed in US Pat. No. 3,802,817 and inductive guns of the type shown in U.S. Pat. No. 3,692,618 and U.S. Pat. No. 3,423,266, the disclosures of which are incorporated by reference.

[0046] Generally described, the damper includes 52 an elongated vertical passage through which the filaments are drawn by suction of air entering from the sides of the passage and flowing down the passage. A shaped, endless, at least partially foraminous forming belt 60 is below the damper 52 positions and takes the continuous filaments from the outlet port of the damper 52 on. The shaping band 60 is a band and runs around the guide rollers 62 hereabouts. A vacuum 64 , which is under the shaping band 60 positioned where the filaments are deposited presses the filaments against the mold surface. Although the shaping tape 60 as a band in figure 8, it should be understood that the forming belt may be in other forms, such as a drum. Details of certain shaped forming belts are discussed below.

[0047] When running the production line 30 become the funnel 36 and 38 with the respective polymer components A and B filled. The polymer components A and B are melted and passed through the respective extruders 32 and 34 through polymer lines 40 and 42 and the spin pack 48 extruded. Although the temperatures of the molten polymers vary depending on the polymers used, when polyethylene and polypropylene are each used as the primary component, the temperatures of the polymers may vary A and secondary component B are used range from about 190°C to about 240°C.

[0048] As the extruded filaments extend below the spinneret, an air stream from the quench fan quenches 50 at least partially the filaments, and in certain fibers 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 from about 0°C to about 35°C and a velocity of from about 100 to about 400 feet per minute. The filaments can be sufficiently quenched before they are discharged onto the forming belt 60 are collected so that the filaments can be arranged by the compressed air passing through the filaments and the forming surface. Quenching the filaments reduces the stickiness of the filaments so that the filaments do not stick together too tightly before they are joined and so that they can be moved or placed on the forming belt during collection of the filaments on the forming belt and during formation of the web.

[0049] After quenching, the filaments are fed into the vertical passage of the damper 52 drawn by a flow of the fiber drawing unit. The damper can be positioned 30 to 60 inches below the bottom of the spinneret.

[0050] The filaments can pass through the damper's outlet port 52 onto the formed moving forming belt 60 be deposited. While the filaments are in contact with the forming surface of the forming belt 60 stand, sucks the vacuum 64 the air and fibers against the forming belt 60 to form a nonwoven web of continuous filaments that assume a shape corresponding to the shape of the mold surface. As described above, since the filaments are quenched, the filaments are not too sticky and the vacuum can hold the filaments on the forming belt 60 move or arrange while the filaments are on the forming belt 60 collected and put into the fabric 10be formed.

[0051] The production line 30 also includes one or more binding devices such as the cylindrical compaction rollers 70 and 72 , which form a nip through which the fabric is compacted, d. H. calendered, and heated to also bond fibers. One or both of the compaction rollers 70 , 72 can be heated to provide enhanced properties and benefits to the nonwoven 10 by joining sections of the fabric. For example, it is believed that heating sufficient to provide a thermal bond improves the tear strength properties of the fabric 10 improved. The compaction rollers may be a pair of smooth surfaced stainless steel rollers with independent heating controls. The compaction rollers can be heated by electrical elements or hot oil circulation. The nip between the compaction rolls can be hydraulically controlled to apply a desired pressure to the fabric as it passes through the compaction rolls on the forming belt. In an embodiment with a forming belt thickness of 1.4 mm and a spunbonded web with a basis weight of 30 grams per square meter, the nip between the compaction rollers 70 and 72 be about 1.4 mm.

[0052] In one embodiment, the upper compaction roller 70 be heated sufficiently to bond fibers to the first surface 12 of the substance 10 to melt to give strength to the fabric so that it comes off the shaping band 60 can be removed without loss of integrity. As in the figure 8 and figure 9 shown if, for example, the roles 70 and 72 turning in the direction indicated by the arrows kicks the band 60 with the spunbonded fabric laid on it into the nip that passes through the rollers 70 and 72 is formed. The hot roll 70 can the sections of non-woven fabric 10 heat up by the raised resin elements of tape 60 be pressed against it, d. H. in areas 21 , to connected fibers 80 on at least the first surface 12 of fabric 10 to create. As can be understood from the description herein, the bonded areas so formed can have the pattern of the raised elements of the forming belt 60 accept. For example, the bonded regions so formed can be a substantially continuous network or a substantially semi-continuous network on the first surface 12 of areas 21 be showing the same pattern as the hearts of figure 1 and figure 11 generate. By adjusting the temperature and dwell time, bonding can be limited primarily to fibers that are on the first surface 12 are closest, or there may be a thermal bond to the second surface 14 be achieved as in figure 11 (which also includes point bonds 90 as discussed in more detail below), and figure 45-49. The bond can also be a discontinuous network, for example as point bonds 90 , as discussed below.

[0053] The raised elements of the shaping ribbon 60 can be selected to provide different network properties of the forming belt and bonded portions of the nonwoven substrate 11 or the fleece 10 to manufacture. The network corresponds to the resin that the raised elements of the shaping band 60 forms, and may include substantially continuous, substantially semi-continuous, discontinuous options, or combinations thereof. These networks can be the raised elements of the shaping ribbon 60 describe when it affects their appearance or appearance in the X-Y planes of the forming ribbon 60 or the three-dimensional features that the nonwoven substrate 11 or the fleece 10 of the present invention relates.

[0054] "Substantially continuous" network refers to an area in which one can connect any two points by an unbroken line that runs completely within the area for the length of the line. That is, the essentially continuous network essentially has "continuity" in all directions parallel to the first plane, terminating only at edges of that area. The term "substantially" in conjunction with "continuous" is intended to indicate that while absolute continuity can be achieved, slight deviations from absolute continuity can be tolerable as long as these deviations are not appreciably the performance characteristics of the fibrous structure (or a molding element) accordingly affect the conception and planning.

[0055] "Essentially semi-continuous" network refers to a surface that has "continuity" in all, but at least one, of the directions parallel to the first plane, where on that surface no two arbitrary points are separated by an unbroken line running the full length of the line runs entirely within the area in question can be connected. The semi-continuous frame can also have continuity only in a direction parallel to the first plane. Analogous to the continuous region described above, while absolute continuity in all directions, at least in one direction, is preferred, small deviations from such continuity may be tolerable so long as these deviations do not appreciably affect the performance characteristics of the fibrous structure.

[0056] "Discontinuous" network refers to discrete and separate surfaces that are discontinuous in all directions parallel to the first plane.

[0057] After compaction, the fabric can enter the forming belt 60 leaving and being calendered through a nip formed by calender rolls 71 , 73 is formed, and then the fabric can be wound onto a roll. As in the schematic cross-section of figure 10, the calender rolls can be stainless steel rolls with an engraved pattern roll 84 and a smooth roller 86 be. The engraved scroll may have raised sections 88 exhibit the need for extra compaction and bonding to the fabric 10 can take care of. The Raised Sections 88 may be a regular pattern of relatively small spaced "pins" that form a pattern of relatively small dot bonds 90 in the nip of the calendar rolls 71 and 73 form. The percentage of point bonds in the nonwoven 10 can range from 3% to 30% or from 7% to 20%. The engraved pattern may be a variety of closely spaced, regular, generally cylindrical in shape, generally flat tipped pen shapes, with pen heights ranging from 0.5mm to 5mm and preferably from 1mm to 3mm. Pin bond calender rolls can have closely spaced regular point bonds 90 in non-woven fabric 10 form as in figure 11 shown. Further gluing can take place, for example, by means of hot-air gluing.

[0058] As with reference to below figure56, the through-air bonding process may be another approach to produce higher bulk nonwoven structures that may be suitable for this application. The through-air bonding process involves applying hot air to the surface of the nonwoven fabric. The hot air flows through holes in a chamber located directly above the fleece. However, the air is not pressed through the fleece as is the case with conventional hot-air ovens. Vacuum or suction pulls the air through the open conveyor apron which supports the web as it passes through the oven. Pulling the air through the nonwoven fabric allows for much faster and more even heat transfer and minimizes fabric deformation. Aside from conventional through-air bonding units, it would be conceivable to place the bonding unit on top of the 3D belt while setting a vacuum under the belt to mimic the through-air bonding process for this specific application.

[0059] Binders used in the through-air bonding process include crystalline binder fibers, bicomponent binder fibers, and powders. When using crystalline binder fibers or powder, the binder melts completely and forms molten droplets within the cross-section of the web. Bonding occurs at these sites upon cooling. In the case of sheath / core binder fibers, the sheath is the binder and the core is the carrier fiber. In one embodiment, in a web comprising sheath / core binder fibers, the sheath comprises a polyethylene and the core comprises polypropylene. For such a web, the temperature of the through-air bonding process can range from 110°C to 150°C and the dwell time can range from 0.5 to 10 seconds, 5-30 seconds, or 30-60 seconds, since the through-air bonding time of basis weight, the degree of strength desired and the speed of operation. Products made using through-air ovens tend to be bulky, open, soft, strong, stretchy, breathable, and absorbent.

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

[0061] As in figure 11, in one embodiment, the heated compaction roller 70 form a weave pattern that is a substantially continuous net weave pattern 80 (e.g. interconnected heart-shaped bonds) on the first surface 12 of non-woven fabric 10 (in figure11 not shown as it faces away from the viewer) and the engraved calender roll 73 can relatively small point bonds 90 on the second surface 14 of fabric 10 form. The point ties 90 secure loose fibers otherwise prone to fuzzing or pilling during fabric use 10 would be. The advantage of the resulting structure of the non-woven fabric 10 is most evident when used as a topsheet in a personal care article such as a diaper or sanitary napkin. When used in a hygiene article, the first surface 12 of the non-woven fabric 10 relatively flat (related to the second surface 14 ) and have a relatively large amount of bonds because the heated compaction roller bonds 80 on the areas of the fabric formed by the raised elements of the forming band 60 be pressed. This bond gives the non-woven fabric 10 structural integrity, but may be relatively stiff or rough on a user's skin. Therefore, the first surface 12 of the non-woven fabric 10 in a diaper or sanitary napkin, be oriented to face the inside of the article, d. H. away from the wearer's body. Similarly, the second surface 14 facing and in contact with the body when in use. It is less likely that the relatively small point bonds 90 visually or tactilely perceived by the user, and the relatively soft three-dimensional features remain visually free of lint and pilling in use while being soft to the touch. Another bond can be used instead of or in addition to the bond mentioned above.

[0062] The shaping band 60 can be made according to the methods and processes described in US Pat. No. 6,610,173 issued to Lindsay et al. on August 26, 2003, or U.S. Pat. No. 5,514,523 issued to Trokhan et al. on May 7, 1996, or U.S. Pat. No. 6,398,910 issued to Burazin et al. on June 4, 2002 or U.S. Pat. No. 2013 / 0199741 published in the name of Stage et al. on August 8, 2013, each with the improved features and patterns disclosed herein for making spunbond nonwoven webs. The Lindsay, Trokhan, Burazin and Stage disclosed herein describe belts representative of papermaking belts made with cured resin on a woven reinforcing member, which belts, with improvements, can be used in the present disclosure as described herein.

[0063] An example of a shaping band 60 of the type useful in the present disclosure and made according to the disclosure of US Pat. No. 5,514,523, is in figure 12 pictured. As taught therein, a reinforcing member 94 (like a woven ribbon of filaments 96 ) is thoroughly coated with a liquid photosensitive polymeric resin to a preselected thickness. A film or negative mask containing the desired repeating elements of the raised element pattern (e.g. figure 14) is juxtaposed on the liquid photosensitive resin. The resin is then exposed through the film to light of an appropriate wavelength, such as UV light for a UV curable resin. This exposure to light causes the resin to cure in the exposed areas (i.e., in the white or non-printed portions in the mask). Uncured resin (resin under the opaque areas in the mask) is removed from the system, leaving the cured resin that forms the pattern shown, e.g. the cured resin elements 92 in figure 12. Other patterns can also be formed as discussed herein.

[0064] figure 12 shows a portion of a forming belt 60 , which is used to manufacture the in figure 1 shown nonwoven 10 is useful. As shown, the shaping tape can 60 hardened resin elements 92on a woven reinforcement element 94 contain. The reinforcement element 94 can be made from woven filaments 96 as is known in the papermaking belt art, including resin-coated papermaking belts. The cured resin elements can have the general structure set out in figure 12 and are made through the use of a mask 97 with the inside figure 14 dimensions shown. As in the schematic cross section in figure 13, the cured resin elements flow 92 around and are hardened to attach to the reinforcement member 94 to be "fixed" and can have a width at a distal end DW from about 0.020 inch to about 0.060 inch, or from about 0.025 inch to about 0.030 inch, and an overall height above the reinforcing member 94 , referred to as the top layer, OB, from about 0.030 inch to about 0.120 inch, or about 0.50 to about 0.80 inch, or about 0.060 inch. figure 14 shows a portion of a mask 97 , showing the outline and representative dimensions for a repeating unit of the repeating heart design in the in figure 1 shown nonwoven 10 represents. The white section 98 is transparent to UV light and during the manufacturing process of the tape, as described in US Pat. No. 5,514,523 describes that UV light cures an underlying layer of resin that is cured to form the raised elements 92 on the reinforcement element 94 to build. After removing the uncured resin, the forming belt 60 , which is a cured resin design as in figure 12, created by suturing the ends of a length of tape, the length of which may be determined by the design of the device, as in FIG figure 7 shown.

[0065] Equally represents figure 15 a section of a mask 97 representing the design for a repeating unit of the repeating design in the in figure 2 non-woven fabric shown 10 represents. The white section 98 is transparent to UV light and in the tape manufacturing process allows UV light to cure an underlying layer of resin that becomes the reinforcing member 94 is hardened. After removing the uncured resin, the forming belt 60 , which is a cured resin construction as in figure 16, created by suturing the ends of a length of tape, the length of which may be determined by the design of the device, as in FIG figure 7 shown.

[0066] Also, by way of further non-limiting example figure 17 depicts a portion of a mask showing the design for a repeating unit of the repeating design in the FIG figure 18 non-woven fabric shown 10 represents. The white section 98 is transparent to UV light and in the tape manufacturing process allows UV light to cure an underlying layer of resin that becomes the reinforcing member 94 is hardened. After washing off the uncured resin, the shaping belt 60 with a hardened resin design, as in figure 18 by sewing the ends of a length of fabric 10 generated.

[0067] Another example of a portion of a forming belt 60 of the type useful in the present disclosure is discussed in figure 19 pictured. The section of the shaping band 60 , the in figure 19 is a separate tape pattern 61 , which may have a length L and a width W equal to the length L and width W of the total area OA of a nonwoven fabric 10 is equivalent to. That is, the shaping band 60 can separate tape pattern 61 (as described in more detail below with reference to figure 22) each having a separate tape pattern total area DPOA corresponding to the total area OA of the nonwoven fabric 10 is equivalent to. figure 20 illustrates a portion of a mask that outlines the design for a repeating unit of the repeating design in the infigure 21 non-woven fabric shown 10 represents. The white section 98 is transparent to UV light and in the tape manufacturing process allows UV light to cure an underlying layer of resin that becomes the reinforcing member 94 is hardened. After washing off the uncured resin, the shaping belt 60 with a hardened resin design, as in figure 19 was created by sewing the ends of a length of ribbon.

[0068] The section of the forming band that is in figure 19 illustrates another advantage of the present disclosure. The section of a forming band 60 , the in figure 19 can have an in figure 21 fabric shown 10 form. the inside figure 21 shown nonwoven fabric 10 may have dimensions of width W and length L and total area OA, making it suitable for use as a topsheet in a disposable diaper, for example. The fleece 10 standing on a shaping belt 60 is manufactured, as exemplified in figure 19 illustrates differs from that in FIGS figure 1-3 shown in that the pattern of three-dimensional features created by the separate resin elements 92 on the forming belt 60 are formed are not present in a normal, repeating pattern throughout the entire surface. Correspondingly, the pattern of three-dimensional raised elements in the separate band pattern overall area DPOA can be described as an irregular pattern comprising different sections called zones. The difference between the zones can be optical, i. H. a visually noticeable difference, or the difference may be in the non-woven fabric 10 produce different average intense properties such as basis weight or density, or combinations of optical and intense properties. A visually discernible difference exists when a viewer visually discerns a pattern between zones, such as the first zone, under normal indoor lighting conditions (e.g., 20 / 20 visibility, sufficient lighting for reading). 112 and the second zone 122 , can recognize.

[0069] the fleece 10 may also have visually recognizable zones corresponding to zones of the forming belt. As in figure 21 shown, for example, the fabric 10 have at least two, three or four optically recognizable zones. A first zone 110 having a first pattern of three-dimensional features and the first average intensity properties may have a first region that is substantially central in the overall area OA located. A second zone 120 having a second pattern of three-dimensional features and second average intensity properties may have a second region, which in one embodiment is within the overall area OA generally around the first zone 110 is distributed around and completely surrounds it. A third zone 130 having a third pattern of three-dimensional features and third average intensity properties may have a third region, which in one embodiment is within the overall area OA generally around the second zone 120 is distributed around and completely surrounds it. A fourth zone 140 having fourth three-dimensional features and fourth average intensity features may have a fourth region that is within the total area OA is positioned at any location, such as at a front portion of an upper layer, such as the in figure 21 heart design shown. In general, there can be n zones, where n is a positive integer. Each of the n zones may have an nth pattern of three-dimensional features and an nth area and nth average intense properties.

[0070] The optically recognizable zones, as in figure21 may include visually recognizable three-dimensional features. These different three-dimensional features can be delimited by areas of relatively high density (relative to the interior of a three-dimensional feature) in the form of a closed figure, such as the heart in FIGS figure 1 and figure 3, and the diamond shape in the figure 2 and figure 3. In general, as discussed in more detail below, including in the context of microzones, the three-dimensional features may be defined by a first region and a second region, where the first region and second region are optically distinct and share a common intense property associated with each of the first and second areas, and there is a difference in the common intensive property value of the first area and the second area. In one embodiment, the three-dimensional features may be defined by a first region and a second region, where the first region is at a higher elevation (dimension measured in the Z-direction) than the second region with respect to the plane of the first surface. In another embodiment, the three-dimensional features may be defined by a first area and a second area, where the first area is on a higher basis than the second area.

[0071] As can be seen, rather than having a constant, repeating pattern uniformly distributed throughout the forming belt, the forming belt enables 60 of the present disclosure, the manufacture of a nonwoven fabric having repeats of irregular separate tape patterns 61 having each separate band pattern 61 like that in figure 19 is the separate band pattern shown. The individual band patterns 61 can each be used to form a non-woven fabric 10 with a total area OA suitable for use in a disposable absorbent article such as a diaper or sanitary napkin. The nonwovens 10 can be sequential, i. H. in series, and optionally sequentially in parallel production lines, each production line being a sequential row of nonwoven fabrics 10 is. The sequential series of non-woven fabrics 10 can be generated in a machine direction along an axis parallel to the machine direction. The nonwoven material can then be slit or otherwise cut to form nonwoven fabrics 10 to produce that can be used as topsheets in disposable absorbent articles such as diapers or sanitary napkins.

[0072] In one embodiment, the pattern may be the same or different within each separate band pattern total area DPOA. That is, the sequentially spaced separate tape patterns may be substantially identical, or they may differ in visual appearance and / or in the intense properties produced in nonwoven substrates fabricated thereon. For example, as shown schematically in figure 22, the pattern of three-dimensional raised elements in the first mold zone 112 from the separate band pattern 61A from the pattern of three-dimensional raised elements in the first form zone 112 from the separate band pattern 61B differentiate. The shaping band 60 thus offers flexibility in the production of nonwoven webs 10 that are suitable for use in consumer products, including disposable absorbent articles. For example, in a diaper package, the topsheets of at least two diapers may differ from one another because they are sequentially manufactured in a spunbond process as described herein wherein sequential separate tape patterns have different zone patterns. In one embodiment, the web pattern of the topsheet or backsheet for one diaper size may differ from the web of the topsheet or backsheet of another diaper size, thereby providing a caregiver with a visual cue of a diaper's size. Similarly, sanitary napkins can use a fabric 10for a topsheet wherein the optical pattern of three-dimensional features indicates the absorbency of the sanitary napkin. In any case, the different structures of the substances 10 be made on a single tape, with the separate tape patterns being made differently as desired.

[0073] Thus, the invention with reference to figure 22 as a forming belt with one axis A , which are written parallel to a longitudinal direction, which is a machine direction. The shaping band 60 can have a variety of separate tape patterns 61 arranged in at least one sequential relationship with respect to the longitudinal direction. Each separate band pattern 61 can a separate band pattern total area DPOA exhibit, in a rectangular shaped pattern, through a length L and width W is defined as with reference to the separate band pattern 61A is specified. Each individual band pattern can be used in its total area DPOA a first mold zone 112 having a first pattern of three-dimensional raised elements extending outwardly from the plane of the first surface, and a second molding zone 122 with second three-dimensional raised elements extending outwardly from the plane of the first surface. The first forming zone can have a first air permeability value and the second forming 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 patch DPOA can be the same or different.

[0074] As an example, and referring to the single band pattern 61 of the shaping belt 60 , this in figure 19 is shown, and the fleece 10 , this in figure 21, the following properties were determined. The first zone 110 of the non-woven fabric 10 can have an average basis weight of from about 5 grams per square meter to about 30 grams per square meter; the second zone 120 can have an average basis weight of from about 50 grams per square meter to about 70 grams per square meter; and the third zone 130 can have an average basis weight of from about 25 grams per square meter to about 60 grams per square meter. The difference in basis weight from one zone to another may be due to a difference in the air permeability of the forming belt 60 be due. In the embodiment used for the manufacture of the non-woven fabric 10 , this in figure 20 is used in which the basis weights for the zones 110 , 120 and 130 15 grams per square meter, 53 grams per square meter and 25 grams per square meter, respectively, is the air permeability of the respective zones 112 , 122 , and 132 of the shaping belt 60 379 cubic feet per minute, 805 cubic feet per minute, and 625 cubic feet per minute. Thus, by varying the air permeability in the zones in the forming belt 10 the intensive characteristics of the average basis weight and the average density in the zones over the total area of ​​​​the fabric 10 be eased away.

[0075] As from the description of the shaping band 60 , this in figure 22 and with reference to figure 23 is described, it can be done on tape 60 fabricated nonwoven substrate 11 in one embodiment described as a nonwoven substrate 11 with a variety of herein as substance 10 described sections that during manufacture on the forming line 60 in at least one sequential relationship with respect to the longitudinal direction, d. i.e., in the machine direction, are ordered. figure 23 is a schematic representation of a spunbonded nonwoven substrate 11 , the sequentially ordered substances 10 represents, where each substance 10 shows a different pattern within the different zones. Any fabric10 can a total area OA having a rectangular pattern defined by a length L and a width W is defined. Any sequentially arranged fabric 10 can within its total area OA at least a first zone 110 having a first pattern of three-dimensional features and first average intensity properties, and a first region located within the overall area OA located; a second zone 120 having a second pattern of three-dimensional features and second average intensity properties, having a second region that is substantially within the total area OA located. Optionally, more zones, e.g. B. a third zone 130 having a third pattern of three-dimensional features and a third average intensity property, and having a third range within the total area OA to be available. As shown in the exemplary schematic representation of figure 23 is shown, the first pattern may differ 110A of the substance 10A from the first pattern 110B of the substance 10B differ and may differ from the first pattern 110C of fabric 10C differentiate. The same can be done for the second zones 120A , 120B and 120C be the case.

[0076] In general, the sequentially ordered nonwoven fabrics 10 of the fleece material 11 , which is on the shaping tape 60 is manufactured, vary in their respective total areas, intensive properties and their visual appearance. A common intense trait is an intense trait shared by more than one zone (referring to a zonal pattern such as that in figure 21) or area (for three-dimensional features, such as the regular, repeating patterns shown in figure 1 shown) is exhibited. Such intense properties of non-woven fabrics 10 can be average values ​​and can include, without limitation, density, volumetric density, basis weight, caliper, and haze. For example, if a density is a common intense property of two differential zones or areas, a value of density in one zone or area may differ from a value of density in the other zone or area. Zones (such as a first zone and a second zone) can be identifiable areas that can be distinguished from one another visually and by different intense properties averaged within the zone.

[0077] After production, the individual non-woven fabrics 10 tailored and used for their intended purposes, such as for topsheets in disposable absorbent articles. For example, a disposable diaper 1006 in a spread orientation in figure 24 shown. A material 10 is cut to the appropriate overall area and incorporated into the diaper by means known in the art 1006 glued. fabrics 10 can before assembling into a diaper 1006 be cut, or during the diaper manufacturing process, the nonwoven substrate 11 sheeted with other diaper components and trimmed after assembly.

[0078] As referring to figure 24, in one embodiment, this can be done on tape 60 fabricated nonwoven substrate 11 be described as a nonwoven fabric 11 with a variety of herein as substance 10 described sections that during manufacture on the forming line 60 in at least one sequential relationship with respect to the longitudinal direction, d. i.e., in the machine direction during manufacture on the forming line 60 , in at least one side-by-side relationship, i.e. i.e., in the transverse direction, are ordered. figure 24 is a schematic representation of a spunbonded nonwoven substrate 11 and shows sequentially ordered fabric 10 in adjacent machine direction production lanes 13, wherein the adjacent machine direction production lanes are juxtaposed fabrics 10 exhibit, in figure 24 as 10D , 10E and 10F illustrated. Any fabric 10 can a total area OA having a rectangular pattern defined by a length L and a width W is defined.

[0079] Any sequentially arranged fabric 10 can within its total area OA at least a first zone 110 having a first pattern of three-dimensional features and first average intensity properties, and a first region located within the overall area OA located; a second zone 120 having a second pattern of three-dimensional features and second average intensity properties, having a second region that is substantially within the total area OA located. Optionally, more zones, e.g. B. a third zone 130 having a third pattern of three-dimensional features and a third average intensity property, and having a third range within the total area OA to be available. Any fabric 10 in juxtaposed production lanes may be substantially identical, or they may differ from one another in terms of size, visual appearance, and / or intense properties. After manufacture, the non-woven substrate 11 coiled for slitting into production webs for processing into consumer products, or slit and then coiled.

[0080] By using a representative sample to compare basis weight differences in a fabric 10 , made with a regular, repeating, uniform pattern and fabric 10 with a non-uniform, zonal pattern, became the fleece 10 of example 1 with a fabric with a pattern similar to that in figure 21 and referred to as Example 3. Example 3 is a bicomponent spunbonded nonwoven web made on the apparatus disclosed herein by a 50:50 spinning ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical Company) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration. The bicomponent spunbond trilobal fibers were formed on a forming belt 60 moving at a linear speed of about 25 meters per minute to an average basis weight of 30 grams per square meter on a zonal pattern forming belt as in figure 19 pictured. The second substrate was formed under identical conditions, but had at least a portion of a regular, repeating, uniform pattern on a forming belt, as in FIG figure 16 from which the basis weight was determined. Fiber spinning conditions, throughput, forming line speed, and compaction roll bond temperature were identical for both substrates. Example 3

[0081] A bicomponent spunbonded nonwoven fabric made by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration, to an average basis weight of 30 grams per square meter was produced. A non-woven fabric was made as referred to in FIG figure 7 and figure 8 and moving at a forming line speed of about 25 meters per minute to form a zonal pattern fabric as in figure 20 shown to form. The fibers of the fabric were on the first surface 12 by heated compaction rollers 70 , 72 further bonded at 130°C and the fabric was wound on the winder 75 wound up on a roll. example 4

[0082] A bicomponent spunbonded nonwoven fabric made by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration, to an average basis weight of 30 grams per square meter was produced. A non-woven fabric was made as referred to in FIG figure 7 and figure 8 and moving at a forming line speed of about 25 meters per minute to form a fabric having a repeating (non-zonal) pattern as in figure 2 to form. The fibers of the fabric were on the first surface 12 by heated compaction rollers 70 , 72 further bonded at 130 °C, and was on the winder 75 wound up on a roll.

[0083] Table 2 below shows the average local basis weight measured according to the Localized Basis Weight Test Method herein and averaged over 10 samples. The samples for the measurement were made from the substances as in Figs figure 25A and figure 25B shown where the dark rectangles are where a 3 cm 2 -Sample was removed for measurement. As can be seen, the fabrics are labeled A - E across the cross direction (CD). The measurements show not only a significant difference in basis weight between the zones of the zonal fabric, but also a CD distribution that is graphically shown in figure 26 is shown. Table 2: Measured Average Basis Weight Distribution in Nonwoven 10 in grams per square meter (gsm) area as in figure 25 shown Example 3: Zonal fabric basis weights Example 4: Non-zonal fabric basis 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

[0084] As can be seen in Table 2, fabrics 10 working on shaping belts 60 be made with zones of different air permeability, a significant change in the fiber laydown and thus the basis weights within the nonwoven CD 10 which indicates the ability of the fibers to move with air zones in high permeability. The non-zonal repeating pattern fabric 10 has approximately the same basis weights within the CD of the fabric.

[0085] In addition to differences in the air permeability of the different zones of the forming belt 60 can the structure of the shaping belt 60 other intensive properties of the zones in the fabric 10 affect, such as average caliper, average softness, average compression resistance, and liquid absorbency properties.

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

[0087] In the fleece 10 is calendered to create point joints 90 exhibit, linting can be reduced. The term "pilling" refers to the tendency of fibers to loosen up and out of the fabric 10 to solve. The loosening and loosening can be due to frictional engagement with manufacturing equipment during manufacture of the disposable absorbent article or another surface, such as the skin of a person contacted with the fabric 10 interacts, arise. In some uses, such as topsheets in disposable absorbent articles, linting is a negative consumer phenomenon. However, bonding fibers in place can also be a consumer disadvantage since it can create roughness on the surface of an otherwise soft nonwoven substrate. We have unexpectedly found that the nonwoven substrates and nonwoven fabrics of the present disclosure can withstand an increase in bond (and consequent reduction in lint) with minimal loss of softness. The bonding can be by relatively closely spaced point bonds 90can be achieved, the distance being determined by the desired level of lint reduction. Bonding can also be achieved by known methods for chemically or thermally bonding nonwovens, such as thermal bonding, ultrasonic bonding, pressure bonding, latex adhesive bonding, and combinations of these methods. Lint reduction by bonding is illustrated with respect to Examples 5 and 6 below. Example 5

[0088] A bicomponent spunbonded nonwoven fabric was made by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration to an average basis weight of about 30 grams per square meter on a forming belt as referred to in FIG figure 7 and figure 8 described, with agitation at a linear speed of about 25 meters per minute, to form a fabric having the repeating pattern as in figure 36 shown to form. Fibers of the fabric were further on a first surface 12 by compaction rollers 70 , 72 tied, with the compaction roller 70 was heated to 130°C to form essentially continuous bonds 80 to build. Example 6

[0089] A bicomponent spunbonded nonwoven fabric was made by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration to an average basis weight of about 30 grams per square meter on a forming belt as referred to in FIG figure 7 and figure 8 described, with agitation at a linear speed of about 25 meters per minute, to form a fabric having the repeating pattern as in figure 37 to form described. Fibers of the fabric were further on a first surface 12 by compaction rollers 70 , 72 tied, with the compaction roller 70 was heated to 130°C to form essentially continuous bonds 80 to build. The fibers of the fabric were drawn on the calendar rollers 71 , 73 further calender-bound, with the roller 73 an engraved roller with raised sections 88 was in the form of pins with a pin height of 1.25 mm and an open gap of 0.62 mm in a 10% point bond pattern. The role 73 was heated to 135 C to create point bonds 90 on the second page 14 of fabric 10 to form as in figure 11 shown.

[0090] The fabrics 10 of Examples 5 and 6 differed only in the absence and presence, respectively, of the point bonds 90 . The second page 14 the fabrics 10 was subjected to a lint test according to the Lint Level Test to determine the effectiveness of the point bonds in securing fibers to the surface of the fabric. The results of the lint test for Examples 5 and 6 are shown in Table 3. Table 3: MR lint results sample no MD Lint Value (mg / cm 2 ) Example 5 0,36 Example 6 0,19

[0091] As shown above, the point bonds lead 90 resulted in a dramatic decrease in MD Lint Value. It unexpectedly retained its softness, absorbency and aesthetic benefits despite the bonding treatment and now also exhibits the desired resistance to linting in consumer use.

[0092] The absorbent articles of the present disclosure are typically placed in packages for shipping, storage, and sale. The packages may include polymeric films and / or other materials. Graphics and / or indicia regarding the properties of the absorbent articles may be molded, printed, positioned and / or placed on exterior portions of the packages. Each package can include a variety of absorbent articles. The absorbent articles can be packaged under compression to reduce the size of the packages while still providing an adequate amount of absorbent articles per package. Compression packaging of the absorbent articles allows caregivers to easily handle and store the packages while also providing manufacturers with distribution savings due to the size of the packages. figure 27 illustrates an example package 1000 , a variety of absorbent articles 1004 includes. The packaging 1000 defines an interior space 1002 , in which the variety of absorbent articles 1004 located. The variety of absorbent articles 1004 is in one or more stacks 1006 arranged.

[0093] Packages of the absorbent articles of the present disclosure can have a stack height in the bag of less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 85 mm, but greater than about 75 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm, or less than about 74 mm, with specific reference to every 0.1 mm increments within the recited ranges and any ranges formed therein or thereby, as provided herein test of the stack height in the bag as described. Alternatively, the packages of the absorbent articles of the present disclosure can have a stack height in the bag of from about 70 mm to about 100 mm, from about 70 mm to about 95 mm, from about 70 mm to about 85 mm, from about 72 mm to about 80 mm or from from about 74 mm to about 78 mm, specifying every 0.1 mm increments within the stated ranges and any ranges formed therein or thereby, according to the In-Bag Stack Height Test described herein. General description of an absorbent article

[0094] The three-dimensional nonwovens 10 of the present disclosure can be used as a component of absorbent articles such as diapers, child care articles such as training pants, personal care articles such as sanitary napkins, and adult articles such as incontinence products, pads and pants. An example of an absorbent article in the form of a diaper 220 is in the figure 28-30 shown. figure Figure 28 is a plan view of the exemplary diaper laid out flat 220 , with sections of structure to better show the construction of the diaper 220 were removed. The wearer facing surface of diaper 220 in figure 28 points to the viewer. This diaper 220 is depicted for illustrative purposes only, as the three-dimensional nonwoven materials of the present disclosure can be used as one or more components of an absorbent article, such as the topsheet, the acquisition layer, the topsheet and the acquisition layer, or the topsheet and the acquisition and / or Distribution System (“ADS”). In any event, however, the three-dimensional nonwoven materials of the present disclosure can be liquid permeable.

[0095] The absorbent article 220 can be a liquid-permeable material or cover sheet 224 , a liquid impervious material or a backsheet 225 , an absorbent core 228 , which is at least partly between the upper class 224 and the underclass 225 positioned, and barrier leg cuffs 234 include. The absorbent article can also be an ADS 250 included, which in the illustrated example is a distribution layer 254 and a receiving layer 252 includes, which are discussed further below. The absorbent article 220 can also elasticized sealing cuffs 232 with rubber bands233 connected to a chassis of the absorbent article, usually via the topsheet and / or backsheet, and are substantially planar with the chassis of the diaper.

[0096] the figure 28 and figure 31 also depict common fastening diaper components, such as a fastening system, the tabs 242 attached towards the rear edge of the article and with a landing zone 244 cooperate on the front side of the absorbent article. The absorbent article may also include other conventional features not shown, such as a back waist elastic feature, a front waist elastic feature, transverse barrier cuff(s), and / or a lotion application.

[0097] The absorbent article 220 can also have a front waistband 210 , one at the front waistline 210 longitudinally opposite rear waist edge 212 , a first margin 203 and one on the first margin 203 longitudinally opposite second side edge 204 exhibit. The front waist edge 210 is the edge of the article to be placed towards the front of the user when worn and the back waist edge 212 is the opposite edge. The absorbent article 220 can have a longitudinal axis 280 feature extending from the lateral midpoint of the front waistline 210 to a lateral center point of the back waistline 212 of the article and the article in two substantially symmetrical halves with respect to the longitudinal axis 280 splits when the article is laid flat and viewed from above, as in figure 28. The absorbent article 220 can also have a transverse axis 290 having extending from the longitudinal midpoint of the first side edge 203 to the longitudinal midpoint of the second side edge 204 extends. The length L of the article can be measured along the longitudinal axis 280 from the front waistline 210 to the back waistline 212 be measured. The width W of the absorbent article can be along the lateral axis 290 from the first margin 203 to the second edge of the page 204 be measured. The absorbent article may include a crotch point C, defined herein as the point placed on the longitudinal axis at a distance of two fifths (2 / 5) of the length of the article from the front edge 210 of the article 220 . The article may have a front waist region 205 , a rear waist region 206 and a crotch area 207 include. 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 absorbent article.

[0098] The upper class 224 , the underclass 225 , the absorbent core 228 and the other components of the article may be assembled in a variety of configurations, particularly by gluing or hot stamping, for example.

[0099] The absorption core 228 may comprise an absorbent material comprising at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% by weight of the superabsorbent polymers, and a core wrap, which encloses the superabsorbent polymers. The core wrap can typically be two materials, substrates or nonwoven materials, for the top and bottom of the core 216 and 216' include. These types of cores are known as non-airfelted cores. The nucleus may include one or more canals figure 28 than the four channels 226 , 226' and 227 , 227' are shown. The canals 226 , 226' , 227 and 227' are optional features. Instead, the core can have no channels or can have any number of channels.

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

[0101] In the present disclosure, the topsheet (that portion of the absorbent article that is in contact with the wearer's skin and receives the liquids) may be formed from a portion of, or all of, one or more of the three-dimensional nonwoven fabrics described herein and / or one or more of the nonwoven materials positioned thereon and / or bonded thereto such that the nonwoven material(s) contacts the wearer's skin. Other portions of the topsheet (besides the three-dimensional nonwoven materials) may also contact the wearer's skin. The three-dimensional nonwoven materials can be used as a stripe or a patch on the usual topsheet 224 be positioned. Alternatively, the three-dimensional nonwoven material can form only a central CD region of the topsheet. The central CD region can extend the entire MD length of the topsheet or less than the full MD length of the topsheet.

[0102] The upper class 224 can with the underclass 225 , the absorbent core 228 and / or any other layers as known to those skilled in the art. Usually the upper class 224 and the underclass 225 attached directly to each other at some locations (e.g. at or near the perimeter of the absorbent article) and indirectly to each other at other locations by directly joining them to one or more other elements of the article 220 put together.

[0103] The upper class 224 can be conformed to the wearer's skin, soft to the touch, and non-irritating. Furthermore, at least a portion of the topsheet 224 liquid permeable, allowing liquids to readily penetrate through its thickness. In addition, a portion or all of the topsheet 224 treated with surfactants or other agents to either hydrophilize or render the web hydrophobic. Any section of the upper class 224 may be coated with a lotion and / or a skin care composition as is generally disclosed in the art. The upper class 224 may also include or be treated with antibacterial agents. underclass:

[0104] The underclass 225 is generally the portion of the absorbent article 220 , which is adjacent to the garment facing surface of the absorbent core 228 and prevents, or at least inhibits, the exudates absorbed and contained therein from soiling items such as bedding and underwear. The underclass 225 is usually impervious, or at least substantially impervious, to liquids (e.g., urine). For example, the backsheet may be or comprise a thin plastic film, such as a thermoplastic film having a thickness of from about 0.012 mm to about 0.051 mm. Other suitable backsheet materials can include breathable materials that allow vapors to escape from the absorbent article 220 escape while still preventing or at least inhibiting liquids from passing through the backsheet 225 reach.

[0105] The underclass 225 can with the upper class 224 , the absorbent core 228 and / or any other element of absorbent article 220 connected by attachment methods known to those skilled in the art.

[0106] The absorbent article may comprise a backsheet comprising an outer cover or an outer cover web. An outer cover or an outer cover web of the absorbent article 220 may include at least a portion or all of the backing 225cover to form a soft, garment-facing surface of the absorbent article. The outer cover or nonwoven outer cover may be formed from the high loft three-dimensional nonwoven materials described herein. Alternatively, the outer cover or nonwoven outer cover may comprise one or more known outer cover materials. When the backsheet comprises one of the three-dimensional nonwoven materials of the present disclosure, the three-dimensional nonwoven material of the backsheet may or may not correspond (i.e., same material, same pattern) to a three-dimensional nonwoven material used as the topsheet, or the topsheet and the acquisition layer, of the absorbent article will. In other instances, the backsheet may have a printed or otherwise applied pattern that matches or visually resembles the pattern of the three-dimensional nonwoven materials used as the topsheet, or topsheet and acquisition layer laminate, of the absorbent article. The outer cover may be attached to at least a portion of the backsheet by mechanical bonding, ultrasonic bonding, thermal bonding, adhesive bonding, or other suitable attachment methods 225 get connected. absorbent core

[0107] The absorbent core is the component of the absorbent article with the highest absorbency and comprises an absorbent material and a core wrap or bag enclosing the absorbent material. The absorbent core does not include the acquisition and / or distribution system or any other components of the absorbent article that are not an integral part of the core wrap or core bag or are disposed within the core wrap or core bag. The absorbent core may comprise, consist essentially of, or consist of a core wrap, absorbent material (e.g., superabsorbent polymers and little or no cellulosic fibers) as discussed, and adhesive.

[0108] The absorption core 228 an absorbent material with a high level of superabsorbent polymers (referred to herein as “ SAP “ abbreviated) included in the core cladding. The SAP content may be 70 wt%-100 wt% or at least 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 95 wt% .-%, 99%, or 100% by weight based on the weight of the absorbent material contained in the core wrap. The core wrap is not considered an absorbent material for the purpose of evaluating the percentage of SAP in the absorbent core. The absorbent core can contain airfelt with or without superabsorbent polymers.

[0109] By "absorbent material" is meant a material that exhibits some absorbent property or liquid acquisition properties, such as SAP, cellulosic fibers, and synthetic fibers. Typically, adhesives used in manufacturing absorbent cores have little or no absorbent properties and are not considered absorbent material. The SAP content may be higher than 80% by weight, for example at least 85% by weight, at least 90% by weight, at least 95% by weight, at least 99% by weight and even up to and including 100 % by weight of the weight of the absorbent material contained in the core wrap. This airfelted core is relatively thin compared to a conventional core, which typically consists of between 40-60% by weight SAP and a high cellulosic fiber content. The absorption material can in particular contain less than 15% by weight or less than 10% by weight natural, cellulosic or synthetic fibers, less than 5% by weight, less than 3% by weight, less than 2% by weight or less than 1% by weight or even be essentially free of natural, cellulosic and / or synthetic fibers.

[0110] As indicated above, the non-airfelted cores with very little or no natural cellulose and / or synthetic fibers are very thin compared to conventional cores, making the overall absorbent article thinner than absorbent articles with cores containing mixed SAP and cellulose fibers (e.g. 40 -60% cellulose fibers). This core thickness can mean that the consumer may experience reduced absorption and performance, although technically this is not the case. Currently, these thin cores are typically used with substantially planar or apertured topsheets. Furthermore, absorbent articles with these thin, non-airfelted cores have reduced capillary voids because there are little or no natural, cellulosic, or synthetic fibers in the cores. Thus, sometimes there may not be enough capillary void space in the absorbent article to fully accommodate a multiple bodily discharge spill or a single large spill.

[0111] To solve such problems, the present disclosure provides absorbent articles having these thin non-airfelted cores in combination with any of the high loft three-dimensional nonwoven materials described herein as a topsheet, or as a topsheet and acquisition layer laminate. In such a case, the absorption and performance perceived by the consumer is increased thanks to the increased caliper of the absorbent article due to the additional caliper provided by the high-loft, three-dimensional nonwoven material. In addition, the three-dimensional nonwovens, when used with these non-airfelted cores and as a topsheet, or topsheet and acquisition layer laminate, add back capillary void space to the absorbent article while still allowing for a minimal stack height, thereby propelling cost savings to consumers and manufacturers. Accordingly, the absorbent articles of the present disclosure can easily absorb multiple spills of bodily discharges or a single large spill through this increased capillary void space. Additionally, absorbent articles comprising the nonwoven materials as a topsheet, or topsheet and acquisition layer laminate, offer consumers an aesthetically pleasing topsheet compared to a planar topsheet or an apertured topsheet with an increased caliper, and thus consumer perceptions of absorbency and performance.

[0112] The exemplary absorbent core 228 of the absorbent article 220 the figure 31-32 is isolated in the figure 33-35 shown. The absorption core 228 can a front 480 , a reverse side 282 and two the front 480 and the back 282 connecting long sides 284 , 286 exhibit. The absorption core 228 also includes a generally planar top surface and a generally planar undersurface. The front 480 of the core is the side of the core that faces the front waistline 210 of the absorbent article is to be placed. the core 228 can have a longitudinal axis 280' having substantially the longitudinal axis 280 of the absorbent article 220 corresponds, in top view and in a planar view as in figure 28. The absorption material can be in larger amounts towards the front 480 than toward the rear 282 be distributed since the front of the particular absorbent article may require higher absorption. The front and back sides 480 and 282 of the core can be shorter than the long sides 284 and 286 be of the core. The core wrap can be made from two nonwoven materials, substrates, laminates or other materials 216 , 216' are formed, at least in part along the sides 284 , 286 of the absorbent core 228 can be sealed. The core wrap may be at least partially along the front 480 , the back 282 and the two long sides 284 , 286be sealed such that substantially no absorbent material can escape from the core wrap of the absorbent article. The first material, substrate or fleece 216 can be at least partially the second material, substrate or fleece 216' surrounded to correspond to the illustration in figure 34 to form the core wrap. The first stuff 216 can be a section of the second material 216' near the first and second margins 284 and 286 surround.

[0113] The absorbent core may include adhesives, for example to immobilize the SAP polymers or other absorbent materials in the core wrap and / or to ensure the integrity of the core wrap, particularly when the core wrap consists of two or more substrates. The adhesive may be a hot melt adhesive such as that supplied by H.B Fuller. The core wrap may extend over an area greater than is strictly necessary to contain the absorbent material therein.

[0114] The absorbent material may be a continuous layer present within the core wrap. Alternatively, this may consist of individual pockets or strips of absorbent material encased within the core wrap. In the first case, the absorbent material can be obtained, for example, by applying a single continuous layer of absorbent material. The continuous layer of absorbent material, particularly SAP, can also be obtained by combining two absorbent layers with discontinuous absorbent material application patterns, the resulting layer being formed, for example, as disclosed in US Patent Application Patent Application Publication No. 2008 / 0312622A1 to Hundorf et al. is substantially continuously distributed over the surface of the absorbent particulate polymeric material. The absorbent core 228 may have a first absorbent layer and a second absorbent layer. The first absorption layer can be the first material 216 and a first layer 261 made of absorbent material that is 100% or less SAP may have. The second absorbent layer can be the second material 216' and a second layer 262 made of absorbent material that is 100% or less SAP may have. The absorbent core 228 can also be a fibrous thermoplastic adhesive material 251 comprising at least partially each layer of absorbent material 261 , 262 to the related material 216 or 216' binds. This is as an example in figure 34-35 with the first and second SAP layers applied as transverse stripes or "landings" to have the same width as the desired absorbent material application area on their respective substrates prior to bonding. The strips may have varying amounts of absorbent material (SAP) to fit along the longitudinal axis of the core 280 to provide a profiled basis weight. The first stuff 216 and the second material 216' can form the core envelope.

[0115] The fibrous thermoplastic adhesive material 251 can at least partially with the absorbent material 261 , 262 in the landing surfaces are in contact, and it can be at least partially with the materials 216 and 216' be in contact in the connection areas. This imparts the fibrous layer of thermoplastic adhesive material 251 , which itself has a substantially two-dimensional structure with a relatively small thickness, a substantially three-dimensional structure compared to the dimension in the lengthwise and widthwise directions. This allows the fibrous thermoplastic adhesive material to provide cavities to cover the absorbent material in the landing areas so that this absorbent material is immobilized which is 100% SAP or less.

[0116] The thermoplastic adhesive for the fibrous layer may have elastomeric properties such that the web formed by the fibers on the SAP -layer is formed, is able to be stretched while the SAP swell. Super absorbent polymer (SAP)

[0117] The SAP useful with the present disclosure can include a variety of water-insoluble but water-swellable polymers capable of absorbing large amounts of liquids.

[0118] The superabsorbent polymer can be in particulate form so that it is flowable when dry. Absorbent polymer particulate materials can be made from poly(meth)acrylic acid polymers. However, starch-based absorbent polymer particulate materials can also be used, such as polyacrylamide copolymer, ethylenemaleic anhydride copolymers, crosslinked carboxymethyl cellulose, polyvinyl alcohol copolymers, crosslinked polyethylene oxide, and starch-grafted copolymer of polyacrylonitrile.

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

[0120] For most absorbent articles, liquid discharges from a wearer occur predominantly in the front half of the absorbent article, particularly for a diaper. The front half of the article (as defined by the area between the front edge and a transverse line, at a distance of half an L from the front waist edge 210 or back waistline 212 placed) can therefore comprise most of the absorbent capacity of the core. Thus, in the front half of the absorbent article, at least 60% of the SAP, or at least 65%, 70%, 75%, 80% or 85% of the SAP be present while the remaining SAP may be located in the back half of the absorbent article. Alternatively, the SAP distribution may be uniform throughout the core, or may have other suitable distributions.

[0121] The total amount of SAP that is present in the absorbent core can also vary according to the expected user. Newborn diapers may require less SAP than infant, child, or adult incontinence diapers. The amount of SAP in the core can be about 5 to 60 g or from 5 to 50 g. The average basis weight of SAP in the (or "in which at least one" if there is more than one) separation area 8 of SAP can be at least 50, 100, 200, 300, 400, 500 or more g / m 2 be. The areas of the channels (e.g. 226 , 226' , 227 , 227' ) that are in the deposition area 8 are present are derived from the deposition area of ​​the absorbent material to calculate this average basis weight. core wrap

[0122] The core wrap may be made from a single substrate, material or web folded around the absorbent material, or may comprise two (or more) substrates, materials or webs attached to one another. Typical attachments are the so-called C-wrap and / or a sandwich wrap. In a C shell, such as in the figure 29 and figure 34, the longitudinal and / or transverse edges of one of the substrates are folded over the other substrate to form folds. These envelopes are then attached to the outer surface of the other substrate, typically by gluing.

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

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

[0125] The core wrap may be at least partially sealed along all sides of the absorbent core such that substantially no absorbent material leaks out of the core. By "essentially no absorbent material" is meant that less than 5%, less than 2%, less than 1%, or about 0% by weight of absorbent material escapes from the core wrap. The term "sealing" is to be understood in a broad sense. The seal need not be continuous along the entire perimeter of the core cladding, but may be discontinuous along part or all of it, for example formed as a series of sealing points spaced apart in a line. A seal can be formed by gluing and / or thermal bonding.

[0126] If the core cladding by two substrates 216 , 216' is formed, four gaskets can be used to seal the absorbent material 260 confine within the core envelope. For example, a first substrate 216 on one side of the core (the top, as in the figure 33-35) and extending around the longitudinal edges of the core to at least partially wrap the opposite underside of the core. The second substrate 216' between the wrapped flaps of the first substrate 216 and the absorption material 260 to be available. The flaps of the first substrate 216 can on the second substrate 216' glued to provide a strong seal. This so-called C-wrap construction can offer advantages such as improved resistance to bursting in a wet loaded condition compared to a sandwich wrap. The front and back of the core wrap can then also be sealed by adhering the first substrate and the second substrate to provide complete containment of the absorbent material around the entire perimeter of the core. For the front and back of the core, the first and second substrates may extend in a substantially planar direction and be butted together, forming a so-called sandwich construction for these edges. In the so-called sandwich construction, the first and second substrates may extend outwardly on all sides of the core and be sealed flat, or substantially flat, along all or part of the perimeter of the core, usually by gluing and / or thermal bonding / compression bonding. In one example, neither the first nor the second substrate need be shaped so that it can be cut square to facilitate manufacturing, however other shapes are also within the scope of the present disclosure.

[0127] The core wrap can also be formed from a single substrate which can enclose the absorbent material as in a packet wrap and which can be sealed along the front and back of the core and a longitudinal seal. SAP separation area

[0128] The absorbent material deposition area 208 can be defined by the perimeter of the layer covered by the absorbent material 260 formed within the core wrap as viewed from the top of the absorbent core. The absorbent material deposition area 208 may have various shapes, in particular a so-called "dogbone" or "hourglass" shape, which has a taper along its width towards the central or "crotch" region of the core. In this way, the absorption material deposition area 8 have a relatively narrow width in an area of ​​the core intended to be placed in the crotch area of ​​the absorbent article, as in figure 28 shown. This can provide better wearing comfort. The absorbent material deposition area 8 may also be generally rectangular, such as in FIGS figure31-33, however, other deposition regions such as a rectangular, "T", "Y", "hourglass" or "dog bone" shape are also within the scope of the present disclosure. The absorbent material can be manufactured using any suitable method which allows relatively accurate separation of SAP at relatively high speed. channels

[0129] The absorbent material deposition area 208 can at least one channel 226 comprise, at least partially in the longitudinal direction of the article 280 is aligned (i.e. has a longitudinal vector component) as in FIGS figure 28 and figure 29 shown. Other channels may be at least partially aligned in the transverse direction (i.e., have a vector component in the transverse direction) or in any other direction. In the following, the plural form "channels" is used to mean "at least one channel". The channels can be one on the longitudinal axis 280 of the article have a projected length L' which is at least 10% of the length L of the article. The channels can be formed in a variety of ways. For example, the channels can pass through zones within the absorbent material deposition area 208 be substantially free of, or free of, absorbent material, particularly SAP. In another example, the channels may pass through zones within the absorbent material deposition area 208 are formed where the absorbent material of the core is cellulose, airfelt, SAP or combinations thereof, and the channels may be substantially free of, or free of, absorbent material, particularly that SAP , cellulose, or airfelt. Additionally or alternatively, the channel(s) may also be formed by continuously or discontinuously bonding the top of the core wrap to the bottom of the core wrap through the absorbent material deposition region 208 are formed. The channels can be continuous, but it is also envisaged that the channels can be discontinuous. The intake distribution system or intake distribution layer 250 or another layer of the article may also include channels, which may or may not correspond to the channels of the absorbent core.

[0130] In some cases, the channels can be at least at the same longitudinal level as the crotch point C or the transverse axis 260 be present in the absorbent article, as in figure 28 with the two longitudinally extending channels 226 , 226' shown. The channels can also extend from the crotch area 207 extend out or can in the front waist area 205 and / or in the back waist area 206 of the article are available.

[0131] The absorption core 228 may also comprise more than two channels, for example at least 3, at least 4, at least 5 or at least 6 or more. Shorter channels can also be present, for example in the back waist area 206 or the front waist area 205 of the nucleus, as through the pair of canals 227 , 227' in figure 28 shown to the front of the article. The channels may comprise one or more channels relative to the longitudinal axis 280 are arranged symmetrically or otherwise.

[0132] The channels can be particularly useful in the absorbent core when the absorbent material deposition area is rectangular, as the channels can improve the flexibility of the core to an extent that using a non-rectangular (shaped) core is less advantageous. Of course, channels can also be present in a SAP layer with a shaped deposition surface.

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

[0134] In order to reduce the risk of liquid spillage, the longitudinal main channels may not extend to one of the edges of the absorbent material deposition area 208 and can therefore be entirely within the absorbent material deposition range 208 be surrounded by the core. The smallest distance between a channel and the nearest edge of the absorbent material deposition area 208 can be at least 5 mm.

[0135] The channels can have a width WC along at least part of its 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 through an absorbent material-free zone within the absorbent material deposition area 208 are formed, the width of the channels is taken to be the width of the free zone of material, ignoring the possible presence of core cladding in the channels. If the channels are not formed by absorbent material-free zones, for example mainly by binding the core wrap through the absorbent material zone, then the width of the channels is the width of this connection.

[0136] At least some or all of the channels may be permanent channels, meaning that their integrity is at least partially maintained in both dry and wet states. Permanent channels can be achieved by providing one or more adhesive materials, for example the fibrous layer of adhesive material or construction glue, to help bond a substrate to an absorbent material within the walls of the channel. Permanent channels can also be formed by separating the top and bottom of the core cladding (e.g., the first substrate 216 and the second substrate 216' ) and / or the upper class 224 with the underclass 225 connected by the channels. Typically an adhesive can be used to bond both sides of the core wrap or the topsheet and backsheet through the channels, however it is also possible to bond via other known methods such as pressure bonding, ultrasonic bonding, thermal bonding or a combination thereof. The core wrap or topsheet 224 and the underclass 225 may be connected continuously or intermittently along the channels. The channels may advantageously remain or become visible at least through the topsheet and / or backsheet when the absorbent article is fully loaded with a liquid. This can be achieved by keeping the channels essentially free of SAP are made so that they do not swell and are sufficiently large that they do not close when wet. It may also be advantageous to bond the core wrap to itself or the topsheet to the backsheet through the channels. barrier leg cuffs

[0137] The absorbent article can include a pair of barrier leg cuffs 34 include. Each barrier leg cuff may be formed by a piece of material joined to the absorbent article so that it can extend upwardly from a wearer-facing surface of the absorbent article and provide improved containment of fluids and other body exudates approximately at the junction of the torso and legs of the Carrier can provide. The barrier leg cuffs are from a near edge 64 bounded, directly or indirectly, with the upper class 224 and / or the underclass 225 connected, and a free end edge 266 designed to contact and form a seal with the wearer's skin. The barrier leg cuffs 234 extend at least partially between the front waist edge 210 and the back waistline 212 of the absorbent article on opposite sides of the longitudinal axis 280 and are at least in the plane of the step point ( C ) or crotch area. The barrier leg cuffs can be attached to the proximal edge 264with the basic unit of the article by a bond 265 be connected, which can be produced by gluing, fusion bonding or a combination of other suitable connection methods. The connection 265 at the proximal edge 264 can be continuous or discontinuous. The binding closest to the raised portion of the leg cuffs 265 limits the proximal edge 264 the standing section of the leg cuffs.

[0138] The barrier leg cuffs can be tucked into the top layer 224 or the underclass 225 integrated or may be a separate material connected to the basic unit of the article. Any blocking leg cuffs 234 can be one, two or more elastic threads 235 near the exposed end edge 266 included to provide a better seal.

[0139] In addition to the barrier leg cuffs 234 the article can seal cuffs 232 associated with the chassis of the absorbent article, particularly the topsheet 224 and / or the underclass 225 and are placed externally in relation to the barrier leg cuffs. The sealing cuffs 232 may provide better closure about the wearer's thighs. Each gasket leg cuff may have one or more elastic threads or elastic members 233 in the chassis of the absorbent article between the topsheet 224 and underclass 225 in the area of ​​the leg openings. All or a portion of the barrier leg cuffs and / or gasket cuffs may be treated with a lotion or other skin care composition. Recording Distribution System

[0140] The absorbent articles of the present disclosure can have an intake-distribution layer or system 250 (“ADS”). A function of the ADS is to rapidly acquire one or more of the fluids and efficiently distribute them to the absorbent core. The ADS can comprise one, two or more layers, which can form a unitary layer or can remain separate layers that can be attached to one another. In one example, the ADS may include two layers: a distribution layer 254 and a receiving layer 252 disposed between the absorbent core and the topsheet, however, the present disclosure is not so limited.

[0141] In one example, the three-dimensional nonwoven materials of the present disclosure can include the topsheet and acquisition layer as a laminate. A distribution layer may also be provided on the garment facing side of the topsheet / binding layer laminate. backing layer

[0142] In an instance where the high loft three-dimensional nonwoven materials of the present disclosure comprise a topsheet and acquisition layer laminate, the distribution layer may need to be supported by a backing layer (not shown), which may comprise one or more nonwoven or other materials. The spreading layer may be coated on or positioned on the backing layer. Accordingly, the backing layer can be positioned between the acquisition layer and the distribution layer and in face-to-face relationship with the acquisition layer and the distribution layer. distribution layer

[0143] The distribution layer of the ADS may comprise at least 50% by weight crosslinked cellulosic fibers. The crosslinked cellulosic fibers may be compressed, twisted, or crimped, or a combination thereof that includes compressed, twisted, and crimped. This type of material is disclosed in US Pat. Publication No. 2008 / 0312622 A1 (Hundorf). The crosslinked cellulosic fibers provide higher resilience and hence higher resilience of the first absorbent layer against compression in product packaging or under conditions of use, e.g. B. under the weight of a wearer. This can provide the core with higher void volume, permeability and liquid absorption, and hence reduced leakage and improved dryness.

[0144] The distribution layer comprising the crosslinked cellulosic fibers of the present disclosure may comprise other fibers, but advantageously this layer may comprise at least 50%, or 60%, or 70%, or 80%, or 90% by weight. -% or even up to 100% by weight of the layer of crosslinked cellulosic fibers (including the crosslinked cellulosic fibers). recording layer

[0145] When a three-dimensional nonwoven material of the present disclosure is provided solely as the topsheet of an absorbent article, the ADS 250 a capture layer 252 include. The acquisition layer can be between the spreading layer 254 and the upper class 224 be arranged. The recording layer 252 may in such a case comprise a nonwoven material, for example a hydrophilic SMS or SMMS material comprising a spunbond, a meltblown and another spunbond layer, or alternatively a carded chemically bonded staple fiber web. The non-woven material can be latex bonded. fastening system

[0146] The absorbent article may include a fastening system. The fastening system can be used to provide lateral tensions around the perimeter of the absorbent article to hold the absorbent article on the wearer, as is conventional with fastener diapers. This fastening system may not be necessary for training pant items since the waist area of ​​these items is already tied. The fastening system can include a fastener such as tape tabs, hook and loop fastener components, interlacing fasteners such as side tabs and slots, buckles, buttons, snaps, and / or hermaphroditic fastening components, although any other suitable fastening mechanisms are also within the scope of the present disclosure. A landing zone 244 is usually on the garment facing surface of the front waist area 205 provided to allow the fastener to be releasably attached thereto. Anterior and posterior lateral lobes

[0147] The absorbent article may have front side flaps 246 and posterior lateral lobes 240 include. The side flaps can be an integral part of the chassis, such as the topsheet 224 and / or the underclass 226 formed as side elements. Alternatively, as in figure 28 illustrates that the side tabs can be separate elements attached by gluing, hot stamping and / or pressure bonding. The posterior lobes 240 can be stretchy to attach the tabs 242 at the impact zone 244 to simplify and keep the taped diapers in place around the wearer's waist. The posterior lateral lobes 240 may be elastic or stretchable to provide a more comfortable and contoured fit by initially fitting the absorbent article comfortably to the wearer and maintaining that fit throughout wear time long after the absorbent article has been loaded with liquids or other body exudates, since the elasticized side flaps allow the sides of the absorbent article to expand and contract. Elastic waist feature

[0148] The absorbent article 220 may have at least one elastic waist feature that helps provide improved fit and containment. The elastic waist feature is generally designed to elastically expand and contract to dynamically fit the wearer's waist. The elastic waist feature can extend longitudinally outward from at least one waist edge of the absorbent core 228 extending and generally forming at least a portion of the end edge of the absorbent article. Disposable diapers can be constructed to have two elastic waist features, one positioned in the front waist area and one in the back waist area. color signals

[0149] In one form, the absorbent articles of the present disclosure can have different colors in different layers, or portions thereof (e.g., topsheet and acquisition layer, topsheet and nonwoven core cover, a first portion and a second portion with a topsheet, a first portion and second portion the recording layer). The different colors can be shades of the same color (e.g. dark blue and light blue) or can actually be different colors (e.g. purple and green). The various colors may have a Delta E in the range of about 1.5-10, about 2-8, or about 2-6, for example. Other delta-E ranges are also within the scope of the present disclosure.

[0150] In one case, different layers of the absorbent articles can be joined using a colored adhesive. The colored adhesive can be patterned onto any suitable layer or layers. The pattern of the adhesive may or may not complement the pattern of the topsheet. Such a pattern can increase the appearance of depth in an absorbent article. In certain cases, the colored glue may be blue.

[0151] In other instances, each of the layers may include indicia, such as a printed ink, to aid in the appearance, depth perception, absorption perception, or quality perception of the absorbent articles.

[0152] In other cases, the colors may be complementary to or registered with the patterns of three-dimensional features of the nonwoven 10 used as a component in an absorbent article. For example, a fabric having first and second zones of optically different patterns of three-dimensional features may also have ink printed thereon to effect the change in the visual appearance of fabric 10 to emphasize, emphasize, contrast with or otherwise alter. The color enhancers can help in imparting certain functional properties to the nonwoven 10 be useful to a user of an absorbent article in use. The color can be used in combination with structural, three-dimensional features in one component, or in combinations of components to provide a visually distinctive absorbent article. For example, a second topsheet or acquisition layer may have a pattern of color(s) printed thereon representing the pattern of three-dimensional features of a fabric 10 used as a topsheet in an absorbent article. Another example is an absorbent article that includes: 1) an absorbent core with a channel, 2) a topsheet with a three-dimensional pattern that registers with or highlights the channel or channels in the core, and 3) a graphic, colored Component, printed ink, or markings visible from the topsheet facing (bodyside surface) or backsheet facing (garment facing surface) to further emphasize the functional characteristics of the core channel(s) and the overall performance of the absorbent article.

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

[0154] The benefit of considering microzones in the present disclosure is to illustrate that in addition to the differences in average intense properties in a zone, such as Zone 110 , 120 , and 130 As discussed above, the present disclosure also provides fabrics that exhibit differences in actual and / or average intensity properties between regions defined by three-dimensional features within a zone, where the three-dimensional features are designed according to the design of the fabrics manufacturing process be placed precisely using the shaping bands used. The difference in intense properties between the areas of three-dimensional features provides additional visual as well as functional advantages. The sharp visual contrast between areas can provide extremely subtle, visually distinguishable designs within and between zones. Likewise, the precise placement of zones made possible by the precisely manufactured shaping tape can provide excellent and tailored softness, strength and fluid handling properties of the zones. Thus, in one embodiment, the invention provides for the unexpected combination of differences in average intense properties between zones and, at the same time, differences in intense properties of the regions that make up a microzone.

[0155] Regions defined by three-dimensional features can be identified with reference to FIG figure 38 and figure 39 be understood. figure 38 shows a light micrograph of a section of fabric 10 according to the present disclosure, and figure 39 shows a scanning electron microscope (SEM) of a cross section of the in figure 38 fabric section shown. So they show figure 38 and figure 39 a section of a non-woven fabric 10 , which has been enlarged to better describe the otherwise visually identifiable characteristics of the substance. The section of non-woven fabric 10 , the in figure 38 is approximately 36 mm in CD and has portions of at least three optically distinct zones, as discussed below.

[0156] Both figure 38 and figure 39 showing a section of a pattern of non-woven fabric 10 show is a first zone 110 (on the left of figure 38) by generally MD aligned rows of first regions 300 variable width characterized by MD aligned rows of second regions 310 variable width are separated. The first area is also the three-dimensional feature 20 , which the first and second areas 300 , 310 Are defined. In one embodiment, a three-dimensional feature is a section of the nonwoven fabric 10 formed between or around a raised element of the forming belt, which in this description is the first region 300 is such that the resulting structure has a relatively larger dimension in the Z-direction. The adjacent second area 310 generally exhibits a common intensive property with the first area 300 and in one embodiment has relatively lower caliper values, i. H. a smaller dimension in the Z-direction. The relative z-direction dimensions with respect to a plane of the first surface 16 , as described above, are in figure 39 illustrated. Absolute dimensions are not critical; however, the dimensional differences can also be seen on the non-woven fabric without magnification 10 be distinguishable.

[0157] The invention of the disclosure allows for beneficial properties that are best expressed in terms of the domains defined by three-dimensional features in microzones. For example, as in figure 38 shown in the zone 110 for each three-dimensional feature 20 a visual distinction between a first area 300 and a second area 310. As stated above, the visible distinction in the nonwoven 10 present without magnification; the enlarged views used herein are for clarity of disclosure. Any area that extends beyond the boundary between a sufficient amount of the first area 300 and the second area 310 extended so that a difference in their respective intense properties can be detected within the range may be a microzone. Additionally, light microscopy or microCT imaging of a structure can also be used to determine the location of regions and the area of ​​a microzone.

[0158] the inside figure 38 shown section of the non-woven fabric 10 further illustrates a beneficial property of the fabric 10 in that the differences in intensity properties between adjacent areas may be cross-zonal differences. Thus, a microzone can be identified spanning an area that is the second area 310 from Zone 120 and the first area 300 from Zone 130 includes. In certain embodiments, including that in FIGS figure 38 and figure 39 non-woven fabric shown 10 , the difference in intense properties exhibited by regions within microzones can mean that a zone boundary can be of a significantly different magnitude than the differences between intense properties exhibited by regions within a zone.

[0159] Regardless of which zone or zonal boundary encompasses a particular microzone, the three-dimensional features can be characterized by the differences between the intense properties of the areas they define. In general, the nonwoven fabric of the present disclosure can be a spunbonded nonwoven fabric having a first surface that defines a plane of the first surface. The fabric may have a plurality of three-dimensional features, each three-dimensional feature defining a first region and a second region, the regions having a common intense property that has a different value between them. In one embodiment, the first region may be distinguished as being at a greater elevation than the second region with respect to the plane of the first surface, thereby presenting a difference in each region's common intensive property of thickness. The two regions can also be distinguished as having different densities, basis weights and volumetric densities. That is, the two regions can be distinguished within a microzone of the spunbonded nonwoven as distinct in terms of common intense properties, including properties such as caliper, density, basis weight, and volumetric density. In one embodiment, one or both regions of a microzone can be liquid permeable. In one embodiment, the higher density region of a microzone can be liquid permeable.

[0160] Inside the zone 110 of the in figure 38, for example, can have three-dimensional features 20 be present that define at least two areas, a first area 300 and a second area 310 . The difference in caliper, basis weight, and volumetric density between the first and second regions for the in figure 38 zone shown 110 can be 274 microns, 1 gram per square meter and 0.437 g / cm respectively 3 be.

[0161] Also can within the zone 130 of the in figure 38, three-dimensional features, for example 20 be present that define at least two areas, a first area 300 and a second area 310 . The difference in caliper, basis weight, and volumetric density between the first and second regions for the in figure 38 zone shown 130 can be 2083 microns, 116 grams per square meter and 0.462 g / cm respectively 3 be.

[0162] Furthermore, within the zone 120 of the in figure38, three-dimensional features, for example 20 be present that define at least two areas, a first area 300 and a second area 310 . The difference in caliper, basis weight, and volumetric density between the first and second regions for the in figure 38 fabric section shown may be 204 microns, 20 grams per square meter and 0.53 g / cm respectively 3 be. In the illustrated embodiment, Zone 120 something in an unmagnified view of non-woven fabric 10 as a sewn border between the zones 110 and 130 appears, formed.

[0163] Continue to exist in a zone, which is the boundary between zones 120 and 130 the in figure 38 illustrated fabric sections comprises, for example, at least two areas, a first area 300 in zones 130 and a second area 310 in zones 120 . The difference in caliper, basis weight, and volumetric density between the first and second regions for the in figure 38 fabric section shown may be 2027 microns, 58 grams per square meter and 0.525 g / cm respectively 3 be.

[0164] The microzones are described in more detail below with reference to FIGS figure 40-42 and the in figure 44 discussed data. the figure 40-42 are micro-CT scans of a section of non-woven fabric 10 , which in its pattern resembles that of the in figure 38 non-woven fabric shown 10 resembles. The microCT scan allows the description of the same features as in figure 38 in a slightly different way and in a way that allows for a very accurate measurement of the intense properties.

[0165] As in figure 40 are the zones 110 , 120 and 130 with their respective three-dimensional characteristics 20 clearly visible. As in the figure 40 and figure 41, the three-dimensional features are the dark colored portions, with the dark color also being the first region 300 a three-dimensional feature 20 represents, and the adjacent light portions are the second area 310 for the three-dimensional feature 20 .

[0166] The microCT scan allows the image to be “sliced” and divided cross-sectionally, as through the slice plane 450 in figure 41 shown. A section plane can be placed anywhere on the image; for the purpose of the present disclosure, the cutting plane intersects 450 a cross-section substantially parallel to the Z-axis so as to provide the cross-sectional image in figure 42 to generate.

[0167] MicroCT technology allows precise and direct measurement of intense properties. Thickness measurements can be taken directly from imaged cross-sections based on scale-up, such as B. the in figure 42 cross-section shown. Furthermore, the color difference between first areas and second areas is representative and proportional to the differences in basis weight, volumetric density and other intense properties, which can also be measured directly. The MicroCT methodology is explained below in the Test Methods section.

[0168] figure 43 is a microCT scan image of the section of non-woven fabric 10 , that in the figure 40 and figure 41 is shown. Use for specific first and second areas that are numbered sections of nonwoven fabric 10 are shown can be analyzed. In figure 43 specific areas were manually selected and analyzed to measure caliper, basis weight, and volumetric density, and the data are presented in figure 44 reproduced.

[0169] figure 44 shows data for the grouping of measurements of the first and second regions within the in figure 44 illustrated three zones. The x-axis are the areas where the numbers correspond to the numbered areas in figure43 match. Measurements of the first area are denoted as Fn (e.g. F1) and measurements of the second area are denoted as Sn (e.g. S1). Thus are the areas 1 - 5 first areas F1 , located respectively in the zone 110 are located. The areas 6 - 10 are second areas S1 who are also in the zone 110 are located. Likewise are the first areas F2 the areas 16 - 20 in zone 120 , and the areas 11 - 15 and 21 - 25 are second areas S2 in zones 120 . Finally, the areas 31 - 35 first areas F3 in zone 130 , and the areas 26 - 30 are second areas S2 in zones 130 . The numbered areas are across all three graphs of figure 44 shown throughout, but the zones are 110 , 120 and 130 only shown on the thickness distribution map for the sake of simplicity.

[0170] In the figure The graphs shown in Figures 44-44 graphically represent the difference in magnitude of the intense features between the first regions and the second regions within each of the zones and can be used to graphically see the difference in the intense features for pairs of regions making up a micro-zone. For example, it can be seen that in Zone 110 the basis weight between the two regions can be substantially the same, but the thickness (caliper) can vary from about 400 microns in the first regions to about 40 microns in the second regions, or by a difference of about 10X. The volumetric density in Zone 110 can be from about 0.1 g / cm 3 to about 0.6 g / cm 3 vary. Similar quantifiable distinctions are understood for each of the zones shown.

[0171] In this way, referring to figure 43 and figure 44 together a further characterization of the advantageous structure of a substance 10 of the present disclosure. the fleece 10 can be described as having at least two optically distinct zones, e.g. B. the zones 110 and 120 , each of the zones having a pattern of three-dimensional features, each of the three-dimensional features being a micro-zone having first and second regions, e.g. B. the areas 300 , 310 , and wherein the difference in values ​​for at least one of the micro-zones in the first zone differs quantifiably from the difference in values ​​for at least one of the micro-zones in the second zone. For example are in figure 43 two representative microzones 400 in the zone 130 referred to as the pair of realms, referred to as the realms 31 and 27 and 33 and 26 are marked. That is, the first area 31 and the second area 27 form a microzone, and the first area 33 and the second area 26 form a microzone. Likewise, two representative microzones 400 in the zone 120 referred to as the pair of realms known as realms 19 and 24 and 17 and 22 are marked. Starting from figure 44, Tables 4-7 can be filled in as shown: Table 4: Illustrative examples of differences in thickness in microzones Thickness (microns) Difference in thickness (microns) 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 basis weight differences in microzones Basic Weights (grams per square meter) Differences in basis 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 / cm 3 ) Difference in volumetric density (g / cm 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 intensive properties in different zones: Thickness (microns) thickness differences Basic Weights (grams per square meter) base weight differences Volumetric density (g / cm 3 ) Volumetric Density Differences zone 130 2147 149 0,069 First area 32 2118 135 0,423 Zone 110 Second Area 8 29 14 0,492

[0172] The four representative microzones from two zones are shown in Tables 4-6 for illustrative purposes. However, it should be understood that each pair of first and second regions in figure43 could equally be quantified to fill in additional rows in Table 4, but for the sake of succinctness this is not done. In general, for any fabric having two or more zones, each zone having a pattern of three-dimensional features defining microzones, the intensive properties can be measured and as herein referred to in FIG figure 43 and figure 44 can be tabulated to track both the difference in intense property values ​​within a zone and the differences in intense property values ​​between one area of ​​the first zone and another area in a second zone.

[0173] A microzone spanning two zones, like the zones 110 and zones 130 , can show an even greater difference in intense properties relative to a microzone within a single zone. For example, considering the data for a microzone, which has a first range of zone 130 spanned, for example in the first area 32 , and a second range of Zone 110 , for example in the second area 8 , the microzone shows dramatic differences in both thickness, basis weight and volumetric density. The thickness of the first region 32 from Zone 130 is about 2100 microns, while the thickness of the second region 8 from Zone 110 is about 29 microns or a differential value of about 72X. Likewise, the basis weight of the first area 32 from Zone 130 be as high as 150 grams per square meter, while the basis weight of the second area 8 from Zone 110 about 14 grams per square meter or a differential value of about 10X. Furthermore, the volumetric density of the first area 32 from Zone 130 about 0.069 g / cm 3 be, while the volumetric density of the second region 8 from Zone 110 about 0.492 g / cm 3 or a difference value of about 7X.

[0174] For each of the parameters of the measured intense properties of the different areas of a microzone, such a measurement is made using the micro-CT method described herein. The resolution used for the method aids in deriving the intense properties of microzonal regions so that difference comparisons and ratio comparisons of regions can be dimensioned as described herein.

[0175] Another characterization of a substance 10 can refer to the figure 45-49, in which the SEMs show certain aspects of the nonwoven 10 and the areas within it in more detail. the figure 45-49 are photographs of enlarged sections of Zone 110 of the in figure 38 fabric shown. the inside figure 38 shown nonwoven 10 was made according to the method described above with reference to figure 7 was made in which the fabric was processed through a nip formed by compaction rollers 70 and 72 was formed, the roller 72 , which is the first page 12 touched, is heated to partially bond the fibers in the second regions 301 bring about. the figure 45 (facing the belt) and 46 (facing the heated compaction roll) are each SEMs of a portion of the second surface 14 or the first surface 12 , magnified 20X. the figure 47 (facing the belt) and 48 (facing the heated compaction roller) are each photographs of a portion of the second surface 14 or the first surface 12 , magnified 90X, and showing in detail the advantageous structuralcharacteristic of the partial bonding of fibers caused by the compaction rollers 70 and 72 are formed.

[0176] How best in the figure 47 and figure 48 and the cross-sectional view of FIG figure49, the heated compaction rollers can thermally bond fibers in varying degrees with a beneficial effect on the whole fabric 10 bring about. As shown, the fibers in contact with a heated roller, e.g. B. Roller 70 in contact with the first surface 12 of fabric 10 , to be fusion bonded, leaving the first surface 12 experiences proportionately more fiber-to-fiber bonding than the second surface 14 . In one embodiment, the bonded fibers 80 the first surface may be substantially completely fusion bonded to effectively form a film skin of bonded fibers while the fibers in the second region 310 on the second page 14 experience little or no attachment. This feature allows a nonwoven fabric 10 for use in an absorbent article, e.g. as a topsheet, to maintain physical integrity during manufacture and use, as well as relative softness on one side, which may be the skin-contacting side facing the user.

[0177] Even in the microzones of greatest caliper differential, this "bond thinning" serves the purpose of maintaining web integrity while not significantly affecting softness, or other beneficial properties such as liquid handling properties. As referring to the figure 50-53, the difference in the degree of thermal fiber bonding can be such that the fibers are on the first surface 12 in a second area 310 may be complete, or substantially complete, with the degree of thermal fiber bonding on the second surface 14 in a first area 300 may have minimal to no thermal bonding.

[0178] figure 50 again shows the section of non-woven fabric 10 , the in figure 38 is shown. the figure 51-53 show magnified images of a microzone found in figure 50 as a first range 300 and a second area 310 is denoted, which visually appears to be a hole or opening. the figure 51 and figure 52 show the microzone as it appears on the second surface 14 appears, enlarged to 40X and 200X respectively. figure 53 shows the second area 310 , like him on the first page 12 appears under 200X magnification. The fibers in the second area 310 are fully, or substantially fully, bonded while the fibers are in the first region 300 are completely, or substantially completely, unbound. The advantage of the illustrated structure is that one microzone can act as a liquid permeable opening while the bonded areas of the second area 310 at the same time serve to ensure the physical integrity of the substance 10 to maintain.

[0179] Microzones therefore play a significant role in the overall physical structure and functioning of a fabric 10 of the present invention. By producing relatively closely spaced, precisely designed three-dimensional features enabled by the forming tape of the present disclosure, a fabric 10 to have optically distinct zones, micro-zones and three-dimensional features that demonstrate functional superiority at least in the areas of 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 10 designed for both strength and softness, both form and function.

[0180] figure 54 is a microCT scan image of the section of non-woven fabric 10 , similar to that in the figure 40 and figure 41, but with the additional processing step of forming point bonds 90 in the nip of the calender rolls 71 and 73 were subjected to. As above in relation to the discussion of figure 43 and figure44, for certain point bonding microzones 400 the first and second areas appearing as numbered sections of the nonwoven fabric 10 are depicted, are analyzed and include dot bound areas, particularly in the numbered sections 31 - 35 . For example, form adjacent areas 32 and 26 a micro zone 400 in the third zone 130 . In figure 54, the specific areas were highlighted to identify areas enclosing the additional point bond areas and analyzed to measure caliper, basis weight, and volumetric density, and these data are presented in figure 55 wherein the caliper, basis weight and volumetric density of all areas, including point bond areas, are quantified and compared.

[0181] figure 55 shows data for the grouping of measurements of the first and second areas within the in figure 54 illustrated three zones. the x- Axis are the areas where the numbers correspond to the numbered areas in figure 43 match. Measurements of the first area are reported as Fn (e.g. F1 ) and measurements of the second areas are denoted as Sn (e.g. S1 ) designated. Thus are the areas 1 - 5 first areas F1 , located respectively in the zone 110 are located. The areas 6 - 10 are second areas S1 who are also in the zone 110 are located. Likewise are the first areas F2 the areas 16 - 20 in zones 120 , and the areas 11 - 15 and 21 - 25 are second areas S2 in zones 120 . Finally, the areas 31 - 35 second areas, however, are point bonds 90 , in the figure 55 may be referred to as B1 to distinguish them as formed by a point bonding process in this disclosure. First areas F3 in zones 130 are areas 26 - 30 and 36 - 40 , while the areas 41 - 44 second areas S2 in zones 130 are. The numbered areas are across all three graphs of figure 55 shown throughout, but the zones are 110 , 120 and 130 only shown on the thickness distribution map for the sake of simplicity.

[0182] In the figure The graphs shown in Figure 54 graphically represent the difference in magnitude of the intense properties between the first regions and the second regions within each of the zones of a fabric which has undergone a calender point bonding step and can be used to graphically represent the difference in the intense properties for pairs of regions, forming a microzone. For example, it can be seen that in Zone 110 basis weight can vary between the two ranges within a narrower range than caliper or volumetric density. For example, the thickness can range from about 325 microns in the first areas to about 29 microns in the second areas of the zone 110 , or a difference value of about 10X. The volumetric density in Zone 110 can of about 0.08 g / cm 3 to about 0.39 g / cm 3 vary. Similar quantifiable distinctions are understood for each of the zones shown. In general, areas of a microzone can have widely varying basis weight, caliper, and volumetric density values.

[0183] In this way, referring to figure 54 and figure 55 together a further characterization of the beneficial structure of a substance 10 of the present disclosure with particular reference to thermal calender point bonding 90 be understood. For the purpose of description on the zone 130 three-dimensional features defining a microzone comprising first and second regions that are point-bound regions can be identified and intensive property values ​​quantified. For example, in figure54 a representative point bond microzone 400 in the zone 130 be the pair of areas that are called the areas 26 and 32 or 30 and 35 are marked. That is, the first area 26 and the second area 32 form a point bonding microzone 400 , and the first area 30 and the second area 35 form a point bonding microzone 400 .

[0184] The differences in certain intense properties for point bond microzones are in figure 55 to see. For example, considering the two point bond microzones described above 400 , e.g. B. the two point bond microzones 400 of the respective areas 26 and 32 and 30 and 35 It can be seen that there is a slight difference in basis weight between the first domains and second domains, ranging from about 55 to about 60 grams per square meter, however, the same domains have a significant difference in thickness from about 430 microns to about 460 microns about 125 microns, and a significant difference in volumetric density of about 0.13-0.14 g / cm 3 to about 0.41-0.48 g / cm 3 . More differences in the intense properties can be found by referring to figure 55 to be observed.

[0185] The binding points 90 therefore play a significant role in the overall physical structure and functioning of a substance 10 of the present invention. By adding binding points 90 to the substance 10 A fabric comprising relatively closely spaced, precisely designed three-dimensional features made possible by the shaping tape of the present disclosure 10 be further enhanced to exhibit an unexpected combination of optically distinct zones, micro-zones and three-dimensional features that provide functional superiority in the high-performance combination of softness, strength, low lint and liquid handling, as well as visually pleasing aesthetic designs. The bond point feature ensures that a non-woven fabric 10 Designed for the highest combined performance of strength, softness, fluid handling and visual aesthetics, with particular consideration for both form and function.

[0186] An advantage of the formed nonwoven webs of the present disclosure is improved softness. Softness can be measured using the Emtec Tissue Softness Analyzer available from Emtec Paper Testing Technology, Emtec Electronic, GmbH. Table 5 below lists the softness values ​​as TS7 measurements by the Emtec Tissue Softness Analyzer, according to the Emtec Test Method below. For all of the following Examples 7-9, the mat was made on a belt as described in figure 16, wherein the nonwoven web has an appearance similar to that in figure 2 has. Table 5: TS7 values ​​for formed webs of the disclosure example no side TS7 value (dB V2 rpm) Ratio FS / SS Example 7 First surface 10,30 1,35 second surface 7,59 example 8 First surface 3,51 0,98 second surface 3,59 example 9 First surface 9,61 1,48 second surface 6,47 Example 7:

[0187] A bicomponent spunbonded nonwoven web obtained by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration as described above with reference to Example 2 discussed. The web was placed on a forming belt with a repeating pattern as in figure 16 centrifuged around a fabric while agitation at a linear speed of about 25 meters per minute 10 with an average basis weight of 25 grams per square meter with a repeating pattern of heart shapes, as in figure 2 shown. Fibers of the fabric were passed through compaction rollers 70 , 72 compacted, but instead of being calendered, further bonding was achieved by a through-air bonding unit, as referred to below with reference to FIG figure 56 described at a temperature of 145 degrees C. Example 8:

[0188] A bicomponent spunbonded nonwoven fabric made by spinning a 30:70 ratio of polyethylene sheath (Aspun 6850-A , available from Dow Chemical) and polypropylene core (HG475 FP, available from Borealis) in a round fiber configuration, using a double-bar spunbond process as described in figure 56. The web was formed on a forming belt with a repeating pattern as in figure 16 spun as described above with respect to FIG figure 7, moving at a linear speed of about 152 meters per minute, to an average basis weight of 35 grams per square meter, to form a repeating pattern of heart shapes, as in figure 2 shown. The difference between formed nonwoven webs made according to the process of figure 7 were prepared, and Example 8, is that Example 8 is based on a hybrid of in figure 7 and the procedure described below in figure 56 described, was carried out. In particular, the method involved two spinning beams, as in figure 56, but the final heating step was by calender rolls 71 , 73 , instead of through-air bonding processes. The fibers of the fabric were on the first surface 12 by heated compaction rollers 70A and 72A at 110 °C after the first jet 48A and the compaction rollers 70B and 72B at 110 °C after the second beam 48B bound, and at about 140 C on the calendar rollers 71 and 73 calender-bound before they reach the winder 75 be wound up on a roll. Example 9:

[0189] A bicomponent spunbonded nonwoven fabric made by spinning a 30:70 ratio of polyethylene sheath (Aspun 6850-A , available from Dow Chemical) and polypropylene core (HG475 FP, available from Borealis) in a round fiber configuration, using a double-bar spunbond process as described in figure 56. The web was formed on a forming belt with a repeating pattern as in figure 16 centrifuged, with agitation at a linear speed of about 228 meters per minute, at an average basis weight of 25 grams per square meter to form a repeating pattern of heart shapes, as in figure 2 shown. The fibers of the fabric were on the first surface 12 by heated compaction rollers 70A and 72A at 110 °C after the first jet 48A and the compaction rollers 70B and 72B at 110 °C after the second beam 48B bound further, and to three heat zones 100 C, 135 C and 135 C of the through-air bonder 76 (as in figure 56 pictured) bound by hot air flow before they reach the winder 75 were wound up on a roll.

[0190] Examples 7-9 are representative of formed nonwoven fabrics of the present disclosure that exhibit improved softness as indicated by Emtec measurements. The measured Emtec values ​​can vary from about 1 dB V 2 RPM to about 15 dB V 2 RPM, or about 3 dB V 2 RPM to about 10 dB and V 2 RPM, or about 5 dB V 2 RPM to about 8 dB V 2 rpm. In general, the measured Emtec readings for either the first surface or the second surface can be any integer value up to about 15 dB V 2 rpm, and any range of integers between 1 and 15. Also, in general, the ratio of the measured Emtec value for the first side to the second side can be between 1 and 3 and any real number between 1 and 3.

[0191] Without wishing to be bound by theory, it is believed that the improvement in softness exhibited by the formed nonwoven fabrics of the present invention is achieved by the method and apparatus of the invention allowing differential intensity properties in relatively small areas, including disclosed zones and microzones. The ability to design and manufacture formed nonwoven fabrics with the disclosed differences in basis weight, density or caliper, for example, while at the same time providing a consolidated fabric useful for topsheets in absorbent articles, for example, eliminates the heretofore existing technical contradictions between surface structure and softness. That is, the formed nonwoven fabrics of the present disclosure can provide visually discernible surface texture, including in irregular patterns, as well as superior softness as indicated by measured Emtec values. Furthermore, the formed nonwoven fabrics of the present disclosure can offer visually discernible surface texture in combination with physical integrity and reduced lint properties, as well as superior softness as indicated by measured Emtec values.

[0192] As discussed above, in one example, a method of making a shaped nonwoven fabric may be a modified version of the method described with reference to FIG figure 7 is described. A modification is made with reference to figure 56 described. As in figure 56, the method can also use a tape 60 as described above in a melt spinning process employing more than one spinning jet. As schematic under illustration of only the spin packs 48A and 48B shown, two beams can be used to tape fibers 60 melt-spinning, with a compression process after each jet 70A , 72A and 70B , 72B he follows. The vacuum boxes 64A and 64B can also each be operative with each spinning beam 48A and 48B get connected.

[0193] After spinning fibers onto tape 60 and after densification, including optional thermal bonding during densification as described above, the formed nonwoven web is subjected to additional heating by the through-air dryer 76 , of multiple chambers, such as three chambers 76A , 76B and 76C comprises, each independently temperature controlled, are subjected to.

[0194] Examples 7 and 9 above were prepared on a twin jet process line and in an in figure56 schematically illustrated method durchluftftverbindungen. Without wishing to be bound by theory, it is believed that through-airflow bonding retains much of the three-dimensionality of the three-dimensional features of the formed web, as indicated by the difference in TS7 values ​​in Table 5. Alternatively, it is believed that when a formed web with fewer sides is desired, the calender bonding tends to balance the TS7 values, as demonstrated by Example 8 in Table 5. Thus, the process parameters can be controlled as described herein to achieve a predetermined softness per side, i. H. To achieve surface of a shaped nonwoven fabric. In addition to the advantages described above, another advantage of the formed nonwoven webs of the present disclosure relates to the ability to provide a nonwoven web with microzones that have a hydrophobic region and a separate hydrophilic region. The hydrophilicity and / or hydrophobicity in a particular area of ​​the microzone can be determined by a wicking time measurement using the wicking time test method described herein and / or a contact angle measurement using the contact angle test method described herein. As used herein, the term "hydrophilic" in relation to a particular area of ​​the microzone means that when tested using the Soak Time Test Method, the soak time for that particular area is less than 10 seconds. As used herein, the term "hydrophobic" in relation to a particular area of ​​the microzone means that when tested using the contact angle test method, the contact angle for that particular area is 90° or greater.

[0195] Table 6 below describes the contact angle and wicking time measurements for formed webs as detailed herein. For both of Examples 10 and 11 below, the mat was made on a belt as described in figure 16, wherein the nonwoven web has an appearance similar to that in figure 2 has. Table 6: Contact angle and wicking time values ​​for formed webs of the disclosure example no area Contact angle (θc) Soak Time (seconds) Example 10 First area 135 60 second area 0 0,307 Example 11 First area 126 60 second area 0 2,360 Example 10:

[0196] A bicomponent spunbonded nonwoven web obtained by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration as described above with reference to Example 2 discussed. The web was placed on a forming belt with a repeating pattern as in figure 16 centrifuged around a fabric while agitation at a linear speed of about 25 meters per minute 10 with an average basis weight of 25 grams per square meter with a repeating pattern of heart shapes, as in figure 2 shown. Fibers of the fabric were passed through compaction rollers 70 , 72 densified, but instead of being calendered, further bonding was effected by a through-air bonding unit as referred to below in relation to FIG figure 56 is reached at a temperature of 145 °C.

[0197] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylates with PEG diesters), provided by Pulcra Chemicals, was then applied to the back of the nonwoven (i.e., the flat side surface opposite the side with the relatively pillowy three-dimensional features disposed thereon). arranged a kiss coating process. The coating process was performed using a Reicofil kiss roll and omega drying process, both of which are state of the art. The surfactant used in the kiss-roll process had a 6% surfactant concentration in water at a temperature of 40°C. The kiss-roll contact angle was set at 250° and the drying temperature was 80°C. The non-woven fabric was then brought into contact with the kiss roll operating at a speed of 13 rpm, giving the non-woven fabric 0.45% by weight of surfactant (% surfactant is the weight of surfactant added per 1 m 2 divided by 1 m 2 Nonwoven) was fed. Example 11:

[0198] A bicomponent spunbonded nonwoven web obtained by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A available from Dow Chemical) and polypropylene core (PH-835 available from LyondellBasell) in a trilobal fiber configuration as described above with reference to Example 2 discussed. The web was placed on a forming belt with a repeating pattern as in figure 16 centrifuged around a fabric while agitation at a linear speed of about 25 meters per minute 10 with an average basis weight of 25 grams per square meter with a repeating pattern of heart shapes, as in figure 2 shown. Fibers of the fabric were passed through compaction rollers 70 , 72 densified, but instead of being calendered, further bonding was effected by a through-air bonding unit as referred to below in relation to FIG figure 56 is reached at a temperature of 145 °C.

[0199] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylates with PEG diesters), provided by Pulcra Chemicals, was then placed on the front side of the nonwoven (i.e., the side with the relatively pillow-like three-dimensional features disposed thereon) by an inkjet printing process. The ink jet printing process was performed using a Dimatix DMP 2831 ink jet printer fitted with a cartridge model # DMC-11610 / PM 700-10702-01 (10 pL). The print head temperature was 40 °C. The surfactant used in the ink jet printing process consisted of 75% by weight Stantex S 6327 and 25% by weight ethanol. A surfactant was printed in the second areas of the microzones of the nonwoven by aligning the nonwoven sample so that the second areas of a first row of microzones were aligned with the printhead direction and a first row of straight lines was printed with the droplet spacing set to 170 µm was set. The nonwoven sample was then rotated at an angle so that the second areas of a second row of microzones were aligned with the printhead and a second row of 170 µm straight lines were printed. The basis weight of the second region fibers is about 16.0 grams per square meter. The basis weight of the surfactant inkjet printed onto the second area is about 0.25 grams per square meter. Accordingly, it was determined that the amount of surfactant locally printed onto the second area is approximately 1.6% by weight surfactant (0.25 grams per square meter / 16.0 grams per square meter). Overall, the ratio of printed line width to line spacing determined that the amount of surfactant printed on the nonwoven sample is approximately 0.2% surfactant by weight.

[0200] In addition to Stantex S 6327, the use of other surfactants to render the first and / or second region of certain microzones hydrophilic and / or hydrophobic (by any method of application) is contemplated to be within the scope of this disclosure. Other potential surfactants for use in the processes and nonwovens detailed here are: nonionic surfactants including esters, amides, carboxylic acids, alcohols, ether polyoxyethylene, polyoxypropylene, sorbitan, ethoxylated fatty alcohols, allyl phenolic polyethoxylates, lecithin, glycerol esters and their ethoxylates, and sugar based surfactants (polysorbates, alkyl polyglycosides), and anionic surfactants including sulfonates, sulfates, phosphates, alkali metal salts of fatty acids, fatty alcohol monoesters of sulfuric acid, linear alkyl benzene sulfonates, alkyl diphenyl oxide sulfonates, lignin sulfonates, olefin sulfonates, sulfosuccinates and sulfated ethoxylates of fatty alcohols, and cationic surfactants including amines ( primary, secondary, tertiary, quaternary ammonium compounds, pyridinium, quaternary ammonium salts - QAS, alkylated pyridinium salts, alkyl primary, secondary, tertiary amines and alkanolamides, and zwitterionic surfactants including amino acids and derivatives , amine oxide, betaines and alkyl amine oxides, and polymeric surfactants including polyamines, carboxylic acid polymers and copolymers, EO / PO block copolymers, ethylene oxide polymers and copolymers and polyvinylpyrrolidone, and silicone surfactants including dimethylsiloxane polymers with hydrophilic and perfluorocarboxylic acid salts and fluorosurfactants.

[0201] The formed nonwoven webs detailed above have microzones with areas that have differences in intense properties such as basis weight, density, or caliper. Precisely these shaped non-woven fabrics can also simultaneously have areas of the microzones that are particularly and separately hydrophobic and / or hydrophilic. Each of the shaped nonwoven examples detailed herein (e.g., samples comprising zones and / or microzones with regions with differences in caliper, basis weight and / or volumetric density and / or surfaces with the various TS7 values ​​disclosed herein) may also have regions a microzone with differences in hydrophilicity as described herein. Hydrophilicity can be provided by targeted application(s) of surfactant(s) to specific areas of the microzones of the formed nonwoven. For example, the second region of a microzone may have a surfactant disposed thereon, while the first region of the same microzone may not have a surfactant disposed thereon. In addition, the first region of a microzone may have a surfactant disposed thereon, while the second region of the same microzone may not have a surfactant disposed thereon. For example, in a microzone, the first or second region can contain a surfactant from about 0.01% to about 5.0%, about 0.05% to about 4.0%, about 1.0% to about 3.0% and in any concentric region ranging from 0.01% to about 5.0% and the other region has no surfactant (i.e., is surfactant-free). As an example, in a microzone, the second region can contain a surfactant from about 0.01% to about 5.0%, from about 0.05% to about 4.0%, from about 1.0% to about 3.0%, and in any concentric region ranging from 0.01% to about 5.0%, and the first region has no surfactant (i.e., is surfactant-free). Accordingly, some of the formed nonwoven fabrics disclosed herein have a microzone with at least one of the first and second regions having a surfactant, and the ratio of the percentage of surfactant in the first region to the percentage of surfactant in the second region is less than 1. Furthermore some formed nonwoven fabrics disclosed herein have a microzone with at least the second region of the microzone having a surfactant, and the ratio of the percentage of surfactant in the first region to the percentage of surfactant in the second region is less than 1.

[0202] As another example, the second region of a microzone may have a particular amount or percentage of surfactant disposed thereon, while the first region of the same microzone may have a different amount or percentage of surfactant disposed thereon. For example, in a microzone, the first region can contain a surfactant at from about 0.01% to about 2.0%, from about 0.05% to about 1.5%, from about 0.1% to about 1.0%, and in a have any concentric area in the range of 0.01% to about 2.0% and the second area can have a different amount. Additionally, the second region in a microzone can contain a surfactant at from about 0.01% to about 5.0%, from about 0.05% to about 4.0%, from about 1.0% to about 3.0%, and in a have any concentric area in the range of 0.01% to about 5.0% and the first area can have a different amount. The percentage of surfactant for a particular area of ​​a microzone can be determined by taking the grams per square meter of surfactant located in the particular area and dividing by the basis weight of the fibers of the formed nonwoven contained in the same area. The grams per square meter of surfactant located in a particular area can be determined using any method presently known in the art (e.g., gravimetric method, etc.). The basis weight of the fibers of the formed nonwoven fabric contained in a specific area of ​​a microzone can also be determined using any method currently known in the art (e.g. gravimetric, micro-CT method, etc.), be determined. For particular microzone examples, the basis weight ranges / examples of fibers contained in the first and second regions are detailed above.

[0203] A surfactant can be placed on the formed nonwoven fabrics by any known method well known in the art. Specific examples include kiss coating, inkjet printing, gravure printing, offset gravure printing, flexographic printing of the surfactant, and registered printing of the surfactant. Any of these methods can apply surfactant to either the first and / or second surface of the formed nonwoven fabric. For the total formed nonwoven fabrics (taking into account all of the individual zones and microzones on the fabric), the surfactant can be added to the formed nonwoven fabric in an amount of from about 0.01% to about 2.0%, about 0.05% to about 1.5% %, about 0.1% to about 1.0% and any concentric area ranging from about 0.01% to about 2.0%. To calculate the percentage of surfactant added to the total formed web, divide the grams per square meter of surfactant in the total formed web by the basis weight of the total formed web. The grams per square meter of surfactant located in the overall formed nonwoven can be determined by any method known in the art (e.g., gravimetric method, etc.). The basis weight of the entire formed web can also be determined using any method known in the art (eg, gravimetric, micro-CT, etc.).

[0204] Referring now to the figure 38 and figure 39 showing a section of a pattern of non-woven fabric 10 show is a first zone 110 (on the left of figure 38) by generally in md aligned rows of first areas 300 variable width marked by in md aligned rows of second areas 310 of variable width are separated (the first and second regions being in a microzone). The first area is also the three-dimensional feature 20 , which the first and second areas 300 , 310 Are defined. In one embodiment, a three-dimensional feature is a section of the nonwoven fabric 10formed between or around a raised element of the forming belt, which in this description is the first region 300 is such that the resulting structure is compared to the second region 310 a proportionately larger dimension in the Z direction, relatively higher basis weight and lower volumetric density. In addition, the first area 300 hydrophobic and the second area 310 be hydrophilic. A targeted addition of a surfactant to the second region 310 the microzone can cause the second region to be hydrophilic. Accordingly, the first area 300 of the microzone has a contact angle greater than about 90°, or between about 90° and about 140°, or between about 110° and about 135°, or between about 125° and about 135°, or any concentric range that is between about 90° and about 140° when tested with the contact angle test method described herein. The second area 310 the microzone may have a contact angle of less than 90° when tested by the contact angle test method described herein. The first area 300 the microzone may have a Soak Time value greater than about 10 seconds or between about 10 seconds and 60 seconds as measured by the Soak Time Test Method described herein. The second area 310 the microzone can have a Soak Time value of less than about 10 seconds, less than about 5 seconds, or less than about 2.5 seconds, or less than about 1 second, or less than about 0.5 seconds as measured by the Soak Time Test Method described herein , exhibit. The formed nonwoven fabrics provided herein incorporate any of the above detailed parameter ranges for contact angle and / or wicking time measurements for the first region and / or the second region in combination with any of the other intensive properties / property differences disclosed herein for the same or different regions in the same or different microzone on the formed nonwoven.

[0205] Shaped nonwovens having the microzones detailed above with areas that have differences in basis weight, density, or caliper, while such areas of a particular microzone are simultaneously separately hydrophobic and / or hydrophilic, can provide many useful applications, such as topsheet materials for the Baby care, feminine care and adult incontinence products, as well as use in medical pads, wipes and cleaning covers, etc.

[0206] The dimensions and values ​​disclosed herein should not be construed as being strictly limited to the precise numerical dimensions and / or values ​​given. Instead, unless otherwise specified, each such dimension and / or value is intended to have the meaning of the specified dimension and / or value and a functionally reasonable area surrounding that dimension and / or value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

[0207] Each document cited herein, including any references or related patents or applications, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. Citation of any document does not imply that it is acknowledged as prior art to any embodiment disclosed or claimed herein, or that it alone or in combination with other cited references teaches, suggests or discloses such embodiment. 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.

[0208] While particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the present invention. It is therefore intended in the appended claims to cover all such changes and modifications as fall within the scope of the invention. Test Method: Compression Aging Test

[0209] Initial thickness measurement: • Cut five 3" by 3" samples per nonwoven to be measured. • Number each sample from 1 to 5. • Check the thickness at 0.5 kPa with the 65mm standard foot using a Thwing Albert thickness tester according to standard procedures. • Record the initial thickness for each of the five specimens. • Record the average thickness of the five samples.

[0210] Aging compression method and aging thickness measurement • Stack the five samples alternately, each separated by a paper towel, beginning and ending with a sample number 1 and 5, respectively. • Place the alternately stacked samples in an aluminum sample holder with an appropriate weight placed on top of the samples (4 KPa, 14 KPa or 35 KPa). • Place the stacked samples with the weight in an oven at 40°C for 15 hours • After 15 hours remove the weight, separate the samples and check the caliper of each sample at 0.5 kPa the 65mm standard foot using a Thwing Albert caliper tester according to standard procedures. • Record the aged thickness value for each of the five scans. • Record the average aged thickness of the five specimens.

[0211] Analysis Reports: • Record average initial and aged thicknesses by position number • Thickness Recovery Index: ( Durchschnittliche gealterte / durchschnittliche anfängliche Dicke ) * 100 Localized Base Weight

[0212] The localized basis weight of the web can be determined by several available methods, however, a simple representative method involves a die having a 3.0 cm area 2 , which is used to cut a sample piece of web from the selected area of ​​the overall surface of a nonwoven fabric. The sample is then weighed and divided by its area to give the localized basis weight of the web in units of grams per square meter. Results are presented as the mean of 2 samples per selected area. Lint Level Check

[0213] The lint level test is used to determine the amount of fibers that are removed from a nonwoven material under an abrasive force (i.e., the lint level).

[0214] The Lint Level Test uses the following materials: • Sutherland 2 pound ink rub tester available from Danilee Co, San Diego, TX. • Factory Rolls, 320 grit size, aluminum oxide cloth manufactured by Plymouth Coatings, (617) 447-7731. This material can also be ordered through McMaster Carr, part number 468.7A51, (330) 995-5500. • Two-sided tape, 3M #409, available from Netherland Rubber Company, (513) 733-1085. • Fiber Removal Tape, 3M #3187, available from Netherland Rubber Company, (513) 733-1085. • Analytical balance (+ / - 0.0001 g) • Paper cutter • 2200g weight (metal) 170mm × 63mm. • Thick release paperboard - 0.0445 inch (1.13mm) thick. material production

[0215] Measure and cut aluminum oxide fabric into 7.5 inch (19.0 cm) long pieces. Measure and cut pieces of 3M #3187 tape 6.5 inches (16.5 cm) in length, two tapes for each sample piece. Fold over approximately 0.25 inch (0.6 cm) on each end of the 3M #3187 tape for ease of handling. Place 3M #3187 tape on the thick release paper for later use. specimen preparation

[0216] Before handling or testing any material, please wash hands with soap and water to remove excess oil from hands. Optionally, latex gloves can 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. Lay out the nonwoven sample to be tested with the side to be tested facing down. Cut a length of 3M #409 double-sided tape from a roll, at least 4.5 inches (11 cm) long. Remove the backing sheet and apply the side of the two-sided tape that faced the backing sheet lengthwise in the machine direction (MD) to the sample web. Place the backing sheet back onto the exposed tape. Using the paper cutter, cut test specimens within the covered area 11 cm MD and 4 cm CD. test procedure 1. Attach the cut piece of alumina 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. Pages are folded down in staples - making sure the alumina cloth and thick release paper board lay flat. 2. Place the sample on a Sutherland ink rub tester centered on the metal plate. Place the 2200 g weight on the sample for 20 seconds. 3. Place the metal plate and 2 pound weight on the Sutherland Ink Rub Tester. 4. Switch on the friction test device. If the backlight is not illuminated, press the reset button. Press the count button to set the friction cycles to 20 cycles. Speed ​​1, select the slow speed (light will not illuminate) using the speed knob. "Press Start. 5. With the friction tester turned off, carefully remove the alumina cloth / weight, making sure not to lose any of the loose microfibers (lint). In some cases, the microfibers are attached to both the alumina fabric and the surface of the sample web. Place the weight upside down on the bench. 6. Weigh the fiber release tapes with release paper attached. Hold the fiber release tape by the folded ends, peel off the release paper and set aside. Gently place the tape on the aluminum oxide cloth to remove all of the lint. Pull off the fiber release tape and put it back on the release paper. The weight of the fiber release tapes is weighed and recorded. 7. Hold another piece of the pre-weighed release tape by the folded ends. Gently place the fiber release tape on the surface of the abraded web sample. Lay a flat metal plate flat on the fiber release belt. 8. Place the 2200g weight on top of the metal plate for 20 seconds. Pull 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 gains of both fiber release tapes. 10. The lint weight is reported as an average of 10 measurements. Calculations:

[0217] For a given sample, the weight in grams of lint collected from the alumina cloth and the weight in grams of lint collected from the abraded sample web are added together. Multiply the combined weight in grams 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 abraded area. air permeability tests

[0218] The Air Permeability Test is used to determine the degree of air flow in cubic feet per minute (cfm) through a forming belt. The air permeability test is performed with a Textest Instruments model FX3360 Portair Air Permeability Tester available from Textest AG, Sonnenbergstrasse 72, CH 8603 Schwerzenbach, Switzerland. The unit uses a 20.7mm perforated plate for air permeability ranges between 300-1000 cubic feet per minute. If the air permeability is lower than 300 cubic feet per minute, the orifice plate needs to be reduced; if it is greater than 1000 cubic feet per minute, the perforated plate must be raised. Air permeability can be measured in localized zones of a forming belt to determine differences in air permeability across a forming belt. test procedure 1. Turn on the FX3360 device. 2. Select a predefined method with the following settings: a. Materials: standard b. Measurement property: air permeability (AP) c. Test pressure: 125 Pa (Pascal) i.e. T-Factor: 1.00 e. Test point distance: 0.8 inch 3. Place the 20.7mm orifice plate on top of the shaping belt (the side with the three-dimensional protrusions) at the position of interest. 4. Select "Spot Measurement" on the test unit touch screen. 5. If necessary, reset the sensor before the measurement. 6. After the reset, select the Start button to begin the measurement. 7. Wait for the measurement to stabilize and record the cubic foot reading on the screen. 8. Select the "Start" button again to stop the measurement. In-Bag Stack Height Check

[0219] The in-bag stack height of a package of absorbent articles is determined as follows: gear

[0220] A thickness gauge with a flat, rigid, horizontal slide plate is used. The thickness gauge is configured so that the horizontal slide plate moves freely in a vertical direction, with the horizontal slide plate always being maintained in a horizontal orientation, directly over a flat, rigid, horizontal base plate. The thickness gage includes an appropriate device for measuring the gaps between the horizontal slide plate and the horizontal base plate to within ±0.5 mm. The horizontal sliding panel and the horizontal base panel are larger than the surface area of ​​the absorbent article package that is in contact with each panel, i. H. each panel extends beyond the contact surface of the absorbent article package in all directions. The horizontal sliding surface exerts a downward force of 850 ± 1 gram force (8.34 N) on the absorbent article package, which is obtained by placing an appropriate weight on the center of the top surface of the horizontal sliding plate not in contact with the package stands, can be achieved so that the total mass of the skid plate plus additional weight is 850 ± 1 grams. test procedure

[0221] Absorbent article packages are equilibrated at 23 ± 2°C and 50 ± 5% relative humidity prior to measurement.

[0222] The horizontal slide plate is raised and an absorbent article package is placed centrally under the horizontal slide plate in such a way that the absorbent articles are in a horizontal orientation within the package (see figure27). Any handle or other packaging feature on the surfaces of the package that would come into contact with one of the panels is folded flat against the surface of the package to minimize its effect on the measurement. The horizontal slide plate is slowly lowered until it contacts the top of the package and is then released. The gap between the horizontal plates is measured to ± 0.5 mm ten seconds after releasing the horizontal sliding plate. Five identical packages (packages of the same size and equal absorbent article counts) are measured and the arithmetic mean is reported as the package width. The "In-Bag Stack Height" = (package width / absorbent article count per stack) x 10 is calculated and recorded to within ± 0.5 mm. Method for micro-CT measurement of intense properties

[0223] Intense property micro-CT metrology measures basis weight, thickness, and volumetric density values ​​in optically observable areas of a substrate sample. It is based on the analysis of a 3D X-ray sample image obtained on a micro-CT device (a suitable device is Scanco µCT 50, available from Scanco Medical AG, Switzerland, or equivalent). The micro-CT instrument is a cone-beam microtomograph with a shielded cabinet. A maintenance-free X-ray tube is used as the source with an adjustable focal spot diameter. The x-ray beam passes through the sample where some of the x-rays are attenuated by the sample. The degree of attenuation correlates to the size of the material through which the X-rays must pass. The transmitted X-rays continue to the digital detector array, creating a 2D projection image of the sample. A 3D image of the sample is generated by collecting multiple individual projection images of the sample as it rotates, which are then reassembled into a single 3D image. The device is connected via an interface to software running on the computer to control the image acquisition and to store 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 comparable) to measure intense properties of basis weight, thickness, and volumetric density of regions within the sample. Sample preparation:

[0224] To obtain a sample for measurement, a single layer of the dry substrate material is spread flat and a circular piece 30 mm in diameter is punched out.

[0225] When the substrate material is a layer of an absorbent article, for example a topsheet, backsheet web, acquisition layer, distribution layer, or other component layer; then the absorbent article is adhered to a solid flat surface in a planar configuration. Carefully separate the single substrate layer from the absorbent article. A scalpel and / or cryogenic sprays (such as Cyto-Freeze, Control Company, of Houston, Texas) can be used to remove a substrate layer from other underlying layers, if necessary, to allow longitudinal and lateral expansion of the material to avoid. Once the substrate layer has been removed from the article, the sample is die cut as described above.

[0226] If the substrate material is in the form of a wet wipe, open a new package of wet wipes and remove the entire stack from the package. Take a single wet wipe from the center of the stack, spread it flat and allow it to dry completely before punching the sample for analysis.

[0227] A sample can be cut from any site containing the visually recognizable 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 includes at least two optically discernible areas. A zone, three-dimensional feature, or microzone may be visually discernible due to changes in texture, elevation, or thickness. Areas within different samples of the same substrate material can be analyzed and compared. Care should be taken to avoid wrinkles, creases or tears when selecting a sampling site. Image capture:

[0228] Set and calibrate the micro-CT device according to the manufacturer's specifications. Place the sample in the appropriate holder between two rings of low density material having an internal diameter of 25 mm. This allows the central portion of the sample to lie horizontally and be scanned without any other materials being directly adjacent to the top and bottom surfaces n. Measurements should be taken in this area. The 3D imaging field of view is approximately 35 mm on each side in the xy plane, with a resolution of approximately 5000 by 5000 pixels, and with a sufficient number of 7 micron thick slices collected around the z-direction of the sample to include fully. The reconstructed 3D image resolution contains isotropic voxels of 7 microns. 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 the maximum contrast in the projection data with sufficient X-ray penetration through the sample, but once optimized are kept constant for all substantially similar samples. A total of 1500 projection images with an integration time of 1000 ms and 3 average values ​​are obtained. The projection images are reconstructed into the 3D image and saved in 16-bit RAW format to retain the full detector output signal for analysis. Image processing:

[0229] Load the 3D image into the image analysis software. Threshold the 3D image to a level that separates and removes the airborne background signal, but preserves the signal from the sample fibers within the substrate.

[0230] Three 2D images with intense features are generated from the thresholded 3D image. The first is the base weight picture. To generate this image, the value for each voxel in one xy-plane slice is summed with all of its corresponding voxel values ​​in the other z-direction slices containing signal from the sample. This produces a 2D image in which each pixel now has a value equal to the sum signal throughout the sample.

[0231] In order to convert the raw data values ​​in the basis weight image into real values, a basis weight calibration curve is generated. A substrate is obtained which has a composition substantially similar to that of the sample to be analyzed and has a uniform basis weight. Follow the procedures described above to obtain at least ten replicates of the calibration curve substrate. Accurately measure the basis weight by recording the mass to the nearest 0.0001 g and dividing by the sample range and converting to grams per square meter (gsm) of each of the single layer calibration samples and the average to the nearest 0.01 grams per Calculate square meters. Following the procedures described above, a micro-CT image of a single layer of the calibration sample substrate is obtained. Following the procedures described above, the micro-CT image is processed and a basis weight image is generated with raw data values. The actual basis weight value for this sample is the average basis weight value measured on the calibration samples. Next, two layers of the calibration substrate samples are stacked and a micro-CT image of the two layers of the calibration substrate is acquired. Generate a basis weight raw data image of both layers together, the actual basis weight value of which is equal to twice the average basis weight value measured at the calibration samples. Repeat this procedure of stacking individual layers of the calibration substrate, acquire a micro-CT image of all layers, generate a raw data basis weight image of all layers whose actual basis weight value is equal to the number of layers times the average basis weight value measured on the calibration samples, amounts to. A total of at least four different basis weight calibration images are obtained. The basis weight values ​​of the calibration samples must include values ​​above and below the basis weight values ​​of the original sample being analyzed to ensure an accurate calibration. The calibration curve is generated by a linear regression based on the raw data versus the actual basis 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 basis weights.

[0232] The second 2D intense property image 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, giving the sample thickness. The top surface of the sample is identified by starting at the top z-direction slice and evaluating each slice, thus stepping through the sample and locating the z-direction voxel for all pixel positions in the xy plane where the sample signal was detected first. The same procedure is followed to identify the bottom surface of the sample, except that the voxels located in the z-direction 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 15×15 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 top and bottom surfaces for each of the pixel locations in the xy plane. This raw thickness value is then converted to actual distance, in microns, by multiplying the voxel count by the 7 µm slice thickness resolution.

[0233] The third 2D intense property image is the volumetric density image. To create this image, each xy plane pixel value in the basis weight image, in units of grams per square meter, is divided by the corresponding pixel in the thickness image, in units of microns. The units of the volumetric thickness figure are grams per cubic centimeter (g / cm 3 ). Intense Properties of MicroCT Basis Weight, Thickness and Volumetric Density:

[0234] Start by identifying the area to analyze. A region to be analyzed is one associated with a three-dimensional feature that defines a microzone. The microzone includes at least two optically discernible areas. A zone, three-dimensional feature, or microzone may be visually discernible due to changes in texture, elevation, or thickness. Next, the boundary of the area to be analyzed is identified. The boundary of a region is identified by visually distinguishing differences in intense properties compared to other regions within the sample. For example, a region boundary can be identified by visually detecting a thickness difference when compared to another region in the sample. Each of the intense features can be used to distinguish region boundaries on one of the physical specimen itself from any of the microCT intense feature images. After the boundary of the region has been identified, draw an oval or circular "area of ​​interest" (ROI) within the interior of the region. The ROI should have an area of ​​at least 0.1 mm2 and be selected to measure an area with intense property values ​​representative of the identified area. From each of the three intense property images, the average basis weight, average caliper, and average volumetric density within the ROI are calculated. These values ​​as the domain basis weight to the nearest 0.01 grams per square meter, caliper to the nearest 0.1 micron and volumetric density to the nearest 0.0001 g / cm 3 record. Emtec test procedure

[0235] TS7 and TS750 values ​​are measured using an EMTEC Tissue Softness Analyzer (“Emtec TSA”) (Emtec Electronic GmbH, Leipzig, Germany) connected to Emtec TSA software (version 3.19 or equivalent) running on the computer. measured. According to Emtec, the TS7 value correlates with the actual softness, while the TS750 value correlates with the perceived smoothness / roughness of the material. The Emtec TSA comprises a rotor with vertical blades rotating on the test specimen with a defined and calibrated rotational speed (set by the manufacturer) and a contact force of 100 mN. The contact between the vertical vanes and the specimen creates vibrations that produce sound that is recorded by a microphone inside the device. The recorded sound file is then analyzed by the Emtec TSA software. Sample preparation, instrument operation, and test procedures are performed according to the instrument manufacturer's specifications. specimen preparation

[0236] Test specimens are made by cutting square or circular specimens from a finished product. The test specimens are cut to a length and width (or diameter if circular) of not less than about 90mm and not more than about 120mm in any of these dimensions to ensure that the specimen is properly seated in the TSA Device can be clamped. Specimens are selected to avoid perforations, creases or creases within the test area. Please prepare 8 substantially similar replicates for testing purposes. Equilibrate all samples at TAPPI standard temperature and relative humidity conditions (23°C ± 2°C and 50% ± 2%) at least 2 hours before performing the TSA test, which is also performed under TAPPI conditions. test procedure

[0237] Calibrate the instrument according to the manufacturer's instructions using the 1-point calibration procedure with Emtec reference standards (“ref. 2 samples”). If these reference samples are no longer available, please use the corresponding reference samples provided by the manufacturer. Calibrate the instrument according to the manufacturer's recommendations and instructions so that the results are comparable to those obtained using the 1-point calibration method under Emtec reference standards (“ref. 2 samples”).

[0238] Provide eight replicate samples of a substance for testing. Place a test sample in the device with one surface facing up and test according to the manufacturer's instructions. Upon completion, the software will display values ​​for TS7 and TS750. Each of these values ​​to the nearest 0.01 dB V 2 Record RPM. The test sample is then removed from the device and discarded. This test is done individually on the same face of four replicates, and then on the other surface of the other four replicates. The first surface checked can be either the first surface 12 or the second surface 14 a formed nonwoven fabric as disclosed herein.

[0239] The four test result values ​​for TS7 and TS750 of the first surface tested are averaged (using a simple numerical average); the same happens for the four test result values ​​for TS7 and TS750 from the second tested surface. The individual mean values ​​of TS7 and TS750 for both the first and second tested surfaces on a given test sample to the nearest 0.01 dB V 2 Record RPM. Additionally, the TS7 ratio of the first surface tested to the second surface tested is calculated by dividing the average TS7 of the first surface tested by the average TS7 of the second surface tested. Contact angle and wicking time test methods

[0240] Contact angle and wicking time measurements are determined using a sessile drop experiment. A specified volume of Type II reagent distilled water (as defined in ASTM DI 193) is applied to the surface of a test sample using an automated liquid delivery system. A high-speed video camera captures time-stamped images of the drop over a 60-second period at a rate of 900 frames per second. The contact angle between the drop and the surface of the test sample is determined for each image taken by image analysis software. The wicking time is determined as the time it takes for the contact angle of a droplet penetrating the test sample to decrease to a contact angle < 10°. All measurements are carried out at a constant temperature (23 °C ± 2 °C) and relative humidity (50 % ± 2 %).

[0241] An automated contact angle tester is required to perform this test. The system consists of a light source, a video camera, a horizontal sample stage, a liquid delivery system with pump and microsyringe, and a computer equipped with software for video image acquisition, image analysis, and evaluation of contact angle data. A suitable instrument is the optical contact angle measuring system OCA 20 (DataPhysics Instruments, Filderstadt, Germany) or an equivalent. The system must be capable of delivering an 8.2 microliter drop and be capable of capturing images at a rate of 900 frames per second. The system is calibrated and operated according to the manufacturer's instructions, unless specifically stated otherwise in this test procedure.

[0242] To obtain a test sample for measurement, a single layer of the dry substrate material is laid out flat and a test sample 15 mm wide and about 70 mm long is die cut. The width of the specimen can be reduced as needed to ensure that the area of ​​interest is not obscured by surrounding features during inspection. If the sample strip is narrower, care must be taken to ensure that the drop of liquid does not reach the edge of the test specimen during the test, otherwise the test will have to be repeated. The samples at 23 °C ± 2 °C and about 50 % ± 2 % relative humidity 2 Precondition for hours before testing. specimen preparation

[0243] A test sample can be punched from any location containing the optically discernible 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 includes at least two optically discernible areas. A zone, three-dimensional feature, or microzone may be visually discernible due to changes in texture, elevation, or thickness. Areas within different test samples from the same substrate material can be analyzed and compared to each other. Care should be taken to avoid wrinkles, creases or tears when selecting a sampling site.

[0244] When the substrate material is a layer of an absorbent article, for example a topsheet or backsheet nonwoven, an acquisition layer, a distribution layer or other component layer; then the absorbent article is adhered to a solid flat surface in a planar configuration. Carefully separate the single substrate layer from the absorbent article. A scalpel and / or cryogenic sprays (such as Cyto-Freeze, Control Company, of Houston, Texas) can be used to remove a substrate layer from other underlying layers, if necessary, to allow longitudinal and lateral expansion of the material to avoid. Once the substrate layer has been removed from the article, proceed to die-cut the test sample as described above. If the substrate material is in the form of a wet wipe, open a new package of wet wipes and remove the entire stack from the package. Take a single wet wipe from the center of the stack, spread it flat and allow it to dry completely before punching the sample for analysis. test procedure

[0245] The test sample is positioned on the horizontal sample table with the test area under the needle of the liquid delivery system in the field of view of the camera, with the test side facing up. The sample is fixed in such a way that it lies flat but unstressed and any interaction between the liquid drop and the underlying surface is avoided to avoid unnecessary capillary forces. A blunt tip stainless steel needle (ID 0.23mm, OD 0.41mm) of gauge 27 is positioned over the test sample with at least 2 mm of the needle tip in the camera's field of view. Adjust the sample stage to achieve a distance of approximately 3mm between the needle tip and the surface of the test sample. An 8.2 microliter drop of reagent distilled water is formed at a rate of 1 microliter per second and is free to fall onto the surface of the test sample. Video image acquisition is initiated before the drop touches the surface of the test sample and then a continuous series of images is collected over a 60 second period after the drop touches the surface of the test sample. Repeat this procedure for a total of five (5) substantially similar replicate test areas. Use a fresh test sample or ensure that the area previously wetted by the drop is avoided during subsequent measurements.

[0246] In each of the images captured by the video camera, the test sample surface and drop contour are identified and used by the image analysis software to calculate and record the contact angle for each drop image to the nearest 0.1 degree. The contact angle is the angle formed by the surface of the test sample and the tangent to the surface of the liquid droplet in contact with the test sample. For each set of images from a test, time zero is the time at which the drop of liquid makes contact with the surface of the test sample. Measure and record the contact angle on the droplet image that corresponds to time zero plus five (5) seconds. The contact angle at five seconds is reported as 0° if the drop has been completely absorbed by the test sample within 5 seconds. Repeat this procedure for the five replicated test areas. Calculate the arithmetic mean of the contact angle at time zero plus five seconds for the five replicate test areas and record this value as the contact angle to the nearest 0.1 degree.

[0247] The wicking time is defined as the time it takes for the contact angle of a drop that is absorbed into the test sample to decrease to a contact angle of <10°. The wicking time is measured by identifying the first frame of a particular series where the contact angle has decreased to a contact angle < 10° and then, based on that frame, calculating and recording the time elapsed since time zero. The wicking time is recorded as 60 seconds if a contact angle of less than 10° is not achieved within 60 seconds. Repeat this procedure for the five replicated test areas. Calculate the arithmetic mean of the imbibition time for the five replicated test areas and record this value to the nearest 0.1 milliseconds.

[0248] The invention of the disclosure can be described by any of the following combinations, which are described in the following paragraphs: A. A spunbond nonwoven fabric comprising: a. a first surface and a second surface and at least a first and a second optically recognizable zone on at least one of the first and second surfaces, each of the first and second zones having a pattern of three-dimensional features, each of the three-dimensional features defining a micro-zone that a first region and a second region, the first and second regions having a value difference for an intensive property; and b. wherein the difference in value for an intensive property for at least one of the micro-zones in the first zone differs from the difference in value for the intensive property for at least one of the micro-zones in the second zone; wherein in at least one of the microzones the first region is hydrophobic and the second region is hydrophilic. B. The spunbonded nonwoven fabric of paragraph A, wherein the difference in value for the intensive property for one of the microzones in the first zone is an order of magnitude different than the difference in value for at least one of the microzones in the second zone. C. The spunbonded nonwoven fabric of paragraphs A-B, wherein the intense property value difference for one of the microzones in the first zone differs from about 1.2X to about 10X the value difference for at least one of the microzones in the second zone. D. The spunbonded nonwoven fabric of paragraphs A-C, wherein the intense property is caliper and the caliper of each region is greater than zero. E. The spunbonded nonwoven fabric of paragraphs A-D, wherein the difference in caliper in the first zone is greater than about 25 microns. F. The spunbonded nonwoven fabric of paragraphs A-E, wherein the intense property is a basis weight and the basis weight in each region is greater than zero. G. The spunbonded nonwoven fabric of paragraphs A-F, wherein the basis weight difference in the first zone is greater than about 5 grams per square meter. H. The spunbonded nonwoven fabric of paragraphs A-G, wherein the intensive property is volumetric density and the volumetric density of each region is greater than zero. I. The spunbonded nonwoven fabric of paragraphs A-H, wherein the difference in volumetric density in the first zone is greater than about 0.042 g / cm 3 is. J. The spunbonded nonwoven fabric of paragraphs A-I, further comprising a third zone having a pattern of three-dimensional features each defining a microzone comprising a first region and a second region, wherein an intense property value difference for one of the microzones is in of the third zone differs a) from the intense property value difference for at least one of the micro-zones in the first zone and b) from the intense property value difference for at least one of the micro-zones in the second zone. K. The spunbonded nonwoven fabric of paragraphs A-J, wherein at least one of the surfaces has a TS7 value of less than about 15 dB V 2 RPM. L. The spunbonded nonwoven fabric of paragraph K, wherein the first surface has a TS7 value of from about 2 to about 12 dB V 2 rpm and the second surface has a TS7 value that differs from the TS7 value of the first surface. M. The spunbonded nonwoven fabric of paragraph L, wherein the second surface has a TS7 value that is lower than the TS7 value of the first surface. N. The spunbonded nonwoven fabric of paragraph K, wherein the second surface has a TS7 from about 3 to about 8 and the first surface has a TS7 that is different than the TS7 of the first surface. O. The spunbonded nonwoven fabric of paragraph N, wherein the first surface has a TS7 value that is greater than the TS7 value of the second surface. P. An absorbent article comprising a spunbonded nonwoven fabric as described in paragraphs A-O. Q. A pack of absorbent articles, each absorbent article comprising a spunbonded nonwoven fabric as described in paragraphs A-P. R. The package of paragraph Q, wherein the package has a pouch stack height of between about 70 mm and about 100 mm, according to the pouch stack height test described herein. S. A spunbonded fabric comprising: a. a first surface and a second surface and at least a first and a second optically recognizable zone on at least one of the first and second surfaces, each of the first and second zones having a pattern of three-dimensional features, each of the three-dimensional features defining a micro-zone that a first region and a second region, the first and second regions having a value difference for an intensive property; and b. wherein the difference in value for an intensive property for at least one of the micro-zones in the first zone differs from the difference in value for the intensive property for at least one of the micro-zones in the second zone; wherein in at least one of the microzones the second region comprises a surfactant and the first region comprises no surfactant. T. The spunbonded nonwoven fabric of paragraph S, wherein the surfactant is selected from a group consisting of: nonionic surfactants including esters, amides, carboxylic acids, alcohols, ether polyoxyethylene, polyoxypropylene, sorbitan, ethoxylated fatty alcohols, allyl phenolic polyethoxylates, lecithin, glycerol esters and their ethoxylates and sugar based surfactants (polysorbates, alkyl polyglycosides), anionic surfactants including sulfonates, sulfates, phosphates, alkali metal salts of fatty acids, fatty alcohol monoesters of sulfuric acid, linear alkyl benzene sulfonates, alkyl diphenyl oxide sulfonates, lignin sulfonates, olefin sulfonates, sulfosuccinates and sulfated ethoxylates of fatty alcohols, cationic surfactants including Amines (primary, secondary, tertiary), quaternary ammonium compounds, pyridinium, quaternary ammonium salts - QAS, alkylated pyridinium salts, alkyl primary, secondary, tertiary amines and alkanolamides, zwitterionic surfactants including amino acids and derivatives, amine oxide, betaine and alkyl amine oxides, polymeric surfactants including polyamines, carboxylic acid polymers and copolymers, EO / PO block copolymers, ethylene oxide polymers and copolymers and polyvinylpyrrolidone, silicone surfactants including dimethylsiloxane polymers with hydrophiles, and perfluorocarboxylic acid salts and fluorosurfactants. U. The spunbonded nonwoven fabric of paragraphs S-T, wherein the surfactant is a combination of castor oil ethoxylates with PEG diesters. V. The spunbonded nonwoven fabric of paragraphs S-U, wherein the difference in value for the intensive property for one of the microzones in the first zone is an order of magnitude different than the difference in value for at least one of the microzones in the second zone. W. The spunbonded nonwoven fabric of paragraphs S-V wherein the intense property value difference for one of the microzones in the first zone differs from about 1.2X to about 10X the value difference for at least one of the microzones in the second zone. X. The spunbonded nonwoven fabric of paragraphs S-W, wherein the intensive property is caliper and the caliper of each region is greater than zero. Y. The spunbonded nonwoven fabric of paragraphs S-X, wherein the difference in caliper in the first zone is greater than about 25 microns. Z. The spunbonded nonwoven fabric of paragraphs S-Y, wherein the intensive property is a basis weight and the basis weight is greater than zero in each region. aa The spunbonded nonwoven fabric of paragraphs S-Z, wherein the basis weight difference in the first zone is greater than about 5 grams per square meter. bb The spunbonded nonwoven fabric of paragraphs S-AA, wherein the intensive property is volumetric density and the volumetric density of each region is greater than zero. CC. The spunbonded nonwoven fabric of paragraphs S-BB, wherein the difference in volumetric density in the first zone is greater than about 0.042 g / cm 3 is. DD. The spunbonded nonwoven fabric of paragraphs S-CC, further comprising a third zone having a pattern of three-dimensional features each defining a microzone comprising a first region and a second region, wherein a value difference for an intense property for one of the microzones is in of the third zone differs a) from the intense property value difference for at least one of the micro-zones in the first zone and b) from the intense property value difference for at least one of the micro-zones in the second zone. EE. The spunbonded nonwoven fabric of paragraphs S-DD, wherein at least one of the surfaces has a TS7 value of less than about 15 dB V 2 RPM. FF. The spunbonded nonwoven fabric of paragraph EE, wherein the first surface has a TS7 value of from about 2 to about 12 dB V 2 rpm and the second surface has a TS7 value that differs from the TS7 value of the first surface. GG The spunbonded nonwoven fabric of paragraph FF, wherein the second surface has a TS7 value that is lower than the TS7 value of the first surface. HH. The spunbonded nonwoven fabric of paragraph EE, wherein the second surface has a TS7 value of from about 3 to about 8 and the first surface has a TS7 value that is different than the TS7 value of the first surface. II. The spunbonded nonwoven fabric of paragraph HH, wherein the first surface has a TS7 value that is higher than the TS7 value of the second surface. yy An absorbent article comprising a spunbonded nonwoven fabric as described in paragraphs SS-II. KK. A pack of absorbent articles, each absorbent article comprising a spunbonded nonwoven fabric as described in paragraphs S-JJ. LL. The package according to paragraph KK, wherein the package has a bag stack height of between about 70 mm and about 100 mm according to the bag stack height test described herein. MM. Spunbonded nonwoven fabric comprising: a. a first surface and a second surface and at least a first and a second optically recognizable zone on at least one of the first and second surfaces, each of the first and second zones having a pattern of three-dimensional features, each of the three-dimensional features defining a micro-zone that a first region and a second region, the first and second regions having a value difference for an intensive property; and b. wherein the difference in value for an intensive property for at least one of the micro-zones in the first zone differs from the difference in value for the intensive property for at least one of the micro-zones in the second zone; wherein in at least one of the microzones the first and second regions comprise a surfactant and the ratio of the percentage of surfactant in the first region to the percentage of surfactant in the second region is less than 1. NN. The spunbonded nonwoven fabric of paragraph MM, wherein the surfactant is selected from a group consisting of: nonionic surfactants including esters, amides, carboxylic acids, alcohols, ether polyoxyethylene, polyoxypropylene, sorbitan, ethoxylated fatty alcohols, allyl phenolic polyethoxylates, lecithin, glycerol esters, and their Ethoxylates and sugar based surfactants (polysorbates, alkyl polyglycosides), anionic surfactants including sulfonates, sulfates, phosphates, alkali metal salts of fatty acids, fatty alcohol monoesters of sulfuric acid, linear alkyl benzene sulfonates, alkyl diphenyl oxide sulfonates, lignin sulfonates, olefin sulfonates, sulfosuccinates and sulfated ethoxylates of fatty alcohols, cationic surfactants including amines ( primary, secondary, tertiary), quaternary ammonium compounds, pyridinium, quaternary ammonium salts - QAS, alkylated pyridinium salts, alkyl primary, secondary, tertiary amines and alkanolamides, zwitterionic surfactants including amino acids and derivatives, amine oxide, Bet ain and alkyl amine oxides, polymeric surfactants including polyamines, carboxylic acid polymers and copolymers, EO / PO block copolymers, ethylene oxide polymers and copolymers and polyvinylpyrrolidone, silicone surfactants including dimethylsiloxane polymers with hydrophiles, and perfluorocarboxylic acid salts and fluorosurfactants. OO. The spunbonded nonwoven fabric of paragraphs MM-NN, wherein the surfactant is a combination of castor oil ethoxylates with PEG diesters. pp The spunbonded nonwoven fabric according to paragraphs MM-OO, wherein the difference in value for the intensive property for one of the microzones in the first zone is an order of magnitude different from the difference in value for at least one of the microzones in the second zone. QQ The spunbonded nonwoven fabric of paragraphs MM-PP, wherein the intensity property value difference for one of the microzones in the first zone differs from about 1.2X to about 10X the value difference for at least one of the microzones in the second zone. RR. The spunbonded nonwoven fabric according to paragraphs MM-QQ, where the intensive property is thickness, and the thickness of each area is greater than zero. SS. The spunbonded nonwoven fabric of paragraphs MM-RR, wherein the difference in caliper in the first zone is greater than about 25 microns. TT. The spunbonded nonwoven fabric according to paragraphs MM-SS, wherein the intensive property is a basis weight and the basis weight is greater than zero in each area. UU. The spunbonded nonwoven fabric of paragraphs MM-TT, wherein the basis weight difference in the first zone is greater than about 5 grams per square meter. vv The spunbonded nonwoven fabric according to paragraphs MM-UU, wherein the intensive property is volumetric density and the volumetric density of each region is greater than zero. ww The spunbonded nonwoven fabric of paragraphs MM-W wherein the difference in volumetric density in the first zone is greater than about 0.042 g / cm 3 is. XX The spunbonded nonwoven fabric of paragraphs MM-WW, further comprising a third zone having a pattern of three-dimensional features each defining a microzone comprising a first region and a second region, wherein a value difference for an intense property for one of the microzones is in of the third zone differs a) from the intense property value difference for at least one of the micro-zones in the first zone and b) from the intense property value difference for at least one of the micro-zones in the second zone. YY. The spunbonded nonwoven fabric of paragraphs MM-XX, wherein at least one of the surfaces has a TS7 value of less than about 15 dB V 2 RPM. currently The spunbonded nonwoven fabric of paragraph YY, wherein the first surface has a TS7 value of from about 2 to about 12 dB V 2 rpm and the second surface has a TS7 value that differs from the TS7 value of the first surface. AAA. The spunbonded nonwoven fabric of paragraph ZZ, wherein the second surface has a TS7 value that is lower than the TS7 value of the first surface. BBB. The spunbonded nonwoven fabric of paragraph YY, wherein the second surface has a TS7 from about 3 to about 8 and the first surface has a TS7 that is different than the TS7 of the first surface. CCC. The spunbonded nonwoven fabric of Paragraph BBB, wherein the first surface has a TS7 value that is higher than the TS7 value of the second surface. DDD. An absorbent article comprising a spunbonded nonwoven fabric as described in paragraphs MM-CCC. EEE. A pack of absorbent articles, each absorbent article comprising a spunbond nonwoven fabric as described in paragraphs MM-DDD. FFF. The package according to paragraph EEE, wherein the package has a bag stack height of between about 70 mm and about 100 mm according to the bag stack height test described herein. GGG. A nonwoven fabric comprising a first surface and a second surface and an optically recognizable pattern of three-dimensional features on one of the first and second surfaces, each of the three-dimensional features defining a microzone having a first region and a second region, the first and the second area have a value difference at an intense property, where the intense property is one or more of: a. Thickness, b. basis weight and c. volumetric density, and wherein in at least one of the microzones the first region is hydrophobic and the second region is hydrophilic. HHH. The nonwoven fabric according to paragraph GGG, wherein the difference in value for the intensive property for one of the micro-zones in the first zone is an order of magnitude different from the difference in value for at least one of the micro-zones in the second zone. III. The nonwoven fabric of paragraphs GGG-HHH, wherein the intensity property value difference for one of the microzones in the first zone differs from about 1.2X to about 10X the value difference for at least one of the microzones in the second zone. yyy The nonwoven fabric according to paragraphs GGG-III, wherein the intensive property is caliper and the caliper of each region is greater than zero. KKK. The nonwoven fabric of heels GGG-JJJ wherein the difference in thickness in the first zone is greater than about 25 microns. LLL. The nonwoven fabric according to paragraphs GGG-KKK, wherein the intensive property is a basis weight and the basis weight is greater than zero in each area. mmm The nonwoven fabric of paragraphs GGG-LLL, wherein the basis weight difference in the first zone is greater than about 5 grams per square meter. NNN. The non-woven fabric according to paragraphs GGG-MMM, wherein the intensive property is volumetric density and the volumetric density of each region is greater than zero. OOO. The nonwoven fabric according to paragraphs GGG-NNN, wherein the difference in volumetric density in the first zone is greater than about 0.042 g / cm 3 is. PPP. The nonwoven fabric according to paragraphs GGG-OOO, wherein at least one of the surfaces has a TS7 value of less than about 15 dB V 2 RPM. QQQ. The nonwoven fabric according to paragraph PPP, wherein the first surface has a TS7 value of from about 2 to about 12 dB V 2 rpm and the second surface has a TS7 value that differs from the TS7 value of the first surface. RRR. The nonwoven fabric of paragraph QQQ, wherein the second surface has a TS7 value that is lower than the TS7 value of the first surface. SSS. The nonwoven fabric according to paragraph PPP, wherein the second surface has a TS7 value of from about 3 to about 8 and the first surface has a TS7 value that is different than the TS7 value of the first surface. TTT. The nonwoven fabric according to paragraph SSS, wherein the first surface has a TS7 value that is higher than the TS7 value of the second surface. UUU. An absorbent article comprising a nonwoven fabric as described in any of paragraphs GGG-TTT. VVV. A pack of absorbent articles, each absorbent article comprising a nonwoven fabric as described in paragraphs GGG-VVV. www. The package according to paragraph VVV, wherein the package has a bag stack height of between about 70 mm and about 100 mm according to the bag stack height test described herein. XXX The nonwoven fabric according to paragraphs GGG-WWW, wherein the nonwoven fabric is a spunbonded construction.

[0249] The dimensions and values ​​disclosed herein should not be construed as being strictly limited to the precise numerical values ​​given. Instead, unless otherwise specified, each such dimension is intended to have the meaning of the specified value and a functionally reasonable range encompassing that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

[0250] Each document cited herein, including any cross references or related patents or applications, and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited is. Citation of any document does not imply that it is acknowledged as prior art to any embodiment disclosed or claimed herein, or that it alone or in combination with other cited references teaches, suggests or discloses such embodiment. 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 apply.

[0251] While particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the present invention. It is therefore intended in the appended claims to cover all such changes and modifications as fall within the scope of the invention. QUOTES INCLUDED IN DESCRIPTION

[0000] This list of the documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Patent Literature Cited

[0000] US3802817

[0045] US3692618

[0045] US3423266

[0045] US6610173

[0062] US5514523 [0062, 0063, 0064] US6398910

[0062] US2013 / 0199741

[0062] US 2008 / 0312622 A1 [0114, 0143]

Claims

[1] Nonwoven fabric comprising a first surface and a second surface and an optically detectable pattern of three-dimensional features on one of the first or second surfaces, wherein each of the three-dimensional features defines a microzone having a first area and a second area, wherein the first and second areas exhibit a difference in value for an intensive property, wherein the intensive property is one or more of: a. Thickness, b. Base weight and c. volumetric density, and wherein in at least one of the microzones the first region is hydrophobic and the second region is hydrophilic. [2] Nonwoven fabric according to claim 1, wherein the difference in value for the intensive property for one of the microzones in the first zone is of an order of magnitude that differs from the difference in value for at least one of the microzones in the second zone. [3] Nonwoven fabric according to one of the preceding claims, wherein the difference in value for the intensive property for one of the microzones in the first zone differs by 1.2X to 10X from the difference in value for at least one of the microzones in the second zone. [4] Nonwoven fabric according to any of the preceding claims, wherein the intensive property is thickness and the thickness of each region is greater than zero. [5] Nonwoven fabric according to claim 4, wherein the difference in thickness in the first zone is greater than 25 micrometers. [6] Nonwoven fabric according to any of the preceding claims, wherein the intensive property is the base weight and the base weight of each region is greater than zero. [7] Nonwoven fabric according to claim 6, wherein the difference in base weight in the first zone is greater than 5 grams per square meter. [8] Nonwoven fabric according to any of the preceding claims, wherein the intensive property is the volumetric density and the volumetric density of each region is greater than zero. [9] Nonwoven fabric according to claim 8, wherein the difference in volumetric density in the first zone is greater than 0.042 g / cm³ 3 is. [10] Nonwoven fabric according to any of the preceding claims, wherein at least one of the surfaces has a TS7 value of less than 15 dB V 2 has a rpm. [11] Nonwoven fabric according to claim 10, wherein the first surface has a TS7 value of 2 to 12 dB V 2 The second surface has a TS7 value that differs from the TS7 value of the first surface. [12] Nonwoven fabric according to claim 11, wherein the second surface has a TS7 value that is smaller than the TS7 value of the first surface. [13] Nonwoven fabric according to claim 10, wherein the second surface has a TS7 value of 3 to 8 and the first surface has a TS7 value that differs from the TS7 value of the first surface. [14] Nonwoven fabric according to claim 13, wherein the first surface has a TS7 value that is higher than the TS7 value of the second surface. [15] Absorbent article comprising a nonwoven fabric as described in any one of the preceding claims.