Nonwovens and absorbent articles with shaped, soft and textured nonwovens

Abstract

Nonwoven fabric (10) comprising a surface, wherein the surface comprises a section having a low base weight area-one total area of ​​5% to 20% of a total area of ​​the section of the surface, wherein the remainder of the section of the surface is a high base weight area-two total area, and the section having: a TS7 value in the range of 1 dB V 2 rms up to 4.5 dB V 2 rms, after the Emtec test; and a TS750 value in the range of 6 dBV 2 rms up to 30 dB V 2 rms, according to the Emtec test.

Description

AREA

[0001] The present disclosure relates to absorption articles with shaped, soft and textured nonwovens. BACKGROUND

[0002] Absorbent products are used to contain and absorb bodily excretions (i.e., urine, bowel movements, and menstrual fluid) in infants, children, and adults. Absorbent products can include, but are not limited to, diapers, briefs, adult incontinence products, feminine hygiene products, and absorbent pads. Various components of these absorbent products include nonwoven fabrics. Two examples of components that include nonwoven fabrics are an outer sheath nonwoven material and a top layer. Consumers desire that these two components, which form at least portions of the garment-side and wearer-side surfaces of an absorbent product, have a certain look and feel while still providing superior performance.Superior performance for a top layer might include a soft feel, while also providing texture for managing bodily excretions, breathability, and skin dryness. Superior performance for an outer sheath nonwoven might include an aesthetically pleasing texture that conveys softness and gentleness, while feeling noticeably soft to the touch. Texture and softness are important attributes that consumers desire in these two components. However, generally, the more textured a nonwoven is, the less soft it is, and vice versa. Therefore, nonwovens should be improved in this respect. Nonwovens and absorbent articles with advantageous properties are already known from WO 2016 / 108 741 A1, WO 2017 / 105 997 A1, WO 00 / 20 675 A1, and WO 2018 / 112 146 A1. SUMMARY

[0003] The present disclosure provides absorbent articles comprising shaped, soft, and textured nonwovens that resolve the contradiction between texture and softness. Generally, the more textured a nonwoven is, the less soft it is. Likewise, softer nonwovens typically exhibit very little texture, if any. The present disclosure provides a solution to this problem by providing absorbent articles comprising nonwovens with both high softness and high texture. Furthermore, the present disclosure provides a solution that resolves the contradiction between high softness and high texture while simultaneously providing several improvements in fluid handling, including rapid penetration of bodily excretions and improved dryness of the skin and upper layers.The nonwovens described in this disclosure can typically form at least one section of a support-side surface (e.g., top layer) and at least one section of a garment-side surface (e.g., outer sheath nonwoven). Softness, texture (i.e., suppleness), and / or stiffness can be measured using an Emtec Tissue Softness Analyzer, according to the Emtec Test described herein. Perceptible softness is measured as TS7. Texture / suppleness is measured as TS750. Stiffness is measured as D. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The aforementioned and other features and advantages of the present revelation, and the manner in which they are achieved, become more apparent, and the revelation itself is better understood in relation to the following description of exemplary forms of the revelation in conjunction with the accompanying drawings, whereby the following applies: Fig. Figure 1 is a photograph of an example of a nonwoven fabric of the present disclosure. Fig. Figure 2 is a photograph of an example of a nonwoven fabric from the present disclosure. Fig. Figure 3 is a photograph of an example of a nonwoven fabric from the present disclosure. Fig. Figure 4 is a cross-sectional view of a section of the nonwoven fabric of the present disclosure, taken along line 4 - 4 of Fig. 1. Fig. Figure 5A is a schematic drawing illustrating a cross-section of a thread produced with a primary component A and a secondary component B in a side-by-side configuration. Fig. 5B is a schematic drawing illustrating a cross-section of a thread produced with a primary component A and a secondary component B in an eccentric sheath / core configuration. Fig. 5C is a schematic drawing illustrating a cross-section of a thread produced with a primary component A and a secondary component B in a concentric sheath / core design. Fig. Figure 6 is a photograph showing a perspective view of a trilobal bicomponent fiber. Fig. Figure 7 is a schematic representation of an example of an apparatus for producing a nonwoven fabric of the present disclosure. Fig. Figure 8 is a detail of a section of the apparatus of Fig. 7 for joining a section of a substance of the present disclosure. Fig. Figure 9 is a further detail of a section of the apparatus for joining a section of a substance of the present disclosure, taken from the detail Fig. 9 in Fig. 8. Fig. Figure 10 is a detail of a section of the apparatus for optionally additionally joining a section of a nonwoven fabric of the present disclosure. Fig. Figure 11 is a photograph of an example of a nonwoven fabric of the present disclosure. Fig. 12 is a photograph of a section of a shaping tape that is useful for forming a nonwoven fabric of the present disclosure. Fig. Figure 13 is a cross-sectional image of a section of the shaping band of Fig. 12. Fig. 14 is an image of a section of a mask used to at least partially control the shaping band of Fig. to generate 12. Fig. 15 is an image of a section of a mask used to at least partially control the shaping band of Fig. to generate 16. Fig. 16 is a photograph of a section of a shaping tape that is useful for forming a nonwoven fabric of the present disclosure. Fig. 17 is an image of a section of a mask used to at least partially control the shaping band of Fig. to generate 18. Fig. 18 is a photograph of a section of a shaping tape that is useful for forming a nonwoven fabric of the present disclosure. Fig. 19 is a photograph of a section of a shaping tape that is useful for forming a nonwoven fabric of the present disclosure. Fig. 20 is an image of a mask used to at least partially control the shaping band of Fig. to generate 19. Fig. 21 is a photograph of a nonwoven fabric of the present disclosure, which is mounted on the forming strip of Fig. It was manufactured in 19. Fig. Figure 22 is a schematic perspective view of a shaping band of the present revelation. Fig. Figure 23 is a top view of a nonwoven substrate, including the nonwovens of the present disclosure. Fig. Figure 24 is a top view of a nonwoven substrate, including the nonwovens of the present disclosure. Fig. 25 is a photograph of an example of a nonwoven fabric of the present disclosure. Fig. Figure 26 is a cross-sectional view of an example of a nonwoven fabric. Fig. 25. Fig. Figure 27 is a perspective view of a micro-CT image of an example of a nonwoven fabric of the present disclosure. Fig. Figure 28 is a perspective view of a micro-CT image of an example of a nonwoven fabric of the present disclosure. Fig. Figure 29 is a micro-CT image of a cross-section of an example of a nonwoven fabric. Fig. 27 and Fig. 28. Fig. Figure 30 is a micro-CT image of a top view of an example of a nonwoven fabric. Fig. 27 and Fig. 28. Fig. Figure 31 is a graphic illustration of various advantages of the nonwovens of the present disclosure. Fig. 32 is a recording of a section of an example of a nonwoven fabric from the present disclosure. Fig. 33 is a recording of a section of an example of a nonwoven fabric from the present disclosure. Fig. 34 is a recording of a section of an example of a nonwoven fabric from the present disclosure. Fig. 35 is a recording of a section of an example of a nonwoven fabric from the present disclosure. Fig. Figure 36 is a photograph of a cross-section of an example of a nonwoven fabric. Fig. 36 and Fig. 35. Fig. 37 is a recording of a section of an example of a nonwoven fabric from the present disclosure. Fig. 38 is a recording of a section of an example of a nonwoven fabric from the present disclosure. Fig. 39 is a recording of a section of an example of a nonwoven fabric from the present disclosure. Fig. 40 is a recording of a section of an example of a nonwoven fabric from the present disclosure. Fig. Figure 41 is a micro-CT image of a top view of an example of a nonwoven fabric. Fig. 27 and Fig. 28 after undergoing additional processing. Fig. Figure 42 is a graphic representation of various advantages of nonwovens from Fig. 41. Fig. Figure 43 is a pictorial representation of a sample page that includes a variety of absorption articles. Fig. Figure 44 is a perspective front view of an absorption article comprising one or more nonwovens. Fig. Figure 45 is a rear perspective view of the absorption article by Fig. 44. Fig. 46-48 are examples of patterns of nonwoven top layers of the present disclosure. Fig. Figures 49-50 are examples of patterns of outer sheath nonwoven materials of the present disclosure. DETAILED DESCRIPTION

[0005] Several non-restrictive forms of the present disclosure are now described to provide a general understanding of the principles of structure, function, manufacture, and use of the reversible and configurable absorbing articles disclosed herein. One or more examples of these non-restrictive forms are illustrated in the accompanying drawings. The person skilled in the art understands that the reversible and configurable absorbing articles described herein and illustrated in the accompanying drawings are non-restrictive example forms and that the scope of protection of the various non-restrictive forms of the present disclosure is determined solely by the claims. The features illustrated or described in connection with one non-restrictive form can be combined with the features of other non-restrictive forms.Such modifications and variations are to be included within the scope of protection of the present disclosure.

[0006] The present disclosure provides formed, soft, and textured nonwovens that are formed directly on a shaped forming belt with continuous spunbond nonwoven filaments in a single forming process. The nonwoven of the present disclosure can assume a shape corresponding to the shape of the forming belt. The nonwovens of the present disclosure resolve the contradiction between softness and texture, providing a high degree of texture while still offering a high degree of softness.

[0007] Photographs of representative examples of shaped nonwovens 10 are in the Fig. Figures 1-3 show that the formed nonwovens can be used, for example, as top layers and / or outer sheath nonwoven materials. They can also be used as other nonwoven components in absorbent articles or in other end products, such as cleaning and dusting products and medical gowns.

[0008] The shaped nonwoven fabric 10 can be a spunbond substrate with a first surface 12 and a second surface 14. In the Fig. 1-3 is the second surface 14 facing the viewer and is opposite the first surface 12, which is in the Fig. 1-3 is not visible, however in Fig. 4 is shown. The term “surface” is widely used to refer to the two sides of a web for descriptive purposes and is not intended to imply any required flatness or suppleness. Although the formed nonwoven fabric 10 is soft and elastic, it is described in a flattened state in relation to one or more XY planes parallel to the flattened state, and which in web manufacturing technology correspond to the plane of the machine transverse direction, CD, or the machine running direction, MD, as shown in the Fig. Figures 1-3 show that the length L in the MD and the width W in the CD determine the total area A for the nonwoven fabric 10. As shown in Fig. Figure 4 shows what a cross-section of a section of the in Fig. For the purposes of description, the three-dimensional features of the shaped nonwoven fabric 10 shown in Figure 1 are described such that they extend outwards in a Z-direction from an XY plane of the first surface 16 (see Figure 1). Fig. 4) A maximum dimension of three-dimensional features in the Z-direction can define the maximum distance between the plane of the first surface 16 and an XY plane of the second surface 18, where the distance can be measured as the average thickness AC of the nonwoven fabric 10. The average thickness can be determined by optical, non-contact means, or it can be determined by devices incorporating spaced-apart flat plates which measure the thickness of the interposed nonwoven fabric at a predetermined pressure. It is not necessary for all three-dimensional features to have the same maximum dimension in the Z-direction, but a multitude of three-dimensional features can have essentially the same maximum dimension in the Z-direction, determined by the fiber placement process and the properties of the forming tape, as discussed below.

[0009] The Fig. The nonwovens shown in Figures 1-4 (as well as other nonwovens disclosed herein) can be fluid-permeable. The entire nonwoven can be considered fluid-permeable. Areas or zones (described below) can be fluid-permeable. Fluid-permeable, as used herein with respect to the nonwoven, means that the nonwoven has at least one zone which allows fluid to pass through it under the conditions of use of an end product. For example, if the nonwoven is used as a top layer on a disposable diaper, it can have at least one zone which has a degree of fluid permeability which allows urine to pass through to an underlying absorbent core. Fluid-permeable, as used herein with respect to an area, means that the area has a porous structure which allows fluid to pass through it.

[0010] As in the Fig. As shown in Figures 1-4, the nonwoven fabric 10 can exhibit a regular repeating pattern of a variety of discrete, recognizably distinct three-dimensional features, including a first three-dimensional feature 20, a second three-dimensional feature 22, and a third three-dimensional feature 24, as shown in the Fig. 2 and Fig. 3 shown. For example, it differs in Fig. 1. The heart-shaped first three-dimensional feature 20 is distinguishable from the smaller, generally triangular-shaped second three-dimensional feature 22. The discernible differences may be visual, such as discernible differences in size and / or shape.

[0011] The three-dimensional features of the nonwoven fabric 10 can be formed by depositing fibers, such as by carding, air spinning, solution spinning, or melt spinning, directly onto a forming strip that has a pattern of corresponding three-dimensional features. In a sense, the nonwoven fabric 10 is cast onto a forming strip that determines the shapes of the three-dimensional features of the fabric 10. However, it is important, as described herein, that the apparatus and method of the present disclosure produce the nonwoven fabric 10 in such a way that, in addition to taking the shape of the forming strip, it is endowed with advantageous properties for use in absorbent articles, garments, medical products, and cleaning products due to the properties of the forming strip and the apparatus for forming the fabric.In particular, due to the nature of the forming tape and other apparatus elements, as described below, the three-dimensional features of the nonwoven fabric 10 exhibit significant dimensions that may differ between a first and a second region within a microzone (described in more detail below), or from feature to feature, in a manner that provides the nonwoven fabric 10 with advantageous properties when used in personal care products, clothing, medical products, and cleaning products. For example, a first three-dimensional feature 20 may have a base weight or density that differs from the base weight or density of a second three-dimensional feature 22, and both may have a base weight or density that differs from the base weight or density of a second three-dimensional feature 22.which differs from that of a third three-dimensional feature 24 and provides advantageous aesthetic and functional properties with respect to fluid uptake, distribution and / or absorption in diapers or sanitary napkins.

[0012] It is assumed that the difference in intensity between the various three-dimensional features of the nonwoven fabric 10 is due to the fiber distribution and compaction resulting from the apparatus and process described herein. The fiber distribution arises during the fiber deposition process, in contrast, for example, to a post-processing process such as embossing. Since the fibers can move freely during a process such as melt spinning, with the movement being determined by the nature of the features, the air permeability of the forming belt, and other processing parameters, it is assumed that the fibers in a nonwoven fabric 10 are more stably and permanently shaped.

[0013] As in the Fig. As can be seen in Figures 1-3, and as the description herein indicates, the various three-dimensional features can be bounded by optically perceptible areas (in relation to the interior of a three-dimensional feature) that are in the form of a closed figure (such as the heart shape in the Fig. 1 and Fig. 3 and the diamond shape in the Fig. 2 and Fig. 3) may be present. The closed figure can be a curvilinear closed figure, such as the heart shape in the Fig. 1 and Fig. 3. The sketched, visually perceptible areas can be the areas of the nonwoven fabric 10 that are most closely adjacent to the first surface 12 in the Z-direction, as shown in Fig. 4 shown areas 21, and which may lie at least partially in or on the first level 16 when they are in a flattened state. For example, as in Fig. Figure 1 shows the first three-dimensional feature 20, which is heart-shaped, and as illustrated here as an example of a first three-dimensional feature 20A, it is defined by a curvilinear closed heart-shaped element. A curvilinear element can be understood as a linear element that has a tangent vector V at any point along its length, where the closed figure can be such that the tangent vector V has both MD and CD components that modify the values ​​of more than 50% of the length of the linear element of the closed figure. Of course, the figure does not have to be completely 100% closed, but the linear element can have breaks that do not affect the overall impression of a closed figure.As discussed below in connection with the shaping tape, the sketching, optically perceptible curvilinear, closed heart-shaped element is formed by a corresponding closed heart-shaped raised element on the shaping tape to create the closed figure of a heart on fabric 10. In a repeating pattern, the individual shapes (in the case of the first three-dimensional feature in ) can be Fig. 1 a heart shape) in aesthetically pleasing, soft, pillow-like features over the total area OA of the second surface 14 of fabric 10. If the nonwoven fabric 10 is to be used as a top layer for a diaper or sanitary napkin, the second surface 14 of the nonwoven fabric 10 can be carrier-side to provide superior aesthetic and performance-related advantages in terms of softness, compression resistance, and fluid absorption.

[0014] The present disclosure can utilize the melt spinning process. In melt spinning, no mass loss occurs in the extrudate. Melt spinning differs from other spinning processes, such as wet or dry spinning from solution, where a solvent is eliminated from the extrudate by volatilization or diffusion, resulting in a mass loss.

[0015] Melt spinning can be carried out at temperatures of approximately 150 °C to 280 °C or 190 °C to 230 °C. Fiber spinning speeds can exceed 100 meters per minute, range from approximately 1,000 to 10,000 meters per minute, 2,000 to 7,000 meters per minute, and 2,500 to 5,000 meters per minute. Spinning speeds can influence the brittleness of the spun fiber; generally, the higher the spinning speed, the less brittle the fiber. Continuous fibers can be produced by spunbond or meltblown processes.

[0016] A nonwoven fabric 10 of the present disclosure can comprise multicomponent continuous polymer filaments comprising a primary polymer component and a secondary polymer component. The filaments can be bicomponent continuous filaments comprising a primary polymer component A and a secondary polymer component B. The bicomponent filaments have a cross-section, a length, and a circumferential area. Components A and B can be arranged in substantially different zones across the cross-section of the bicomponent filaments and can extend continuously along the length of the bicomponent filaments. The secondary component B forms at least a portion of the circumferential area of ​​the bicomponent filaments along the length of the bicomponent filaments in a continuous manner. The polymer components A and B can be melt-spun into multicomponent fibers on conventional melt-spinning equipment.The equipment is selected based on the desired multi-component configuration. Commercially available melt spinning equipment is supplied by Hills, Inc., located in Melbourne, Florida. The spinning temperature ranges from approximately 180°C to 230°C. The spunbond bicomponent fibers can have an average diameter of approximately 6 to 40 micrometers or approximately 12 to 40 micrometers.

[0017] Components A and B can either be arranged side by side, as in Fig. 5A shown, arranged or in an eccentric shell / core configuration, as shown in Fig. 5B shows how to obtain threads that exhibit a natural spiral crimp. Alternatively, components A and B can be arranged in a concentric core configuration, as shown in Fig. 5C shown. Additionally, components A and B can be arranged in a multi-nose core configuration, as shown in Fig. Figure 6 shows that other multi-component fibers can be produced using the compositions and processes of this disclosure. The bi-component and multi-component fibers can be arranged in a pie-slice, ribbon, or island configuration, or any combination thereof. The fiber sheath can be continuous or discontinuous around the core. The fibers of this disclosure can have different geometries, including round, elliptical, star-shaped, rectangular, and other various eccentricities.

[0018] Methods for extruding multi-component polymer threads into such designs are generally known to the average professional.

[0019] A wide variety of polymers, including polyolefins (such as polyethylene, polypropylene, and polybutylene), polyesters, polyamides, polyurethanes, elastomeric materials, and the like, are suitable for carrying out the present disclosure. Examples of polymeric materials that can be spun into threads may include natural polymers.

[0020] The primary component A and the secondary component B can be selected such that the resulting bicomponent yarn provides improved nonwoven bonding and substrate softness. The primary polymer component A can have a melting temperature lower than that of the secondary polymer component B.

[0021] The primary polymer component A can comprise polyethylene or a statistical copolymer of propylene and ethylene. The secondary polymer component B can comprise polypropylene or a statistical copolymer of propylene and ethylene. Polyethylenes include linear low-density polyethylene and high-density polyethylene. Additionally, the secondary polymer component B can include additives to enhance the natural helical crimp of the fibers, lower the bonding temperature of the fibers, and increase the wear resistance, strength, and softness of the resulting fabric.

[0022] Inorganic fillers, such as the oxides of magnesium, aluminum, silicon and titanium, can be added, for example, as cost-effective fillers or processing aids.

[0023] The fibers of the present invention may also comprise a lubricant additive in an amount sufficient to impart the desired feel to the fiber. As used herein, “lubricant additive” or “lubricant” means an external lubricant. Upon melting with the resin, the lubricant gradually separates or migrates to the surface during cooling or after manufacture, forming a uniform, invisibly thin coating, which provides permanent lubrication. The lubricant may be a rapidly blooming lubricant.

[0024] During manufacturing, in a post-treatment, or even both, the nonwoven fabric of this disclosure can be treated with surfactants or other agents to either hydrophilize or hydrophobize the web. For example, a nonwoven fabric used for a top layer can be treated with a hydrophilizing material or surfactant to make it permeable to bodily excretions such as urine. For further absorbent articles, the top layer can remain in its natural hydrophobic state or be made even more hydrophobic by the addition of a hydrophobizing material or surfactant.

[0025] Suitable materials for the production of the multi-component threads of the substance of the present disclosure may include PP3155 polypropylene, obtained from Exxon Mobil Corporation, and PP3854 polypropylene, obtained from Exxon Mobil Corporation.

[0026] If polypropylene is component A and the second polypropylene composition is component B, the adjacent bicomponent threads can contain approximately 5 wt% to approximately 95 wt% polypropylene and approximately 95 wt% to approximately 5 wt% another polypropylene composition. The threads can contain approximately 30 wt% to approximately 70 wt% polyethylene and approximately 70 wt% to approximately 30 wt% of each component.

[0027] With reference to Fig. Figure 7 discloses a typical production line 30 for the manufacture of fabrics 10 of the present disclosure. The production line 30 is arranged to produce a fabric from bicomponent continuous filaments, but it is understood that the present disclosure includes nonwovens manufactured with mono- or multicomponent filaments with more than two components. Bicomponent filaments can be trilobal.

[0028] Production line 30 includes a pair of extruders 32 and 34, each driven by extruder drives 31 and 33 respectively, to separately extrude the primary polymer component A and the secondary polymer component B. Polymer component A is fed into extruder 32 from a first hopper 36, and polymer component B is fed into extruder 34 from a second hopper 38. Polymer components A and B can be fed from extruders 32 and 34 through respective polymer lines 40 and 42 into filters 44 and 45 and melt pumps 46 and 47, which pump the polymer into a spinning pack 48. Spindle nozzles for extruding bicomponent filaments are widely known to the average person skilled in the art and are therefore not described in detail here.

[0029] In general terms, the spinning package 48 comprises a housing containing a plurality of plates stacked one on top of the other, with a pattern of openings arranged to create flow paths for the separate conveyance of polymer components A and B through the spinneret. The spinning package 48 has openings arranged in one or more rows. The spinneret openings form a downward-extending curtain of filaments as the polymers are ejected through the spinneret. For the purposes of this disclosure, spinnerets can be arranged to form sheath / core or side-by-side bicomponent filaments that are in Fig. 5A, Fig. 5B and Fig. 5C are illustrated, as well as non-circular fibers, such as trilobal fibers, as in Fig. Figure 6 shows. In addition, the fibers can be a single component comprising a polymer component such as polypropylene.

[0030] Production line 30 also includes a quench blower 50, which is located adjacent to the curtain of threads extending from the spinneret. Air from the quench blower 50 quenches the threads extending from the spinneret. The quench air can be directed from one side of the thread curtain or from both sides of the thread curtain.

[0031] A damper 52 is arranged below the spinneret and receives the quenched fibers. Fiber drawing units or aspirators for use as dampers in melt-spun polymers are generally known. Suitable fiber drawing units for use in the process of the present disclosure include a linear fiber damper of the type shown in U.S. Patent No. 3,802,817 and eductive guns of the type shown in U.S. Patent No. 3,692,618 and U.S. Patent No. 3,423,266.

[0032] In general terms, the damper 52 comprises an elongated vertical passage through which the threads are drawn by the intake of air that enters from the sides of the passage and flows downwards through it. A shaped, endless, at least partially foraminous forming belt 60 is arranged below the damper 52 and receives the endless threads from the outlet opening of the damper 52. The forming belt 60 is a belt and runs around the guide rollers 62. A vacuum 64, arranged below the forming belt 60 where the threads are deposited, presses the threads against the forming surface. Although the forming belt 60 is described as a belt in Fig. As shown in Figure 8, it is understood that the forming belt can also be in other shapes, such as a drum. Details of specific shaped forming belts are explained below.

[0033] During operation of production line 30, hoppers 36 and 38 are filled with the respective polymer components A and B. The polymer components A and B are melted and extruded through the respective extrusion presses 32 and 34, via polymer lines 40 and 42, and the spinning pack 48. Although the temperatures of the molten polymers vary depending on the polymers used, when polyethylene is used as primary component A and secondary component B, the temperatures can range from approximately 190 °C to approximately 240 °C.

[0034] As the ejected filaments extend below the spinneret, an airflow from the quench blower 50 at least partially quenches the filaments and, in the case of certain filaments, induces the crystallization of molten filaments. The quench air can flow in a direction substantially perpendicular to the length of the filaments at a temperature of about 0 °C to about 35 °C and a speed of about 100 to about 400 feet per minute. The filaments can be sufficiently quenched before being gathered on the forming belt 60 so that they can be arranged by the compressed air passing through the filaments and the forming surface. Quenching the filaments reduces their stickiness, preventing them from sticking too tightly to one another before being joined, and allowing them to be moved or arranged on the forming belt during filament gathering and web formation.

[0035] After quenching, the threads are drawn into the vertical passage of the damper 52 by a flow of the fiber drawing unit. The damper can be located 30 to 60 inches below the base of the spinneret.

[0036] The threads can be deposited through the outlet opening of the damper 52 onto the shaped, running forming belt 60. While the threads are in contact with the forming surface of the forming belt 60, the vacuum 64 draws the air and threads against the forming belt 60 to form a nonwoven web of continuous threads that assume a shape corresponding to the shape of the forming surface. As discussed above, because the threads are quenched, they are not too sticky, and the vacuum can move or arrange the threads on the forming belt 60 as the threads are collected on the forming belt 60 and formed into the fabric 10.

[0037] Production line 30 further comprises one or more binding devices, such as the cylindrical compression rollers 70 and 72, which form a roller gap through which the fabric can be compacted (e.g., calendered) and which can be heated to bind fibers as well. One or both of the compression rollers 70, 72 can be heated to provide improved properties and benefits for the nonwoven fabric 10 by bonding sections of the fabric. For example, it is assumed that heating sufficient to provide thermal bonding improves the tensile strength properties of the fabric 10. The compression rollers can be a pair of smooth-surface stainless steel rollers with independent heating controls. The compression rollers can be heated by electric elements or hot oil circulation.The gap between the compaction rollers can be hydraulically controlled to exert a desired pressure on the material as it passes through the compaction rollers on the forming belt. For example, with a forming belt thickness of 1.4 mm and a spunbond nonwoven fabric with a base weight of 25 grams per square meter, the roller gap between compaction rollers 70 and 72 can be approximately 1.4 mm.

[0038] An upper compaction roller 70 can be heated sufficiently to melt binding fibers on the first surface 12 of the fabric 10, thus giving the nonwoven fabric strength so that it can be removed from the forming belt 60 without losing its integrity. As in the Fig. 8 and Fig. As shown in Figure 9, when, for example, rollers 70 and 72 rotate in the direction indicated by the arrows, the tape 60 with the spunbond nonwoven fabric laid on it enters the roller gap formed by rollers 70 and 72. The heated roller 70 can heat the sections of the nonwoven fabric 10 that are pressed against it by the raised resin elements of tape 60, i.e., in areas 21, to produce bonded fibers 80 on at least the first surface 12 of fabric 10. As can be understood from the description herein, the bonded areas thus formed can adopt the pattern of the raised elements of the forming tape 60. For example, the bonded areas thus formed can be an essentially continuous network or an essentially semi-continuous network on the first surface 12 of areas 21, which exhibit the same pattern as the cores of Fig. 1 and Fig. 11. By adjusting the temperature and residence time, the bonding can be primarily limited to fibers that are closest to the first surface 12, or a thermal bond to the second surface 14 can be achieved, as in Fig. 11 (which also shows point bindings 90, as discussed in more detail below) and Fig. Figures 34-38 show that the bond can also be a discontinuous network, for example as point bonds 90, as discussed below.

[0039] The raised elements of the forming strip 60 can be selected to define various network properties of the forming strip and the connected areas of the nonwoven substrate 11 or the nonwoven fabric 10. The network corresponds to the resin forming the raised elements of the forming strip 60 and can comprise essentially continuous, essentially semi-continuous, discontinuous options, or combinations thereof. These networks can describe the raised elements of the forming strip 60 with respect to their appearance in the XY planes of the forming strip 60 or the three-dimensional features comprising the nonwoven substrate 11 or the nonwoven fabric 10 of the present invention.

[0040] An "essentially continuous" network refers to an area in which any two points can be connected by an unbroken line that passes completely within the area along its entire length. This means that the essentially continuous network exhibits continuity in all directions parallel to the first plane and terminates only at the edges of this area. The term "essentially" in conjunction with "continuous" is intended to indicate that, while absolute continuity can be achieved, minor deviations from absolute continuity may be tolerable, provided these deviations do not noticeably impair the performance of the fiber structure (or a compression molding element) as designed and planned.

[0041] A “substantially semi-continuous” network refers to an area that has “continuity” in all, or at least one, directions parallel to the first plane, where no two arbitrary points on this area can be connected by an unbroken line that lies entirely within the area along its entire length. The semi-continuous framework can only exhibit continuity in one direction parallel to the first plane. Analogous to the continuous region described above, while absolute continuity in all directions, or at least in one direction, is preferred, slight deviations from such continuity may be tolerable as long as these deviations do not noticeably impair the performance of the fiber structure.

[0042] “Discontinuous” network refers to individual and separate surfaces that are discontinuous in all directions parallel to the first level.

[0043] After compaction, the nonwoven fabric 10 can leave the forming belt 60 and be calendered through a roller gap formed by calender rollers 71, 73, after which the fabric 10 can be wound onto a roll 75. As shown in the schematic cross-section of Fig. As shown in Figure 10, the calender rolls 71 and 73 can be stainless steel rolls, comprising an engraved pattern roll 84 and a smooth roll 86. The engraved roll can have raised sections 88 that can provide additional compaction and bonding to the fabric 10. The raised sections 88 can be a regular pattern of relatively small, spaced-apart "pins" forming a pattern of relatively small spot bonds 90 in the roll gap of the calender rolls 71 and 73. The percentage of spot bonds in the nonwoven fabric 10 can range from about 3% to about 30% or from about 7% to about 20%. The engraved pattern can be a variety of closely spaced, regular, generally cylindrical, and generally flat-tipped pin shapes, with pin heights ranging from about 0.5 mm to about 5 mm, and preferably from about 1 mm to about 3 mm.Pin-jointing calender rollers can form closely spaced regular point bonds 90 in the nonwoven fabric 10, as in . Fig. 11 shown. Further bonding can be achieved, for example, by hot air gluing.

[0044] The “spot bond,” 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 rollers, comprising a heated, outward-facing, patterned or engraved metal roller and a smooth or patterned metal roller. The outward-facing patterned roller may have a variety of raised, generally cylindrical pins that create circular spot bonds. The smooth roller may or may not be heated, depending on the application. In a nonwoven production line, the fabric, which may be an unbonded fiber web, is fed into the calender nip, and the fiber temperature is raised to the point at which fibers thermally fuse together at the tips of the engraved spots and against the smooth roller.The heating time is typically on the order of milliseconds. The material properties depend on process settings, such as roll temperatures, web speeds, and roll gap pressures, which can be determined by a person skilled in the art to achieve the desired degree of spot bonding. Other types of spot bonding, commonly known as hot calender bonding, can utilize different geometries for the bonds (other than circular), such as ovals, lines, and circles, for example. In one example, spot bonding produces a pattern of spot bonds that are circles with a diameter of 0.5 mm and a total bond area of ​​10%. Other bond shapes may feature raised pins that have a longest dimension across the bond area of ​​a pin ranging from about 0.1 mm to 2.0 mm, and the total bond area ranging from about 5% to about 30%.

[0045] As in Fig. As shown in Figure 11, a heated compaction roller 70 can form a bonding pattern that exhibits an essentially continuous net bonding pattern 80 (e.g., interconnected heart-shaped bonds) on the first surface 12 of nonwoven fabric 10 (in Fig. (11 not shown, as it is turned away from the viewer) and the engraved calender roll 73 can form relatively small spot bonds 90 on the second surface 14 of fabric 10. The spot bonds 90 secure loose fibers that would otherwise be prone to fuzzing or pilling during use of the fabric 10. The advantage of the resulting structure of the nonwoven fabric 10 is most evident when it is used as a top layer in an absorbent article, such as a diaper or sanitary napkin. When used in an absorbent article, the first surface 12 of the nonwoven fabric 10 can be relatively flat (relative to the second surface 14) and have a relatively large number of bonds because the heated compaction roll forms bonds 80 on the areas of the fabric that are pressed through the raised elements of the forming belt 60.This bond gives the nonwoven fabric 10 structural integrity, but can be relatively stiff or rough against a user's skin. Therefore, the first surface 12 of the nonwoven fabric 10 in a diaper or sanitary napkin can be oriented so that it faces the inside of the article, i.e., away from the wearer's body or is garment-side. Likewise, the second surface 14 can be wearer-side and in contact with the body when in use. The relatively small dot bond 90 is less likely to be perceived visually or by touch by the user, and the relatively soft three-dimensional features remain visually free of linting and pilling when in use, while feeling soft against the skin. Another bond can be used instead of, or in addition to, the bond mentioned above.

[0046] The shaping strip 60 can be manufactured according to the methods and processes described in US Patent No. 6,610,173, granted to Lindsay et al. on August 26, 2003, or US Patent No. 5,514,523, granted to Trokhan et al. on May 7, 1996, or US Patent No. 6,398,910, granted to Burazin et al. on June 4, 2002, or US Patent No. 2013 / 0199741, published on behalf of Stage et al. on August 8, 2013, each with the improved features and patterns disclosed herein for the manufacture of spunbond webs. The disclosures of Lindsay, Trokhan, Burazin and Stage describe tapes that are representative of papermaking tapes made with hardened resin on a woven reinforcing element, these tapes, with improvements, can be used in the present disclosure as described herein.

[0047] An example of a shaping band 60 of the type useful in the present disclosure and manufactured according to the disclosure of US Patent No. 5,514,523 is shown in Fig. Figure 12 shows that, as taught therein, a reinforcing element 94 (such as a woven band of threads 96) is thoroughly coated with a liquid photosensitive polymeric resin to a preselected thickness. A film or negative mask containing the desired repeating elements of the raised element pattern (e.g., Fig. 14) is arranged side by side on the liquid photosensitive resin. The resin is then exposed to light of a suitable wavelength through the film, such as UV light for a UV-curable resin. This light exposure causes the resin to cure in the exposed areas (i.e., in the white sections or unprinted sections in the mask). Uncured resin (resin beneath the opaque areas in the mask) is removed from the system, leaving the cured resin, which forms the depicted pattern, for example, the cured resin elements 92 in Fig. 12. Other patterns can also be formed.

[0048] Fig. Figure 12 shows a section of a shaping band 60, which is used to produce the in Fig. The nonwoven fabric 10 shown is useful. As shown, the forming tape 60 can comprise cured resin elements 92 on a woven reinforcing element 94. The reinforcing element 94 can be made of woven threads 96, as is known in the field of papermaking tapes, including resin-coated papermaking tapes. The cured resin elements can have the general structure shown in Fig. 12 is shown, and are achieved by using a mask 97 with the in Fig. 14 dimensions shown. As in the schematic cross-section in Fig. As shown in Figure 13, the hardened resin elements 92 flow around and are cured to be “fixed” to the reinforcing element 94, and can have a width at a distal end DW of about 0.020 in to about 0.060 in, or of about 0.025 in to about 0.030 in, and an overall height above the reinforcing element 94, referred to as the top layer, OB, of about 0.030 in to about 0.120 in, or about 0.50 in to about 0.80 in, or about 0.060 in. Fig. 14 represents a section of a mask 97, which defines the design and typical dimensions for a repeating unit of the repeating heart design in the in Fig. Figure 1 shows the nonwoven fabric 10. The white section 98 is transparent to UV light and allows, during the manufacturing process of the tape as described in US Patent No. 5,514,523, UV light to cure an underlying resin layer, which is cured to form the raised elements 92 on the reinforcing element 94. After washing out the uncured resin, the forming tape 60, which has a cured resin version as shown in Figure 1, is applied to the tape. Fig. 12 shows, produced by sewing together the ends of a length of the band, the length of which can be determined by the design of the apparatus, as in Fig. 7 shown.

[0049] Similarly, Fig. 15 represents a section of a mask 97, which defines the execution for a repetition unit of the repetitive execution in the in Fig. The nonwoven fabric 10 shown in Figure 2 is shown. The white section 98 is permeable to UV light and, during the tape manufacturing process, allows UV light to cure an underlying resin layer, which is then cured to form the reinforcing element 94. After the removal of the uncured resin, the forming tape 60, which has a cured resin structure as shown in Figure 2, is used. Fig. Figure 16 shows that the tape is produced by sewing together the ends of a length of tape, the length of which can be determined by the design of the apparatus, as shown in Fig. 7 shown.

[0050] Furthermore, in an example Fig. 17 represents a section of a mask that defines the execution for a repetition unit of the repetitive execution in the in Fig. The nonwoven fabric 10 shown in Figure 18 represents the white section 98, which is transparent to UV light. During the manufacturing process of the tape, this allows UV light to cure an underlying resin layer, which then hardens to form the reinforcing element 94. After the uncured resin is washed out, the

[0051] Shaping strip 60 with a cured resin version, as in Fig. 18 shown, produced by sewing together the ends of a length of fabric 10.

[0052] Another example of a portion of a shaping band 60 of the type that is useful in the present disclosure is shown in Fig. 19 shown. The section of the shaping band 60, which is in Fig. Figure 19 shows a discrete band pattern 61, which can have a length L and a width W corresponding to the length L and width W of the total area OA of a nonwoven fabric 10. That is, the shaping band 60 can have discrete band patterns 61 (as described in more detail below with reference to Figure 19). Fig. 22 discussed), each of which has a discrete band pattern total area DPOA corresponding to the total area OA of the nonwoven fabric 10. Fig. 20 represents a section of a mask that defines the execution for a repetition unit of the repetitive execution in the Fig. The nonwoven fabric 10 shown in Figure 21 represents the white section 98, which is transparent to UV light. During the manufacturing process of the tape, this UV light cures an underlying resin layer, which then hardens to form the reinforcing element 94. After washing out the uncured resin, the shaping tape 60 is coated with a cured resin design, as shown in Figure 21. Fig. 19 shown, produced by sewing the ends of one length of the band together.

[0053] The section of the shaping band that is in Fig. Figure 19 illustrates another advantage of the present disclosure. The section of a shaping band 60, which is shown in Fig. As shown in 19, it can form a substance 10 which is in Fig. 21 is shown. The one in Fig. The nonwoven fabric 10 shown in Figure 21 can have dimensions of a width W and a length L and a total area OA, which makes it suitable, for example, for use as a top layer in a disposable diaper. The nonwoven fabric 10, which is produced on a forming belt 60, as shown in Figure 21, ... total area OA, which makes it suitable, for example, for use as a top layer in a disposable diaper. Fig. 19 shown, differs from that shown in the Fig. Figures 1-3 show that the pattern of three-dimensional features formed by the discrete resin elements 92 on the forming strip 60 does not exhibit a normal repeating pattern across the entire surface. Accordingly, the pattern of three-dimensional raised elements in the discrete strip pattern surface DPOA can be described as an irregular pattern comprising diverse sections called zones. The difference between the zones can be optical, i.e., a visually perceptible difference, or, in the nonwoven fabric 10, the difference can produce a difference in average intensive properties, such as base weight or density, or combinations of optical and intensive properties.An optically perceptible difference exists if an observer under normal indoor lighting conditions (for example, 20 / 20 vision, sufficient light for reading) can optically perceive a pattern between the zones, such as the first zone 112 and the second zone 122.

[0054] The nonwoven fabric 10 can also have visually perceptible zones that correspond to the zones of the shaping tape. As in Fig. As shown in Figure 21, for example, fabric 10 can have at least two, three, or four optically perceptible zones. A first zone 110, exhibiting a first pattern of three-dimensional features and first average intensity sizes, can have a first area located substantially centrally within the total area OA. A second zone 120, exhibiting a second pattern of three-dimensional features and second average intensity sizes, can have a second area distributed substantially around and completely surrounding the first zone 110 within the total area OA. A third zone 130, exhibiting a third pattern of three-dimensional features and third average intensity sizes, can have a third area distributed substantially around and completely surrounding the second zone 120 within the total area OA.A fourth zone 140, which has a fourth pattern of three-dimensional features and fourth average intensity sizes, may have a fourth area located within the total area OA at any position, such as on a frontal surface of an upper layer, like the heart design shown in . Fig. Figure 21 shows that, in general, there can be n zones, where n is a positive integer. Each of the n zones can have an nth pattern of three-dimensional features, an nth area, and nth average intensity sizes.

[0055] The visually perceptible zones, as in Fig. Figure 21 shows that these features can include optically perceptible three-dimensional features. These diverse three-dimensional features can be bounded by areas of relatively high density (with respect to the interior of a three-dimensional feature) in the form of a closed figure, such as the heart shape in the figures. Fig. 1 and Fig. 3 and the diamond shape in the Fig. 2 and Fig. 3. In general, the three-dimensional features, as discussed in more detail below, including in the context of microzones, can be defined by a first region and a second region, wherein the first region and the second region are optically distinct from each other and there is a common intensity magnitude assigned to each of the first and second regions, and a difference exists in the common intensity magnitude value of the first region and the second region. The three-dimensional features can be defined by a first region and a second region, wherein the first region is located at a higher elevation (dimension measured in the Z-direction) than the second region with respect to the plane of the first surface. The three-dimensional features can be defined by a first region and a second region, wherein the first region is located at a higher base than the second region.

[0056] It is understood that, instead of having a constant repeating pattern uniformly distributed over the entire forming strip, the forming strip 60 of the present disclosure enables the production of a nonwoven fabric having repetitions of irregular discrete strip patterns 61, each discrete strip pattern 61 being like that in Fig. The 19 separate tape patterns shown are each used to form a nonwoven fabric 10 with a total area OA suitable for use in a disposable absorbent product, such as a diaper or sanitary napkin. The nonwoven fabrics 10 can be produced sequentially, i.e., in a row, and optionally sequentially in parallel production webs, each production web being a sequential row of nonwoven fabrics 10. The sequential row of nonwoven fabrics 10 can be produced in a machine direction along an axis parallel to the machine direction. The nonwoven material can then be cut or otherwise trimmed to produce nonwoven fabrics 10 that can be used as a top layer in disposable absorbent products.

[0057] The pattern within each discrete band pattern total area (DPOA) can be the same or different. That is, the sequentially spaced discrete band patterns can be essentially identical, or they can differ from one another in their optical appearance and / or in their intensive sizes produced on nonwoven substrates. For example, as schematically shown in Fig. Figure 22 shows the pattern of three-dimensional raised elements in a first forming zone 112 of the discrete band pattern 61A differing from the pattern of three-dimensional raised elements in the first forming zone 112 of the discrete band pattern 61B. The forming band 60 thus offers flexibility in the production of nonwoven webs 10 suitable for use in consumer goods, including disposable absorbent products.

[0058] Referring to Fig. Figure 22 shows a forming belt with an axis A parallel to a longitudinal direction, which is a machine direction. The forming belt 60 can have a plurality of discrete belt patterns 61 ordered in at least one sequential relationship with respect to the longitudinal direction. Each discrete belt pattern 61 can have a discrete belt pattern total area DPOA, which is defined in a rectangularly shaped pattern by a length L and a width W, as specified with respect to the discrete belt pattern 61A. Within its total area DPOA, each discrete belt pattern can have a first forming zone 112, which has a first pattern of three-dimensional raised elements extending outwards from the plane of the first surface, and a second forming zone 122, which has second three-dimensional raised elements extending outwards from the plane of the first surface.The first shaping zone can have a first air permeability value, and the second shaping zone can have a second air permeability value, and the first air permeability value can differ from the second air permeability value. The pattern within each sequentially ordered discrete band pattern total area DPOA can be the same or different.

[0059] By way of example and with reference to the discrete band pattern 61 of the shaping band 60, which is in Fig. 19 is shown, and the nonwoven fabric 10, which is in Fig. As shown in Figure 21, the following properties were determined. A first zone 110 of the nonwoven fabric 10 can have an average base weight of approximately 5 grams per square meter to approximately 30 grams per square meter; the second zone 120 can have an average base weight of approximately 50 grams per square meter to approximately 70 grams per square meter; and the third zone 130 can have an average base weight of approximately 25 grams per square meter to approximately 60 grams per square meter. The difference in base weight from one zone to the next can be attributed to a difference in the air permeability of the forming tape 60. Referring to the nonwoven fabric 10 of Fig. In the fabric 10, where the base weights for zones 110, 120, and 130 are 15 grams per square meter, 53 grams per square meter, and 25 grams per square meter respectively, the air permeability of zones 112, 122, and 132 of the forming strip 60 is 379 cubic feet per minute, 805 cubic feet per minute, and 625 cubic feet per minute, respectively. Thus, by varying the air permeability in the zones of the forming strip 10, the intensive values ​​of the average base weight and the average density in the zones can be adjusted across the entire surface of the fabric 10.

[0060] As can be seen from the description of the in Fig. 22 described shaping band 60 and with reference to Fig. 23 can be understood, the nonwoven substrate 11 produced on belt 60 can be described as a nonwoven substrate 11 having a plurality of sections, which are described herein as nonwovens 10, which are ordered in at least one sequential relationship with respect to the longitudinal direction, i.e. the machine direction, when produced on the forming belt 60. Fig. Figure 23 is a schematic representation of a spunbond nonwoven substrate 11 showing the sequentially ordered fabrics 10, each fabric 10 having a different pattern within the different zones. Each fabric 10 can have a total area OA defined in a rectangular pattern by a length L and a width W. Each sequentially arranged fabric 10 can have, within its total area OA, at least a first zone 110, having a first pattern of three-dimensional features and first average intensive properties, and a first area located within the total area OA; a second zone 120 with a second pattern of three-dimensional features and second average intensive properties, with a second area located substantially within the total area OA. Optionally, several zones, e.g.,A third zone 130, exhibiting a third pattern of three-dimensional features, a third average intensity size, and a third area within the total area OA, may be present. As in . Fig. As shown in Figure 23, the first pattern 110A of fabric 10A can differ from the first pattern 110B of fabric 10B and can differ from the first pattern 110C of fabric 10C. The same can apply to the second zones 120A, 120B, and 120C.

[0061] In general, the sequentially ordered nonwovens 10 of the nonwoven material 11 produced on the forming belt 60 can vary in their respective total areas, intensive sizes, and optical appearance. A common intensive size is an intensive size shared by more than one zone (in terms of zonal patterns, such as the one in Fig. 21 shown) or more than one area (for three-dimensional features, such as the regular repetition patterns, as shown in Fig. 1 shown). Such intensive quantities of the nonwovens 10 can be average values ​​and can, without limitation, include density, volumetric density, base weight, thickness, and opacity. If, for example, density is a common intensive quantity of two distinct zones or areas, a density value in one zone or area may differ from a density value in the other zone or area. Zones (such as a first zone and a second zone) may be identifiable areas that can be distinguished from one another visually and by distinct intensive quantities averaged within the zone.

[0062] Once produced, the individual nonwoven fabrics 10 can be cut to size and used for their intended purposes, such as for top layers in disposable absorbent products. A fabric 10 is cut to the appropriate total area and glued into a diaper using methods known in the prior art. Fabrics 10 can be cut to size before assembly into a diaper, or during the diaper manufacturing process, the nonwoven substrate 11 can be formed into a web along with other diaper components and cut to size after assembly.

[0063] As with reference to Fig. 24 can be understood, the nonwoven substrate 11 produced on belt 60 can be described as a nonwoven fabric 11 having a plurality of sections described herein as fabric 10 which are arranged during production on the forming belt 60 in at least one sequential relationship with respect to the longitudinal direction, i.e. the machine direction, and in at least one adjacent relationship, i.e. in the machine transverse direction. Fig. Figure 24 is a schematic representation of a spunbond substrate 11, which shows the sequentially ordered materials 10 in adjacent machine direction webs 13, wherein adjacent webs have the materials 10 arranged side by side, which are in Fig. 24 are designated as 10D, 10E, and 10F. Each fabric 10 can have a total area OA defined in a rectangular pattern by a length L and a width W. Each sequentially arranged fabric 10 can have, within its total area OA, at least a first zone 110, exhibiting a first pattern of three-dimensional features and first average intensive sizes, and a first area located within the total area OA; a second zone 120 with a second pattern of three-dimensional features and second average intensive properties, with a second area located substantially within the total area OA. Optionally, several zones can be present, e.g., a third zone 130, exhibiting a third pattern of three-dimensional features and a third average intensive size, and a third area located within the total area OA.Each of the fabric 10 in adjacent strips can be essentially identical, or they can differ from one another in terms of size, visual appearance, and / or density. Once produced, the nonwoven substrate 11 can be wound up for cutting into strips for processing into finished products, or cut and then wound up.

[0064] Another aspect of the present disclosure relates to spunbond nonwoven production lines in which multiple beams are used to improve the opacity and uniformity of the fabric. In some cases, the apparatus can include triple spunbond nonwoven beams (known in the prior art as “SSS”) and can be combined with meltblown nonwoven (M), for example in an apparatus known as an “SSMMS” spunbond nonwoven line.

[0065] By calendering the nonwoven fabric 10 to create point connections 90°, pilling can be reduced. The term "pocking" refers to the tendency of fibers to loosen and detach from the fabric 10. This loosening and detachment can occur due to friction with the manufacturing equipment during the production of disposable absorbent products or with another surface, such as a person's skin, that interacts with the fabric 10. In some applications, such as top layers in disposable absorbent products, pilling is a negative consumer phenomenon. However, the binding of fibers in place can also be negative for consumers, as it can create roughness on the surface of an otherwise soft nonwoven substrate.As expected, we found that the nonwoven substrates and nonwovens of the present disclosure can withstand an increase in bond strength (and a subsequent reduction in pilling) with minimal loss of softness. Bonding can be achieved by relatively closely spaced spot bonds, the spacing being determined by the desired degree of pilling reduction. Bonding can also be achieved by known methods for chemical or thermal bonding of nonwoven fibers, such as thermal bonding, ultrasonic bonding, pressure bonding, latex adhesion bonding, and combinations of such methods.

[0066] A further characterization of the present disclosure can be achieved by focusing on the three-dimensional features within an optically perceptible zone. Each zone discussed above, such as zones 110, 120, and 130, can be further described in terms of the microzones. A microzone is a section of the nonwoven fabric 10 within a zone that has at least two optically perceptible areas, and there is a difference in the common intensity levels between these two areas. A microzone may comprise a section of the nonwoven fabric 10 that crosses two or more zone boundaries, each having at least two optically perceptible areas, and there is a difference in the common intensity levels between these two areas.

[0067] The advantage of including microzones in the present disclosure is to illustrate that, in addition to differences with average intensity sizes within a zone, such as zones 110, 120, and 130, as discussed above, the present disclosure also provides materials exhibiting differences in actual and / or average intensity sizes between regions defined by the three-dimensional features within a zone, the three-dimensional features being precisely positioned according to the design of the forming strip used to manufacture the materials. The difference in intensity sizes between regions of the three-dimensional features provides additional optical and functional advantages. The sharp optical contrast between regions can provide extremely fine, optically distinguishable designs within and between zones.Similarly, the precise placement of areas, made possible by the precisely manufactured shaping strip, can provide excellent and tailored softness, strength, and fluid handling properties for the zones. Thus, this discovery results in the unexpected combination of differences in the average intensity sizes between the zones, as well as differences in the intensity sizes of the areas that constitute a microzone.

[0068] Areas defined by three-dimensional features can be described with reference to Fig. 25 and Fig. 26 can be understood. Fig. Figure 25 shows a light microscope image of a section of a substance 10 according to the present disclosure, and Fig. 26 is a scanning electron micrograph (SEM) of a cross-section of the in Fig. 25 shown section of material 10. Thus, the Fig. 25 and Fig. 26 a section of a nonwoven fabric 10, which was enlarged to describe the otherwise visually perceptible characteristics of the fabric in more detail. The in Fig. The section of nonwoven fabric 10 shown in Figure 25 measures approximately 36 mm in the CD and has sections of at least three optically distinct zones, as discussed below.

[0069] Both Fig. 25 and Fig. 26, which shows a section of a pattern of a nonwoven fabric 10, is a first zone 110 (on the left side of Fig. 25) characterized by generally MD-oriented rows of first regions 300 of variable width, separated by MD-oriented rows of second regions 310 of variable width. The first region is also the three-dimensional feature 20 that defines the first and second regions 300 and 310. A three-dimensional feature is a section of the nonwoven fabric 10 formed between or around a raised element of the forming tape, which in this description is the first region 300, such that the resulting structure has a relatively larger dimension in the Z-direction. The adjacent second region 310 generally has a common intensive size with the first region 300 and may have a relatively lower thickness value, i.e., a smaller dimension in the Z-direction.The relative dimensions in the Z-direction with respect to a plane of the first surface 16, as described above, can be found in . Fig. 26 are considered. Absolute dimensions are not critical; however, the dimensional differences can be visually perceived on the nonwoven fabric 10 without magnification.

[0070] The present disclosure enables advantageous properties that can best be expressed in terms of the areas defined by three-dimensional features in microzones. For example, as shown in Fig. Figure 25 shows that in zone 110, for each three-dimensional feature 20, a visible distinction exists between a first region 300 and a second region 310. As explained above, the visible distinction in the nonwoven fabric 10 may be present without magnification; the magnified views used herein are for clarity of disclosure. Any area extending sufficiently beyond the boundary between the first region 300 and the second region 310 such that a difference in their respective intensity sizes can be determined within the area may be a microzone. Additionally, light microscopy or micro-CT imaging of a structure may also be used to determine the location of regions and the area of ​​a microzone.

[0071] The Fig. The section of nonwoven fabric 10 shown in Figure 25 further illustrates another advantageous property of the fabric 10 insofar as the differences in intensity sizes between adjacent areas can be differences across zones. Thus, a microzone can be identified that spans an area surrounding the second area 310 of zone 120 and the first area 300 of zone 130. Referring to the section shown in the Fig. 25 and Fig. In the case of the nonwoven fabric shown in Figure 26, the difference in the intensity sizes exhibited by the areas in microzones may mean that a zone boundary may have a significantly different order of magnitude than the differences between the intensity sizes exhibited by the areas within a zone.

[0072] Regardless of which zone or zone boundary surrounds a particular microzone, the three-dimensional features can be characterized by the differences in the intensity levels of the regions they define. In general, the nonwoven fabric of the present disclosure can be a spunbond nonwoven having a first surface defining a plane. The fabric can have a variety of three-dimensional features, each defining a first region and a second region, the regions having a common intensity level that differs between them. The first region can be distinguished as being located at a higher elevation relative to the plane of the first surface than the second region, thus exhibiting a difference in the common intensity level of the thickness of each region.The two regions can also be distinguished by their different densities, base weights, and volumetric densities. That is, the two regions within a microzone of the spunbond nonwoven can be differentiated by differing common intensive properties, including characteristics such as thickness, density, base weight, and volumetric density. One or both regions of a microzone may be fluid-permeable. The higher-density region of a microzone may be fluid-permeable.

[0073] Within zone 110 of the in Fig. In the material section shown in Figure 25, for example, three-dimensional features 20 may be present that define at least two regions, a first region 300 and a second region 310. The difference in thickness, base weight, and volumetric density between the first and second regions for the in Fig. Zone 110, as shown in section 25, can be 274 micrometers, 1 gram per square meter or 0.437 g / cm². 3 be.

[0074] Also within zone 130 of the in Fig. In the material section shown in Figure 25, for example, three-dimensional features 20 may be present that define at least two regions, a first region 300 and a second region 310. The difference in thickness, base weight, and volumetric density between the first and second regions for the in Fig. Zone 130, shown in Figure 25, can, for example, have a density of 2083 micrometers, 116 grams per square meter, or 0.462 g / cm². 3 be.

[0075] Additionally, within zone 120 of the in Fig. In the material section shown in Figure 25, for example, three-dimensional features 20 may be present that define at least two regions, a first region 300 and a second region 310. The difference in thickness, base weight, and volumetric density between the first and second regions for the in Fig. The fabric section shown in section 25 can, for example, be 204 micrometers, 20 grams per square meter, or 0.53 g / cm². 3 Zone 120 forms something that appears in an unmagnified view of nonwoven fabric 10 as a sewn boundary between zones 110 and 130.

[0076] Furthermore, in a zone which forms the border between zones 120 and 130 of the in Fig. The material section shown in Figure 25 is surrounded, for example, by at least two areas: a first area 300 in zone 130 and a second area 310 in zone 120. The difference in thickness, base weight, and volumetric density between the first and second areas for the [material section shown in Figure 25] is [a specific example of a different material section]. Fig. The fabric section shown in section 38 can, for example, be 2027 micrometers, 58 grams per square meter or 0.525 g / cm². 3 be.

[0077] The microzones are discussed in more detail with reference to the Fig. 27-29 and those in Fig. The data presented in section 31 is discussed. Fig. Figures 27-29 are micro-CT scans of a section of a nonwoven fabric 10, whose pattern is similar to that of the one in Fig. The nonwoven fabric shown in Figure 25 resembles Figure 10. Micro-CT scanning allows the description of the same features as in Figure 25. Fig. 25 shown, in a slightly different way and in a manner that allows for a very precise measurement of the intensive quantities.

[0078] As in Fig. As shown in Figure 27, zones 110, 120, and 130 with their respective three-dimensional features are clearly visible. As in the Fig. 27 and Fig. As shown in Figure 28, the three-dimensional features are the dark colored sections, where the dark color also represents the first area 300 of a three-dimensional feature 20, and the adjacent light colored sections are the second area 310 for the three-dimensional feature 20.

[0079] Micro-CT scanning allows the image to be "sliced" and divided cross-sectionally, as from the 450° section plane. Fig. 28 shown. A sectioning plane can be placed at any point on the image; for the purposes of the present disclosure, the sectioning plane 450 intersects a cross-section substantially parallel to the Z-axis, thus creating the cross-sectional image in Fig. to generate 29.

[0080] Micro-CT technology enables precise and direct measurement of complex quantities. Thickness measurements can be taken directly from imaged cross-sections, such as the one shown in Fig. The cross-section shown in Figure 29 is based on the scale magnification. Furthermore, the color difference between the first and second areas is representative and proportional to the differences in base weight, volumetric density, and other intensive properties that can be measured directly. The micro-CT methodology is explained below in the section "Test Procedures."

[0081] Fig. Figure 30 is an image from a micro-CT scan of the section of nonwoven fabric 10 that is in Fig. 27 and Fig. Figure 28 shows the use for specific first and second areas, shown as numbered sections of nonwoven fabric 10, which can be analyzed. Fig. 30 specific areas were manually selected and analyzed to measure thickness, base weight, and volumetric density, and the data are in Fig. 31 reproduced.

[0082] Fig. Figure 31 shows data for the grouping of measurements from first and second areas, which are within the Fig. The three zones shown in the diagram were used. The x-axis represents the areas, with the numbers corresponding to the numbered areas. Fig. 30. Measurements of the first range are designated Fn (e.g., F1), and measurements of the second ranges are designated Sn (e.g., S1). Thus, ranges 1–5 are first ranges F1, each located in zone 110. Ranges 6–10 are second ranges S1, also located in zone 110. Similarly, the first ranges F2 are ranges 16–20 in zone 120, and ranges 11–15 and 21–25 are second ranges S2 in zone 120. Finally, ranges 31–35 are first ranges F3 in zone 130, and ranges 26–30 are second ranges S2 in zone 130. The numbered ranges are across all three graphs of Fig. The entire 31 area is shown, however, for the sake of simplicity, zones 110, 120 and 130 are shown exclusively on the thickness map.

[0083] The Fig. The graphs shown in Figure 31 graphically represent the difference in intensity between first and second regions within each zone and can be used to graphically visualize the difference in intensity for pairs of regions that form a microzone. For example, it is evident that in Zone 110, the base weight may be essentially the same between the two regions, but the thickness may vary from about 400 micrometers in the first regions to about 40 micrometers in the second regions, or by a difference of about 10 times. The volumetric density in Zone 110 can range from about 0.1 g / cm³. 3 up to approximately 0.6 g / cm³ 3 They vary. Similar quantifiable distinctions can be understood for each of the zones shown.

[0084] Thus, with reference to Fig. 30 and Fig. 31. Together, a further characterization of the advantageous structure of a material 10 of the present disclosure may be understood. The nonwoven material 10 can be described as having at least two optically distinct zones, e.g., zones 110 and 120, wherein each of the zones has a pattern of three-dimensional features, each of the three-dimensional features defining a microzone comprising the first and second regions, e.g., regions 300 and 310, and wherein the difference in value of at least one of the microzones in the first zone is quantifiably different from the difference in value of at least one of the microzones in the second zone. For example, in Fig. 30 Two representative microzones 400 in zone 130 are designated as the pair of areas marked as areas 31 and 27 and 33 and 26. That is, the first area 31 and the second area 27 form one microzone, and the first area 33 and the second area 26 form another microzone. Likewise, two representative microzones 400 in zone 120 are designated as the pair of areas marked as areas 19 and 24 and 17 and 22. Starting from Fig. 31. Tables 4-7 can be filled out as shown: Table 1: Illustrative examples of differences in thickness in microzones Dicke (Mikrometer) Unterschied in der Dicke (Mikrometer) Zone 130 Mikrozone 1 Erster Bereich 31 1802 1709 Zweiter Bereich 27 93 Mikrozone 2 Erster Bereich 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 2: Illustrative examples of differences in base weight in microzones Base weights (grams per square meter) Differences in base weights (grams per square meter) Zone 130 Microzone 1 First area 31 124 107 Second area 27 17 Microzone 2 First area 33 106 72 Second area 26 34 Zone 120 Microzone 1 First area 19 32 5 Second area 24 27 Microzone 2 First area 17 42 30 Second area 23 12 Table 3: Illustrative examples of differences in volumetric density in microzones Volumetric density (g / cm 3 ) Difference in volumetric density (g / cm³) 3 ) Zone 130 Microzone 1 First area 31 0,069 0,116 Second area 27 0,185 Microzone 2 First area 33 0,041 0,49 Second area 26 0,531 Zone 120 Microzone 1 First area 19 0,133 0,251 Second area 24 0,384 Microzone 2 First area 17 0,185 0,044 Second area 23 0,229 Table 4: Illustrative examples of differences in intensity levels within different zones: Thickness (micrometers) Thickness differences Base weights (grams per square meter) Base weight differences Volumetric density (g / cm 3 ) Volumetric density differences Zone 130 First Area 32 2147 2118 149 135 0,069 0,423 Zone 110 Second Area 8 29 14 0,492

[0085] The four representative microzones from two zones are shown in Tables 1-4 for illustration. It is understood, however, that each pair of first and second zones in Fig. 30 could be quantified equally to fill additional rows in Table 1, however, this is not done for the sake of conciseness. In general, for any fabric having two or more zones, each zone having a pattern of three-dimensional features defining the microzones, the intensive sizes can be measured and, as described herein with reference to the Fig. 30 and Fig.Figure 31 illustrates, presented in tables, to understand both the difference in values ​​for intensive quantities within a zone and the difference in values ​​of intensive quantities between an area in a first zone and another area in a second zone.

[0086] A microzone spanning two zones, such as Zone 110 and Zone 130, can exhibit even greater differences in intensity compared to a microzone within a single zone. For example, when considering the data for a microzone spanning a first region of Zone 130, say in first region 32, and a second region of Zone 110, say in second region 8, the microzone shows dramatic differences in thickness, base weight, and volumetric density. The thickness of first region 32 of Zone 130 is approximately 2100 micrometers, while the thickness of second region 8 of Zone 110 is approximately 29 micrometers, a difference of about 72x, or more than about 25 micrometers.Similarly, the base weight of the first area 32 of zone 130 can be as high as 150 grams per square meter, while the base weight of the second area 8 of zone 110 can be approximately 14 grams per square meter, or a difference of about 10 times or more than 5 grams per square meter. Furthermore, the volumetric density of the first area 32 of zone 130 can be approximately 0.069 g / cm³. 3 the volumetric density of the second area 8 of zone 110 is approximately 0.492 g / cm³ 3 or a difference of approximately 7x or more than approximately 0.042 g / cm² 3 can amount to.

[0087] For each parameter of the measured intensive properties of the different regions of a microzone, such a measurement is performed using the micro-CT method described herein. The resolution of the method supports the derivation of the intensive magnitudes of microzone regions, allowing for the dimensioned comparisons of the differences and ratios of regions, as described herein.

[0088] A further characterization of substance 10 can be made with reference to the Fig. 32-36, which are SEMs that describe certain aspects of the nonwoven fabric 10 and the areas within it in more detail. Fig. Figures 32-36 are enlarged sections of Zone 110 of the area in Fig. 25 of the fabric shown. The one in Fig. The nonwoven fabric 10 shown in section 25 was produced according to the process described above with reference to Fig.7 produced, in which the material was processed through a roller gap formed by compression rollers 70 and 72, wherein the roller 72, which touches the first side 12, is heated to bring about a partial bonding of the fibers in the second areas 301. Fig. 32 (facing the belt) and 46 (facing the heated compaction roller) are each SEMs of a section of the second surface 14 and the first surface 12 respectively, magnified to 20X. Fig. Figures 34 (facing the belt) and 48 (facing the heated compaction roller) are each images of a section of the second surface 14 and the first surface 12, magnified to 90x, and show in detail the advantageous structural characteristics of the partial bonding of fibers formed by the compaction rollers 70 and 72.

[0089] How best to Fig. 34 and Fig. 35 can be seen, as well as in the cross-sectional view of Fig.36, the heated compaction rollers can induce thermal bonding of fibers to varying degrees with a beneficial effect on the entire fabric 10. As shown, the fibers in contact with a heated roller, e.g., roller 70 in contact with the first surface 12 of fabric 10, can be melt-bonded such that the first surface 12 experiences relatively more fiber-to-fiber bonding than the second surface 14. The bonded fibers 80 of the first surface can be essentially completely melt-bonded to effectively form a film skin of bonded fibers, while the fibers in the second area 310 on the second side 14 may experience little to no bonding. This feature enables a nonwoven fabric 10 to be used in a disposable absorbent article, e.g.,as an upper layer, to maintain physical integrity during manufacture and use, as well as relative softness on one side, which may be the carrier-side, skin-contacting side.

[0090] Even in the microzones with the greatest thickness variation, this "bond thinning" serves the purpose of maintaining web integrity, while softness or other beneficial properties such as fluid handling characteristics are not significantly affected. As referred to in the Fig. 37-40 can be understood, the difference in the degree of thermal fiber bonding can be such that the fibers on the first surface 12 in a second area 310 may be completely, or substantially completely, bonded, with the degree of thermal fiber bonding on the second surface 14 in a first area 300 being minimal, down to no thermal bonding.

[0091] Fig.Figure 37 again shows the section of nonwoven fabric 10, which is in Fig. 25 is shown. Fig. Figures 38-40 show enlarged images of a microzone located in Fig. 37 is indicated as a first area 300 and a second area 310, which appears to be a hole or opening. Fig. 38 and Fig. Figure 39 shows the microzone as it appears on the second surface 14, magnified to 40X and 200X respectively. Fig.Figure 40 shows the second region 310 as it appears on the first page 12 at 200X magnification. The fibers in the second region 310 are completely, or substantially completely, bound, whereas the fibers in the first region 300 are completely, or substantially completely, unbound. The advantage of the illustrated structure is that a microzone can function as a fluid-permeable opening, while the bound regions of the second region 310 can simultaneously serve to maintain the physical integrity of the material 10.

[0092] Microzones therefore play a significant role in the overall physical structure and function of a nonwoven fabric 10 of the present disclosure. By creating relatively closely spaced, precisely formed three-dimensional features, which is made possible by the shaping band of the present disclosure, a fabric 10 can exhibit optically distinct zones, microzones, and three-dimensional features that offer functional superiority, at least in terms 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 fabric 10 to be designed for both strength and softness, as well as for both form and function.

[0093] Fig. Figure 41 is an image of a micro-CT scan of the section of nonwoven fabric 10, similar to the one in Fig. 27 and Fig.28 shown, which, however, was subjected to the additional processing step of forming spot bonds 90 in the roll gap of the calender rolls 71 and 73. As above, with regard to the discussion of the Fig. 30 and Fig. 31, for certain point-bonding microzones 400, the first and second areas, depicted as numbered sections of the nonwoven fabric 10, can be analyzed, and include point-bonding areas, particularly in numbered sections 31-35. For example, adjacent areas 32 and 26 form a microzone 400 in the third zone 130. In Fig. 41. The specific areas were optically distinguished to identify areas that included the added point binding areas and analyzed to measure thickness, base weight, and volumetric density, and the data are in Fig.42 is reproduced, quantifying and comparing the thickness, base weight and volumetric density of all areas, including the point binding areas.

[0094] Fig. Figure 42 shows data for the grouping of measurements from first and second areas, which are within the area in Fig. The three zones shown in the diagram (41) were used. The x-axis represents the areas, with the numbers corresponding to the numbered areas in the diagram. Fig.30. Measurements of the first range are designated Fn (e.g., F1), and measurements of the second ranges are designated Sn (e.g., S1). Thus, ranges 1-5 are first ranges F1, each located in zone 110. Ranges 6-10 are second ranges S1, also located in zone 110. Similarly, the first ranges F2 are ranges 16-20 in zone 120, and ranges 11-15 and 21-25 are second ranges S2 in zone 120. Finally, ranges 31-35 are second ranges, but are point bindings 90, located in Fig. 55 are designated as B1 to distinguish them in this revelation as being formed by a point-connection process. First regions F3 in Zone 130 are regions 26-30 and 36-40, while regions 41-44 are second regions S2 in Zone 130. The numbered regions are across all three graphs of Fig.The entire 42 range is shown, however, for the sake of simplicity, zones 110, 120 and 130 are shown exclusively on the thickness map.

[0095] The in Fig.The 42 graphs shown graphically represent the difference in intensity between the first and second regions within each zone of a material that has undergone a calender point bonding step. They can be used to graphically visualize the difference in intensity for pairs of regions that form a microzone. For example, it is evident that in zone 110, the base weight between the two regions can vary more narrowly than the thickness or volumetric density. For example, the thickness can vary from about 325 micrometers in the first regions to about 29 micrometers in the second regions of zone 110, or by a difference of about 10 times. The volumetric density in zone 110 can range from about 0.08 g / cm³. 3 up to approximately 0.39 g / cm³ 3 They vary. Similar quantifiable distinctions can be understood for each of the zones shown.

[0096] In general, areas within a microzone can exhibit widely varying values ​​for base weight, thickness, and volumetric density.

[0097] Thus, with reference to Fig. 41 and Fig. 42 A further characterization of the advantageous structure of a substance 10 of the present disclosure, in particular with regard to the thermal calender point bonds 90, can be understood. For the purpose of describing zone 130, three-dimensional features defining a microzone, which includes first and second regions that are point-bonded regions, can be identified, and the values ​​of intensive quantities can be quantified. For example, in Fig.41. A representative point-binding microzone 400 in zone 130 will be the pair of areas labeled as areas 26 and 32 or 30 and 35. That is, the first area 26 and the second area 32 form a point-binding microzone 400, and the first area 30 and the second area 35 form a point-binding microzone 400.

[0098] The differences in certain intensity sizes for point-binding microzones can be found in Fig.42. For example, considering the two point-binding microzones 400 described above, e.g., the two point-binding microzones 400 of the respective areas 26 and 32 and 30 and 35, it is evident that there is a slight difference in base weight between the first and second areas, in the range of approximately 55 to approximately 60 grams per square meter. However, the same areas exhibit a significant difference in thickness, ranging from approximately 430 micrometers to approximately 460 micrometers to approximately 125 micrometers, and a significant difference in volumetric density of approximately 0.13–0.14 g / cm³. 3 up to approximately 0.41-0.48 g / cm³ 3 Other differences in intensity levels can be seen by referring to Fig. 42 are observed.

[0099] The bonding points 90 can play a significant role in the overall physical structure and function of a substance 10 of the present disclosure. By adding bonding points 90 to the substance 10, which comprises relatively closely spaced, precisely designed three-dimensional features, as made possible by the shaping band of the present disclosure, a substance 10 can be further enhanced to exhibit an unexpected combination of optically distinct zones, microzones, and three-dimensional features, providing functional superiority in the high-performance combination of softness, strength, low linting, and fluid handling, as well as visually appealing aesthetic finishes.The bonding point feature provides a nonwoven fabric 10 designed for the highest performance combination of strength, softness, fluid handling and optical aesthetics, especially considering both form and function. Packaging

[0100] The absorbent articles 10 of this disclosure can be placed in packaging. The packaging may comprise polymer films and / or other materials. Graphics and / or markings relating to the properties of the absorbent articles may be formed, printed, positioned, and / or placed on outer sections of the packaging. Each package may contain a variety of absorbent articles. The absorbent articles may be packaged under compression to reduce the size of the packaging while still providing an adequate quantity of absorbent articles per package. By packaging the absorbent articles under compression, caregivers can easily handle and store the packages, while manufacturers also benefit from distribution savings due to the reduced package size.

[0101] Accordingly, packaging of the absorption articles of the present disclosure may have a bag stack height of less than about 110 mm, less than about 105 mm, less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm, less than about 74 mm, less than about 72 mm or less than about 70 mm, wherein in particular all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby, according to the bag stack height test described herein, are specified.Alternatively, the packagings of the absorption articles of the present disclosure may have a bag stack height of about 70 mm to about 110 mm, of about 70 mm to about 105 mm, of about 70 mm to about 100 mm, of about 70 mm to about 95 mm, of about 70 mm to about 90 mm, of about 70 mm to about 85 mm, of about 72 mm to about 80 mm or of about 74 mm to about 78 mm, wherein specifically all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby, according to the bag stack height test described herein, are specified.

[0102] Fig. Figure 43 illustrates an example package 1000 containing a variety of absorbent articles 1004. The package 1000 defines an interior space 1002 in which the variety of absorbent articles 1004 are located. The variety of absorbent articles 1004 are arranged in one or more stacks 1006. Absorption articles

[0103] The nonwovens of this disclosure can form sections of absorbent articles. Absorbent articles can include adhesive-backed diapers, briefs, adult incontinence diapers or pads, panty liners, and / or other suitable absorbent articles. The nonwovens can also be useful in other end products. In an absorbent article context, the nonwovens can form an outer sheath nonwoven material, a top layer, an absorption layer, a distribution layer, a section of a core bag, a wing nonwoven material, a secondary top layer, a waistband laminate, and / or other suitable nonwoven absorbent article components. The nonwovens can also form sections of these components.

[0104] Fig. 44 and Fig.Figure 45 illustrates an example of an absorbent article in the form of briefs, although diapers with adhesive tape are also within the scope of protection of this disclosure. The briefs may comprise the nonwovens of this disclosure, such as a top layer and / or an outer sheath nonwoven material, or sections of a top layer and / or an outer sheath nonwoven material. Fig. Figure 44 is a perspective front view of an absorption article comprising one or more nonwovens of the present disclosure. Fig. Figure 45 is a rear perspective view of the absorption article by Fig. 44.

[0105] With further reference to Fig. 44 and Fig.Figure 45 shows an absorbent article 710 in the form of briefs with a waistband. The absorbent article 710 comprises a front section 712, a crotch section 714, and a back section 716. The absorbent article may include a central basic unit 726 that extends at least partially between the front section 712 and the back section 716. The absorbent article 710 may define leg openings 760 and comprise a front waistband 754 and a back waistband 756. The front and back waistbands 754 and 756 may comprise a first elastic material and a second elastic material. An elastic band, such as an elastic film or a plurality of elastic strands, may be arranged between the first elastic material and the second elastic material. The first waistband 754 and the second waistband 756 can be attached to each other at their side edges to form side seams 758.The side seams can include butt seams or overlap seams.

[0106] The central basic unit 752 can comprise a top layer 760, a bottom layer film 761, and an absorption core that is at least partially arranged between the top layer and the bottom layer film. The top layer 760 can form a section of a carrier-side surface of the absorption article 710 and can comprise one or more of the nonwovens disclosed herein. The central basic unit 752 can comprise an outer sheath nonwoven material 762 that forms a section of a clothing-side surface of the absorption article and is in a mutually facing relationship with the bottom layer film. The outer sheath nonwoven material 762 can comprise one or more of the nonwovens disclosed herein. The central basic unit can comprise one or more absorption layers and / or one or more distribution layers at least partially between the top layer and the absorption core. The nonwovens can comprise crimped fibers. Emtec

[0107] The present disclosure provides a solution to the problem discussed in the background section by providing absorbent articles comprising nonwovens with improved softness while still exhibiting high texture. The present disclosure further resolves the conflict between high softness and high texture while simultaneously providing several improvements in fluid handling, including rapid penetration of body excretions and improved dryness of the skin and outer layer. Typically, the nonwovens of the present disclosure can form at least one portion of a carrier-side surface (e.g., outer layer) and at least one portion of a garment-side surface (e.g., outer sheath nonwoven). The softness, texture (i.e., suppleness), and / or stiffness can be measured using an Emtec Tissue Softness Analyzer, according to the Emtec Test herein.The perceived softness is measured as TS7. The texture / suppleness is measured as TS750. Stiffness is measured as D.

[0108] All of the following examples 1-10 are side-by-side bicomponent spunbond nonwovens produced by spinning a 30:70 ratio of polypropylene (PP3155, obtained from Exxon Mobil Corporation) and a 25 / 75 blend of polypropylenes (PP3155 and PP3854, obtained from Exxon Mobil Corporation) in a circular fiber configuration. Approximately 1% titanium dioxide and 1% erucamide were added to the polymers to improve whiteness and softness. A blue pigment melt additive was incorporated into the top layer of Example 2 at 0.25 wt% of the nonwoven to enhance the optical perception of three-dimensionality. The nonwovens were all spun onto a shaping tape exhibiting a three-dimensional pattern, as is generally the case with regard to Fig.16 described, although the patterns are different. The belts moved at a linear speed of about 28 meters per minute to form the 25-gram-per-square-meter nonwovens. The belt was operated at slower linear speeds for the higher base weight nonwoven outer sheath materials in Examples 7-10. Fibers of the nonwovens in Examples 1-10 were compacted by a heated compaction roll 70, 72 and further bonded by a calender roll with an 8% dot pattern at a temperature of about 140 °C. Table 5: Emtec properties of upper-class comparison examples and upper-class examples of the present disclosure product Comparison example 1: Goon Premium, purchased in November 2018 in China Comparative example 2: Merries, acquired in November 2018 in China Comparison example 3: P&G Pampers Premium Care, produced in Japan in April 2017 Example 1: Pattern of Fig. 46, Fig. 25 grams per square meter Example 2: Patterns of Fig. 47, Fig. 25 grams per square meter, 0.25% blue melt additive Example 3: Pattern of Fig. 47, Fig. 25 grams per square meter, Example 4: Patterns of Fig. 48, Fig. 25 grams per square meter Stiffness (D) mm / N 4,9 4,4 4,3 3,95 3,16 3,9 3,9 Softness (TS7) microphone dB V 2 rms 6,4 4,9 7,0 3,8 2,85 3,7 3,8 Smoothness (TS750) Macro dB V 2 rms 2,9 15,1 4,1 8,29 9,6 7,3 7 * All values ​​in Table 5 are measured here according to the Emtec test.

[0109] A section of or all of the carrier-side surfaces of the top layers of the present disclosure can exhibit a TS7 value in the range of 1 dB V 2 rms up to 4.5 dB V 2 rms, 2 dB V 2 rms up to 4.5 dB V 2rms or 2 dBV 2 rms up to 4.0 dB V 2 exhibit rms. The section of or all carrier-side surfaces of the top layers of the present disclosure may also exhibit a TS750 value in the range of 4 dB V. 2 rms up to 30 dB V 2 rms, 6 dB V 2 rms up to 30 dB V 2 rms, 6 dB V 2 rms up to 20 dB V 2 rms, 6 dB V 2 rms up to 15 dB V 2 rms, 6 dB V 2 rms up to 12 dB V 2 rms or 6.5 dBV 2 rms up to 10 dB V 2exhibiting rms. The section of or all carrier-side surfaces of the top layers of this disclosure may also exhibit a D-value in the range of 1 mm / N to 10 mm / N, 3 mm / N to 8 mm / N, 2 mm / N to 6 mm / N, 2 mm / N to 4 mm / N, or 3 mm / N to 4 mm / N. All values ​​are measured according to the Emtec test herein. The TS7 value is the tactile softness, so low numbers are desirable (the lower the number, the softer the material). The TS750 value is the texture, so a high number is desirable (the higher the number, the more texture the material has). A low TS7 value and a high texture value is contradictory insofar as a nonwoven fabric is generally less soft the more texture it has.Without wishing to be bound to any theory, the applicants have discovered the unexpected results of highly textured nonwovens that are still very soft by providing a selected range of area-1 and area-2 surfaces in the nonwovens, as discussed below. Table 6: Emtec properties of outer sheath nonwoven material comparison examples and outer sheath examples of the present disclosure product Comparison example 1: Goon Premium, purchased in November 2018 in China Comparative example 2: Merries, acquired in November 2018 in China Comparison example 3: P&G Pampers Premium Care, produced April 2017, in Japan Example 5: Pattern of Fig. 49, Fig. 25 grams per square meter Example 6: Patterns of Fig. 50, Fig. 25 grams per square meter, Example 7: Pattern of Fig. 49, Fig. 35 grams per square meter, Example 8: Pattern of Fig. 50, Fig. 35 grams per square meter Example 9: Patterns of Fig. 49, Fig. 46 grams per square meter Example 10: Pattern of Fig. 50, Fig. 46 grams per square meter Stiffness (D) mm / N 4,1 2,9 4,1 4,66 4,67 3,8 3,97 3,53 3,55 Softness (TS7) microphone dB V 2 rms 4,7 3,1 3,1 2,69 2,79 2,83 2,74 3,04 2,88 Smoothness (TS750) Macro dB V 2 rms 3,7 3,1 2,7 6,1 5,87 12,9 12,3 20,5 17,5 * All values ​​in Table 6 are measured here according to the Emtec test.

[0110] A section of the clothing-side surface of the outer jacket nonwoven materials of the present disclosure can have a TS7 value in the range of 1 dB V 2 rms up to 4.5 dB V 2 rms, 2 dB V 2 rms up to 4.5 dB V 2 rms or 2 dBV 2 rms up to 4.0 dB V 2The section of the cladding-side surfaces of the outer sheath nonwoven materials of this disclosure may also have a TS750 value in the range of 4 dB V2 rms to 30 dB V2 rms, 6 dB V2 rms to 30 dB V2 rms, 6 dB V2 rms to 20 dB V2 rms, 6 dB V2 rms to 15 dB V2 rms, 6 dB V2 rms to 12 dB V2 rms, or 6.5 dB V2 rms to 10 dB V2 rms. The section of the cladding-side surfaces of the outer sheath nonwoven materials of this disclosure may also have a D-value in the range of 1 mm / N to 10 mm / N, 3 mm / N to 8 mm / N, 2 mm / N to 6 mm / N, 2 mm / N to 4 mm / N, or 3 mm / N to 4 mm / N. All values ​​are measured according to the Emtec test. A low TS7 value and a high texture value are contradictory, as a nonwoven fabric is generally less soft the more texture it has.Without wishing to be bound to any theory, the applicants have discovered the unexpected results of highly textured nonwovens that are still very soft by providing a selected range of area-1 and area-2 surfaces in the nonwovens, as discussed below.

[0111] It may be desirable to have the certain TS7 and TS750 properties discussed above in both the outer sheath nonwoven material and the top layer. This provides a soft texture on both sides (i.e., the backing side and the garment side) of the absorbent article.

[0112] An absorption article can comprise a nonwoven top layer, a bottom layer, an absorption core that is at least partially arranged between the top layer and the bottom layer, and a nonwoven outer sheath that is bonded to the bottom layer. A first section of a carrier-side face of the nonwoven top layer and a second section of a clothing-side face of the nonwoven outer sheath can each have a TS7 value in the range of 1 dB V. 2 rms up to 4.5 dB V 2 The second section of the garment-side side of the nonwoven outer layer can exhibit a TS750 value that is 1.2 to 4 times, 1.3 to 3 times, or 1.5 to 2 times greater than the TS750 value of the first section of the carrier-side side of the nonwoven top layer. Percentage share of area 1 and area 2 areas

[0113] To achieve the desired results of the present disclosure, namely improved softness along with enhanced texture in the nonwovens, such as the outer sheath and top layers, a total area of ​​Region One (e.g., low base weight areas) is provided in a section of the nonwovens (corresponding to a resin pattern on the tape) in the range of 5% to 20%, preferably 10% to 20%, of the total area of ​​the section of the nonwovens, wherein the remainder of the section of the nonwovens is a total area of ​​Region Two (e.g., high base weight areas) (corresponding to resin-free areas on the tape). The higher base weight areas are generally softer than the low base weight areas because the higher base weight areas contain more fibers.Nonwovens with low base weight areas ranging from 5% to 20% of the total fabric weight generally achieve good dryness and softness. Areas with a low base weight below 5% generally result in high softness, but typically not good dryness. Areas with a low base weight above 25% generally result in good dryness, but typically not good softness.

[0114] In addition to the advantages described above, another advantage of the shaped, soft, and textured nonwovens of this disclosure is the ability to provide a nonwoven with microzones comprising one or more hydrophobic regions and one or more separate hydrophilic regions. The hydrophilicity and / or hydrophobicity in a particular region of the microzone can be determined by a time-to-wick measurement using the time-to-wick test procedure described herein and / or a contact angle measurement using the contact angle test procedure described herein. As used herein, the term "hydrophilic" with respect to a particular region of the microzone means that, when tested using the time-to-wick test procedure, the time-to-wick for that particular region is 10 seconds or less.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.

[0115] Table 7 below describes in detail the contact angle and time-to-wick measurements for shaped, soft, and textured nonwovens, as detailed herein. For both of the following examples 11 and 12, the nonwoven was produced on a belt, as described in Fig. 16 is described, the nonwoven fabric having a similar appearance to that described in Fig. 2 shown. Table 7: Contact angle and time-to-wick values ​​for shaped, soft and textured nonwovens of the revelation Example No. Area Contact angle (Θc) Time-to-Wick (seconds) Example 11 First area 135 60 Second area 0 0,307 Example 12 First area 126 60 Second area 0 2,360 Example 11:

[0116] A bicomponent spunbond nonwoven was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration. The nonwoven was formed on a forming belt with a [missing information] as in [missing information]. Fig. 16 described repetition patterns under motion at a linear speed of about 25 meters per minute, spun to produce a fabric 10 having an average base weight of 25 grams per square meter with a repetition pattern as in Fig. The 2 diamond shapes shown were formed. Fibers of the fabric were compacted by compaction rollers 70, 72, but instead of being calendered, further bonding was achieved by an air bonding unit at a temperature of 145 °C.

[0117] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylates with PEG diesters), provided by Pulcra Chemicals, was then applied to the reverse side of the nonwoven fabric (i.e., the flat side opposite the side with the relatively cushion-like three-dimensional features) by a kiss-coating process. The coating process was carried out using a Reicofil kiss-roll and omega drying method, both of which are generally known in the art. The surfactant used in the kiss-roll process had a 6% surfactant concentration in water at a temperature of 40 °C. The kiss-roll contact angle was set to 250°, and the drying temperature was 80 °C. The nonwoven fabric was then brought into contact with the Kiss roller operating at a speed of 13 rpm, thereby impregnating the nonwoven fabric with 0.45 wt% surfactant (% surfactant is the weight of added surfactant per 1 m²).2 divided by 1 m 2 nonwoven fabric) was added. Example 12:

[0118] A bicomponent spunbond nonwoven was produced by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A, available from Dow Chemical) and polypropylene core (PH-835, available from LyondellBasell) in a trilobal fiber configuration. The nonwoven was formed on a forming belt with a [missing information] as in [missing information]. Fig. 16 described repetition patterns under motion at a linear speed of about 25 meters per minute, spun to produce a fabric 10 having an average base weight of 25 grams per square meter with a repetition pattern as in Fig. The 2 diamond shapes shown were formed. Fibers of the fabric were compacted by compaction rollers 70, 72, but instead of being calendered, further bonding was achieved by an air bonding unit at a temperature of 145 °C.

[0119] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylates with PEG diesters), provided by Pulcra Chemicals, was then applied to the front side of the nonwoven fabric (i.e., the side with the relatively cushion-like three-dimensional features) by an inkjet printing process. The inkjet printing was performed using a Dimatix DMP 2831 inkjet printer equipped with a cartridge model # DMC-11610 / PM 700-10702-01 (10 pl). The printhead temperature was 40 °C. The surfactant used in the inkjet printing process consisted of 75% (wt / wt) Stantex S 6327 and 25% (wt / wt) ethanol.Surfactant was printed into the second regions of the microzones of the nonwoven fabric by orienting the sample so that the second regions of a first row of microzones were aligned with the printhead direction and printing a first row of straight lines with the droplet spacing set to 170 µm. The sample was then rotated so that the second regions of a second row of microzones were aligned with the printhead and printing a second row of straight lines at 170 µm. The base weight of the fibers in the second region is approximately 16.0 grams per square meter. The base weight of the surfactant printed onto the second region using the inkjet method is approximately 0.25 grams per square meter. Accordingly, it was determined that the amount of surfactant printed locally onto the second region was approximately 1.6 wt.The surfactant content is -% (0.25 grams per square meter / 16.0 grams per square meter). Overall, the ratio between printed line width and line spacing determined that the amount of surfactant printed on the nonwoven sample is approximately 0.2 wt% surfactant.

[0120] In addition to Stantex S 6327, the use of other surfactants to make the first and / or second area of ​​certain microzones hydrophilic and / or hydrophobic (by any application method) is considered to be within the scope of protection of this disclosure.

[0121] The nonwovens described in detail above comprise microzones with regions exhibiting differences in significant properties, such as base weight, density, or thickness. Such identical nonwovens may also simultaneously include regions of the microzones that are specifically and separately hydrophobic and / or hydrophilic. Each of the shaped nonwoven examples described in detail herein (e.g., samples comprising zones and / or microzones with regions exhibiting differences in thickness, base weight, and / or volumetric density, and / or surfaces with the various TS7, TS750, and D values ​​disclosed herein) may further exhibit regions of a microzone with differences in hydrophilicity, as described in detail herein. Hydrophilicity can be provided by the targeted application of surfactant(s) to specific regions of the microzones of the nonwoven.For example, the second region of a microzone may contain a surfactant, while the first region of the same microzone may not. Similarly, the first region of a microzone may contain a surfactant, while the second region of the same microzone may not. For example, in a microzone, either the first or the second region may contain a surfactant concentration of approximately 0.01% to approximately 5.0%, approximately 0.05% to approximately 4.0%, or approximately 1.0% to approximately 3.0%, and in any concentric region, the concentration may be in the range of 0.01% to approximately 5.0%, while the other region contains no surfactant.As an example, in a microzone, the second region may contain a surfactant of approximately 0.01% to approximately 5.0%, approximately 0.05% to approximately 4.0%, approximately 1.0% to approximately 3.0%, and in any concentric region in the range of 0.01% to approximately 5.0%, and the first region may not contain a surfactant (i.e., surfactant-free). Accordingly, some nonwovens disclosed herein have a microzone with at least one of the first and second regions containing a surfactant, and the ratio of the percentage surfactant content in the first region to the percentage surfactant content in the second region is less than 1. Furthermore, some nonwovens disclosed herein have a microzone with at least the second region of the microzone containing a surfactant, and the ratio of the percentage surfactant content in the first region to the percentage surfactant content in the second region is less than 1.

[0122] As another example, the second region of a microzone can contain a specific amount or percentage of surfactant, while the first region of the same microzone can contain a different amount or percentage of surfactant. For instance, in a microzone, the first region might contain approximately 0.01% to 2.0% surfactant, approximately 0.05% to 1.5%, approximately 0.1% to 1.0% surfactant, and in any concentric region, the concentration might range from 0.01% to 2.0%, while the second region might contain a different amount. Furthermore, the second area in a microzone can have a surfactant concentration of approximately 0.01% to approximately 5.0%, approximately 0.05% to approximately 4.0%, approximately 1.0% to approximately 3.0%, and in any concentric area in the range of 0.01% to approximately 5.0%, and the first area can have a different amount.The percentage of surfactant for a specific area of ​​a microzone can be determined by taking the grams per square meter of surfactant located in that area and dividing this by the base weight of the molded nonwoven fibers contained in the same area. The grams per square meter of surfactant located in a specific area can be determined using any method currently known in the art (e.g., gravimetrically, etc.). The base weight of the nonwoven fibers contained within a specific area of ​​a microzone can also be determined using any method currently known in the art (e.g., gravimetrically, micro-CT, etc.).

[0123] A surfactant can be applied to the nonwoven fabric by any known method generally known to those skilled in the art. Specific examples include KISS coating, inkjet printing, engraved printing, offset engraved printing, flexographic printing of the surfactant, and registered printing of the surfactant. Each of these methods can apply the surfactant to either the first and / or second surface of the nonwoven fabric. For the entire formed nonwoven fabric (taking into account all the individual zones and microzones on the fabric), the surfactant can be added to the formed nonwoven fabric in an amount of approximately 0.01% to approximately 2.0%, approximately 0.05% to approximately 1.5%, approximately 0.1% to approximately 1.0%, and to any concentric area in the range of approximately 0.01% to approximately 2.0%.To calculate the percentage of surfactant added to the entire formed nonwoven fabric, the grams per square meter of surfactant in the entire formed nonwoven fabric are divided by the base weight of the entire formed nonwoven fabric. The grams per square meter of surfactant in the entire formed nonwoven fabric can be determined using any method currently known in the art (e.g., gravimetrically, etc.). The base weight of the entire formed nonwoven fabric can likewise be determined using any method currently known in the art (e.g., gravimetrically, micro-CT, etc.).

[0124] With further reference to the Fig. 25 and Fig. 26, which shows a section of a pattern of a nonwoven fabric 10, is a first zone 110 (on the left side of Fig.25) characterized by generally MD-oriented rows of first regions 300 of variable width, separated by MD-oriented rows of second regions 310 of variable width (where the first and second regions are within a microzone). The first region is also the three-dimensional feature 20 that defines the first and second regions 300, 310. A three-dimensional feature can be a section of the nonwoven fabric 10 formed between or around a raised element of the shaping tape, which in this description is the first region 300, such that the resulting structure has a relatively larger dimension in the Z-direction, a relatively higher base weight, and a lower volumetric density compared with the second region 310. Furthermore, the first region 300 can be hydrophobic and the second region 310 hydrophilic.The targeted addition of a surfactant to the second region 310 of the microzone can cause the second region to be hydrophilic. Accordingly, the first region 300 of the microzone can exhibit a contact angle greater than approximately 90°, or between approximately 90° and approximately 140°, or between approximately 110° and approximately 135°, or between approximately 125° and approximately 135°, or any concentric region lying between approximately 90° and approximately 140°, when tested using the contact angle test procedure described herein. The second region 310 of the microzone can exhibit a contact angle of less than 90° when tested using the contact angle test procedure described herein. The first area 300 of the microzone may have a time-to-wick value of more than approximately 10 seconds or between approximately 10 seconds and 60 seconds, as measured by the time-to-wick test method described herein.The second area 310 of the microzone can have a time-to-wick value of less than approximately 10 seconds, less than approximately 5 seconds, less than approximately 2.5 seconds, less than approximately 1 second, less than approximately 0.5 seconds, or in the range of approximately 0.5 seconds to approximately 10 seconds, or approximately 0.5 seconds to approximately 5 seconds, as measured by the time-to-wick test method described in detail herein. The nonwovens provided herein incorporate any of the parameter ranges for contact angle and / or time-to-wick measurements described in detail above for the first area and / or the second area, in combination with any of the other intensive size / size variations disclosed herein for the same or different areas in the same or different microzone on the formed nonwoven.Molded nonwovens that exhibit the microzones described in detail above, with areas exhibiting differences in base weight, density, or thickness, while simultaneously exhibiting such areas of a particular microzone that are separately hydrophobic and / or hydrophilic, can provide many useful applications, such as top layer materials for absorbent articles, as well as use in medical pads, wipes, and cleaning covers. Test procedure: Localized base weight

[0125] The localized base weight of the nonwoven fabric can be determined by several available techniques, but one simple representative technique involves a die-cutting tool covering an area of ​​3.0 cm². 2This method involves cutting a sample of the web from the selected area of ​​a nonwoven fabric. The sample is then weighed and divided by its area to obtain the localized base weight of the nonwoven fabric in grams per square meter. The results are presented as the mean of two samples per selected area. Bag stack height check

[0126] The stack height of bags in a package of absorbent products is determined as follows: equipment

[0127] A thickness gauge with a flat, rigid, horizontal sliding plate is used. The thickness gauge is configured such that the horizontal sliding plate moves freely in a vertical direction, while always being held in a horizontal orientation directly above a flat, rigid, horizontal base plate. The thickness gauge includes a suitable device for measuring the gap between the horizontal sliding plate and the horizontal base plate to within ± 0.5 mm. The horizontal sliding plate and the horizontal base plate are larger than the surface area of ​​the absorbent packaging that is in contact with each plate; that is, each plate extends over the contact surface of the absorbent packaging in all directions.The horizontal sliding surface exerts a downward force of 850 ± 1 gram force (8.34 N) on the absorbent packaging, which can be achieved by placing a suitable weight on the center of the upper surface of the horizontal sliding plate, which is not in contact with the packaging, so that the total mass of the sliding plate plus additional weight is 850 ± 1 gram. Testing procedure

[0128] Absorption article packaging is equilibrated at 23 ± 2 °C and 50 ± 5 % relative humidity before measurement.

[0129] The horizontal sliding plate is lifted and an absorbent material package is placed centrally under the horizontal sliding plate in such a way that the absorbent materials inside the package are in a horizontal orientation (see Fig.43) Any handle or other packaging feature on the packaging surface that would come into contact with one of the plates is folded flat against the surface of the packaging to minimize its effect on the measurement. The horizontal sliding plate is lowered slowly until it makes contact with the top of the packaging and is then released. The gap between the horizontal plates is measured to ± 0.5 mm ten seconds after the horizontal sliding plate is released. Five identical packages (packages of the same size and with the same number of absorbents) are measured, and the arithmetic mean is reported as the package width. The "stack height" = (package width / number of absorbents per stack) × 10 is calculated and recorded to ± 0.5 mm. Micro-CT measurement methods for intensive quantities

[0130] The micro-CT measurement technique for intensive quantities measures the base weight, thickness, and volumetric density values ​​in optically perceptible areas of a substrate sample. It is based on the analysis of a 3D X-ray image of the sample obtained on a micro-CT scanner (a suitable device is the Scanco µCT 50, available from Scanco Medical AG, Switzerland, or equivalent). The micro-CT scanner is a cone-beam microtomograph with a shielded cabinet. A maintenance-free X-ray tube with an adjustable focal spot diameter is used as the source. The X-ray beam passes through the sample, where some of the X-rays are attenuated. The degree of attenuation correlates with the dimensions of the material through which the X-rays must pass. The transmitted X-rays then proceed to the digital detector array, generating a 2D projection image of the sample.A 3D image of the sample is generated by collecting multiple individual projection images of the sample during rotation, which are then recombined into a single 3D image. The device is connected via an interface to computer-based software for controlling image acquisition and storing the raw data. The 3D image is then analyzed using image analysis software (suitable software is MATLAB, available from The MathWorks, Inc., Natick, MA, or similar) to measure key parameters such as base weight, thickness, and volumetric density of regions within the sample. Rehearsal preparation:

[0131] To obtain a sample for measurement, a single layer of the dry substrate material is spread out flat and a circular piece with a diameter of 30 mm is punched out.

[0132] If the substrate material is a layer of an absorbent article, for example, a top layer, bottom layer fleece, absorption layer, distribution layer, or other component layer, adhere the absorbent article to a firm, flat surface in a planar configuration. Carefully separate the individual substrate layer from the absorbent article. A scalpel and / or cryogenic sprays (such as Cyto-Freeze, Control Company, Houston, Texas) may be used to remove a substrate layer from any underlying layers, if necessary, to prevent longitudinal and lateral expansion of the material. Once the substrate layer has been removed from the article, punch the sample as described above.

[0133] If the substrate material is in the form of a wet wipe, open a new pack of wet wipes and remove the entire stack from the packaging. Take a single wet wipe from the center of the stack, spread it out flat, and allow it to dry completely before punching the sample for analysis.

[0134] A sample can be cut from any location containing the optically perceptible zone to be analyzed. Within a zone, areas to be analyzed are those associated with a three-dimensional feature that defines a microzone. The microzone comprises at least two optically perceptible areas. A zone, a three-dimensional feature, or a microzone can be optically perceptible due to changes in texture, elevation, or thickness. Areas within different samples of the same substrate material can be analyzed and compared. Care should be taken to avoid creases, wrinkles, or tears when selecting a sampling location. Image capture:

[0135] Set up and calibrate the micro-CT scanner according to the manufacturer's instructions. Place the sample in the appropriate holder between two rings of low-density material with an inner diameter of 25 mm. This ensures that the central section of the sample lies horizontally and is scanned without any other materials directly adjacent to the upper and lower surfaces. Measurements should be taken in this area. The 3D imaging field of view is approximately 35 mm on each side in the xy-plane, with a resolution of approximately 5000 by 5000 pixels and a sufficient number of 7-micrometer-thick slices collected to fully encompass the z-direction of the sample. The reconstructed 3D image resolution contains isotropic voxels of 7 micrometers. Images are acquired with a source at 45 kVp and 133 µA without an additional low-energy filter.These current and voltage settings can be optimized to generate maximum contrast in the projection data with sufficient X-ray penetration through the sample, but after optimization, they are kept constant for all substantially similar samples. A total of 1500 projection images are acquired with an integration time of 1000 ms and 3 averages. The projection images are reconstructed into the 3D image and stored in 16-bit RAW format to retain the full detector output signal for analysis. Image processing:

[0136] Load the 3D image into the image analysis software. Adjust the 3D image below the threshold to a value that separates and removes the background signal caused by the air, but preserves the signal from the sample fibers within the substrate.

[0137] Three 2D images of intense sizes are generated from the threshold 3D image. The first is the base weight image. To generate this image, the value for each voxel in an xy-plane slice is summed with all its corresponding voxel values ​​in the other z-direction slices that contain a signal from the sample. This produces a 2D image where each pixel now has a value equal to the sum signal across the entire sample.

[0138] To convert the raw data values ​​in the base weight image into real values, a base weight calibration curve is generated. This yields a substrate with a substantially similar composition to the sample being analyzed and a uniform base weight. Follow the procedures described above to obtain at least ten replica samples of the calibration curve substrate.

[0139] The base weight is accurately measured by recording the mass to the nearest 0.0001 g, dividing it by the sample area, and converting it to grams per square meter (gsm) for each of the single-layer calibration samples. The average is then calculated to the nearest 0.01 grams per square meter. 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 then processed, and a base weight image with raw data values ​​is generated, following the procedures described above. The actual base weight value for this sample is the average base weight value measured across the calibration samples. Next, two layers of the calibration substrate samples are stacked on top of each other, and a micro-CT image of the two layers of the calibration substrate is acquired.Generate a raw base weight image of both layers together, where the actual base weight is twice the average base weight measured in the calibration samples. Repeat this process of stacking individual layers of the calibration substrate, acquire a micro-CT image of all layers, and generate a raw base weight image of all layers where the actual base weight is equal to the number of layers multiplied by the average base weight measured in the calibration samples. A minimum of four distinct base weight calibration images will be obtained. The base weight values ​​of the calibration samples must include values ​​above and below the base weight values ​​of the original sample being analyzed to ensure accurate calibration.The calibration curve is generated by a linear regression based on the raw data compared to the actual base weights 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 process. This calibration curve is then used to convert the raw data values ​​into actual base weights.

[0140] The second 2D image of significant size is the thickness image. To generate this image, the top and bottom surfaces of the sample are identified, and the distance between these surfaces is calculated, yielding the sample thickness. The top surface of the sample is identified by starting at the uppermost z-direction slice and evaluating each slice to traverse the sample and locate the z-direction voxel for all pixel positions in the xy-plane where the sample signal was first detected. The same process is followed to identify the bottom surface of the sample, except that the z-direction voxels are all positions in the xy-plane where the sample signal was last detected. Once the top and bottom surfaces have been identified, they are smoothed with a 15x15 median filter to remove signals from stray fibers.The "2D thickness image" is then generated by counting the number of voxels that exist between the upper and lower surfaces for each pixel position in the xy-plane. This raw thickness value is then converted into the actual distance, in micrometers, by multiplying the number of voxels by the 7-µm disk thickness resolution.

[0141] The third 2D image of significant size is the volumetric density image. To generate this image, each xy-plane pixel value in the base density image, in units of grams per square meter, is divided by the corresponding pixel in the thickness image, in units of micrometers. The units of the volumetric density image are grams per cubic centimeter (g / cm³). 3 ). Intensive parameters of micro-CT base weight, thickness, and volumetric density:

[0142] Begin by identifying the area to be analyzed. An area to be analyzed is one associated with a three-dimensional feature that defines a microzone. The microzone comprises at least two optically perceivable areas. A zone, three-dimensional feature, or microzone can be optically perceivable due to changes in texture, elevation, or thickness. Next, identify the boundary of the area to be analyzed. The boundary of an area is identified by optically discriminating against differences in intensity compared to other areas within the sample. For example, an area boundary can be identified based on the optical perception of a thickness difference when compared to another area in the sample.Each of the intensive sizes can be used to distinguish area boundaries on the physical sample itself from any of the micro-CT images of intensive sizes. Once the area boundary has been identified, draw an oval or circular "area of ​​interest" (ROI) within the interior of the area. The ROI should have an area of ​​at least 0.1 mm² and be selected to measure an area with intensive size values ​​that is representative of the identified area. From each of the three intensive size images, calculate the average base weight, average thickness, and average volumetric density within the ROI. Refine these values ​​as the base weight of the area to the nearest 0.01 grams per square meter, the thickness to the nearest 0.1 micrometers, and the volumetric density to the nearest 0.0001 g / cm³. 3 record. Emtec Test

[0143] The Emtec test is performed on sections of interest from outer sheath nonwovens or face sheets. In this test, TS7, TS750, and D values ​​are measured using an Emtec Tissue Softness Analyzer (“Emtec TSA”) (Emtec Electronic GmbH, Leipzig, Germany) connected to computer-running Emtec TSA software (version 3.19 or equivalent). The Emtec TSA incorporates a rotor with vertical blades that rotate on the test specimen at a defined and calibrated rotational speed (set by the manufacturer) and a contact force of 100 mN. Contact between the vertical blades and the test specimen creates vibrations in both the blades and the specimen, and the resulting sound is recorded by a microphone inside the device. The recorded sound file is then analyzed by the Emtec TSA software to determine TS7 and TS750 values.The D-value is a measure of specimen stiffness and is based on the vertical distance required to increase the contact force of the blades on the test specimen from 100 mN to 600 mN. Specimen preparation, equipment operation, and test procedures are carried out according to the equipment manufacturer's instructions. Sample preparation

[0144] A test specimen is prepared by cutting a square or circular section of interest from the outer sheath nonwoven material or the top layer of an absorbent article. It is preferred that freeze spray not be used to remove the portion of the outer sheath nonwoven material or top layer to be analyzed, although it is acceptable to use freeze spray in a distal area to assist initiating layer separation. Test specimens are cut to a length and width (diameter in the case of a circular specimen) of not less than approximately 90 mm and not more than approximately 120 mm to ensure that the specimen can be properly clamped into the TSA device.(If an absorbent does not contain a sufficiently large area of ​​the substrate of interest to obtain a sample of the size specified above, a suitable material may be taken from a rolling material.) Test specimens are selected to avoid unusually large kinks or folds within the test area. Six substantially similar replica specimens are prepared for testing.

[0145] All samples are equilibrated at TAPPI standard temperature and relative humidity conditions (23 °C ± 2 °C and 50 % ± 2 %) for at least 2 hours prior to performing the TSA test, which is also carried out under TAPPI conditions. Testing procedure

[0146] The device is calibrated according to Emtec's instructions using the 1-point calibration procedure with suitable reference standards (so-called "ref.2 samples" or equivalents available from Emtec).

[0147] A test specimen is mounted in the device with its surface facing upwards, and the test is performed according to the manufacturer's instructions. The software displays values ​​for TS7, TS750, and D when the automated device test is complete. TS7 and TS750 are each measured to within 0.01 dBV. 2 The rems-to-difference (Rm) is recorded with an accuracy of 0.01 mm / N. The test specimen is then removed from the device and discarded. This test procedure is performed individually on the relevant surfaces of interest for each of the six replica samples (the carrier-side surface for top-layer samples and the lining-side surface for outer sheath nonwoven material samples).

[0148] The values ​​of TS7, TS750, and D are each averaged over the six replicate samples (arithmetic mean). The mean values ​​of TS7 and TS750 are adjusted to 0.01 dBV. 2 The mean value of D is passed on with rms accuracy. The mean value of D is passed on with an accuracy of 0.01 mm / N. Contact angle and time-to-wick testing methods

[0149] Contact angle and time-to-wick measurements are determined using a sessile drop experiment. A specified volume of distilled water of type II reagent (as defined in ASTM D1193) is applied to the surface of a test specimen using an automated liquid delivery system. A high-speed video camera records time-stamped images of the drop over a period of 60 seconds at a rate of 900 frames per second. The contact angle between the drop and the surface of the test specimen is determined for each recorded image using image analysis software. Time-to-wick is determined as the time it takes for the contact angle of a drop penetrating the test specimen to decrease to a contact angle of < 10°. All measurements are performed at a constant temperature (23°C ± 2°C) and relative humidity (50% ± 2%).

[0150] An automated contact angle tester is required to perform this test. The system includes a light source, a video camera, a horizontal sample stage, a liquid delivery system with pump and microsyringe, and a computer equipped with software for video image acquisition, image analysis, and evaluation of contact angle data. A suitable instrument is the OCA 20 optical contact angle measurement system (DataPhysics Instruments, Filderstadt, Germany) or an equivalent. The system must be capable of dispensing an 8.2 microliter drop and capturing images at a rate of 900 frames per second. The system is calibrated and operated according to the manufacturer's instructions unless explicitly stated otherwise in this test procedure.

[0151] To obtain a test specimen for measurement, a single layer of the dry substrate material is laid flat, and a test specimen approximately 15 mm wide and 70 mm long is punched out. The width of the specimen can be reduced as needed to ensure that the area in question is not obscured by surrounding features during testing. With a narrower specimen strip, care must be taken to ensure that the liquid droplet does not reach the edge of the specimen during testing, as this would necessitate repeating the test. Precondition the specimens at 23 °C ± 2 °C and 50% ± 2% relative humidity for 2 hours prior to testing. Sample preparation

[0152] A test sample can be punched out from any point containing the optically detectable zone to be analyzed. Within a zone, areas to be analyzed are those associated with a three-dimensional feature that defines a microzone. The microzone comprises at least two optically detectable areas. A zone, a three-dimensional feature, or a microzone can be optically detectable due to changes in texture, elevation, or thickness. Areas within different test samples made from the same substrate material can be analyzed and compared. Care should be taken to avoid creases, wrinkles, or cracks when selecting a sampling location.

[0153] If the substrate material is a layer of an absorbent article, for example, a top- or bottom-layer nonwoven material, an absorption layer, a distribution layer, or another component layer, adhere the absorbent article to a firm, flat surface in a planar configuration. Carefully separate the individual substrate layer from the absorbent article. A scalpel and / or cryogenic spray (such as Cyto-Freeze, Control Company, Houston, Texas) may be used to remove a substrate layer from any underlying layers, if necessary, to avoid any longitudinal and lateral expansion of the material. Once the substrate layer has been removed from the article, proceed with punching out the test specimen as described above. If the substrate material is in the form of a wet wipe, open a new pack of wet wipes and remove the entire stack from the packaging.Take a single wet wipe from the middle of the stack, spread it out flat and allow it to dry completely before punching the sample for analysis. Testing procedure

[0154] The test specimen is positioned on the horizontal sample stage with the test area within the camera's field of view, below the needle of the liquid delivery system, and the test side facing upwards. The specimen is secured so that it lies flat but unloaded, and any interaction between the liquid droplet and the underlying surface is avoided to prevent unnecessary capillary forces. A blunt-tipped stainless steel needle (ID 0.23 mm, OD 0.41 mm) with a thickness of 27 mm is positioned above the test specimen, with at least 2 mm of the needle tip within the camera's field of view. The sample stage is adjusted to achieve a distance of approximately 3 mm between the needle tip and the surface of the test specimen. An 8.2-microliter droplet of distilled water reagent is dispensed at a rate of 1 microliter per second and is allowed to fall freely onto the surface of the test specimen.Video image acquisition is initiated before the drop touches the surface of the test specimen, and subsequently, a continuous series of images is collected for a duration of 60 seconds after the drop touches the surface of the test specimen. This procedure is repeated for a total of five (5) substantially similar replicated test areas. A fresh test specimen is used, or care is taken to ensure that the area previously wetted by the drop is avoided during subsequent measurements.

[0155] In each image captured by the video camera, the test specimen surface and the droplet contour are identified and used by the image analysis software to calculate and record the contact angle for each droplet image to the nearest 0.1 degrees. The contact angle is the angle formed by the surface of the test specimen and the tangent to the surface of the liquid droplet in contact with the test specimen. For each set of images from a test, time zero is the time at which the liquid droplet comes into contact with the surface of the test specimen. The contact angle is measured and recorded on the droplet image corresponding to time zero plus five (5) seconds. The contact angle at five seconds is reported as 0° if the droplet was completely absorbed by the test specimen within five seconds. This procedure is repeated for the five replicated test areas.Calculate the arithmetic mean of the contact angle at time zero plus five seconds for the five replicated test areas and record this value as the contact angle to the next 0.1 degrees.

[0156] Time-to-wick is defined as the time it takes for the contact angle of a droplet penetrating the test sample to decrease to a contact angle of < 10°. Time-to-wick is measured by identifying the first image in a given series where the contact angle has decreased to < 10°, and then calculating and recording the time elapsed since time zero based on this image. Time-to-wick is recorded as 60 seconds if a contact angle of less than 10° is not reached within 60 seconds. Repeat this procedure for the five replicated test areas. Calculate the arithmetic mean of the time-to-wick for the five replicated test areas and record this value to the next 0.1 milliseconds.

[0157] The dimensions and values ​​disclosed herein shall not be construed as being strictly limited to the exact numerical values ​​stated. Instead, unless otherwise specified, each of these dimensions shall have the meaning of the stated value and a functionally appropriate range surrounding that value. For example, a dimension disclosed as "40 mm" shall mean "about 40 mm".

[0158] Every document referenced herein, including any cross-references or related patents or applications, and any patent application or patent to which this application claims priority or benefit, is hereby incorporated herein by reference in its entirety, unless expressly excluded or otherwise limited. The citation of a document does not imply that it is recognized as prior art for any embodiment disclosed or claimed herein, or that it teaches, suggests, or discloses such embodiment, either alone or in combination with other referenced literature. Furthermore, should any meaning or definition of a term in this document conflict with any meaning or definition of the same term in any document incorporated by reference, the meaning or definition assigned to the term in this document shall prevail.

[0159] Although specific examples of the present disclosure have been illustrated and described, it is obvious to the person skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of protection of the present disclosure. Therefore, the accompanying claims are intended to cover all such changes and modifications that fall within the scope of protection of the present disclosure.

Claims

[1] A nonwoven fabric (10) comprising a surface, the surface comprising a portion having a region-one total area of ​​low basis weight from 5% to 20% of a total area of ​​the portion of the surface, the remainder of the portion of the surface being a region-two total area of ​​high basis weight, and the portion comprising: a TS7 value in the range of 1 dB V 2 rms up to 4.5 dB V 2 rms, according to the Emtec test; and a TS750 value in the range of 6 dB V 2 rms up to 30 dB V 2 rms, according to the Emtec test. [2] Nonwoven fabric (10) according to claim 1, wherein the portion of the garment-side surface has a D-value in the range of 2 mm / N to 6 mm / N, according to the Emtec test. [3] Nonwoven fabric (10) according to claim 1 or 2, wherein a basis weight of the nonwoven material is in the range of 20 grams per square meter to 50 grams per square meter. [4] Nonwoven fabric (10) according to any one of the preceding claims, wherein fibers of the nonwoven fabric comprise bicomponent spunbond fibers. [5] The nonwoven fabric (10) of any preceding claim, wherein the portion of the surface has a region-one total area of ​​10% to 20% of a total area of ​​the portion of the surface, the remainder of the portion of the surface being a region-two total area. [6] Nonwoven fabric (10) according to any one of the preceding claims, wherein the section has a TS750 value in the range of 6 dB V 2 rms up to 15 dB V 2 rms, according to the Emtec test. [7] Nonwoven fabric (10) according to any one of the preceding claims, wherein the nonwoven fabric comprises crimped fibers. [8] An absorbent article (710) comprising the nonwoven fabric (10) according to any one of the preceding claims. [9] The absorbent article (710) of claim 8, wherein the nonwoven fabric (10) forms a portion of a topsheet (760). [10] The absorbent article (710) of claim 9, wherein a wearer-facing surface of the topsheet (760) comprises a first region (300) and a second region (310), and wherein the first region is hydrophobic and the second region is hydrophilic. [11] The absorbent article (710) of claim 8, wherein the nonwoven fabric (10) forms a portion of an outer sheath nonwoven material (762). [12] The absorbent article (710) of claim 8, comprising: a nonwoven topsheet (760) comprising a carrier-side surface, wherein a portion of the carrier-side surface corresponds to the portion of the surface of the nonwoven fabric (10); and an outer shell nonwoven material (762) comprising a garment-facing surface, a portion of the garment-facing surface comprising: a TS7 value in the range of 1 dB V 2 rms up to 4.5 dB V 2 rms, according to the Emtec test; and a TS750 value in the range of 6 dB V 2 rms up to 30 dB V 2 rms, preferably 6 dB V 2 rms up to 15 dB V 2 rms, according to the Emtec test. [13] The absorbent article (710) of claim 12, wherein the portion of the wearer-facing surface has a D-value in the range of 2 mm / N to 6 mm / N, according to the Emtec test, and wherein the portion of the garment-facing surface has a D-value in the range of 2 mm / N to 6 mm / N, according to the Emtec test. [14] The absorbent article (710) of any of claims 12 or 13, wherein the region one total area comprises in the range of 10% to 20% of a total area of ​​the portion of the wearer-facing surface, the remainder of the portion of the wearer-facing surface being the region two total area. [15] The absorbent article (710) of any one of claims 12 to 14, wherein the portion of the garment-facing surface has a region-one total area of ​​10% to 20% of a total area of ​​the portion of the garment-facing surface, the remainder of the portion of the garment-facing surface being a region-two total area.

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