Absorbent article with peel-off adhesive

Abstract

A menstrual and / or incontinence absorbent article having a pressure sensitive adhesive uniformly applied on the back surface of the absorbent article. The absorbent article optionally has an embossing that creates a variety of topographies along the body-facing side of the absorbent article, including a cover layer and optionally an inner transfer layer and / or a core layer. The absorbent article includes a release material or an absorbent article having a releasable adhesive applied to a release material, after which the absorbent article is applied to the pressure sensitive adhesive on the release material by a nip that includes a lobed roller. Apparatus and methods are provided herein to aid in the manufacture of such absorbent articles.

Description

[Technical field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 292,760, filed December 22, 2021, the entirety of which is incorporated herein by reference.

[0002] The present disclosure relates to absorbent articles for menstrual and / or incontinence. In particular, the present disclosure relates to absorbent articles having a backsheet (or backside) having an adhesive that allows the absorbent article to adhere to, be removed from, and applied to, and then removed from, a wrapper, outer packaging, or release material such as a release paper. [Background technology]

[0003] Current absorbent products have several areas that could be improved. Some current absorbent products are manufactured on equipment that requires the application of a release paper, as the manufacturing equipment is not designed to handle materials with different material properties. Such equipment ultimately results in products with both release paper and wrapper, which increases costs and the number of items that may ultimately be discarded by the consumer. Some current absorbent products are provided with only a wrapper, which acts as a protective barrier, and the adhesive on the back side of the absorbent product is temporarily attached during storage and before use. Current manufacturing equipment is capable of accommodating the latter product configuration, where the product is substantially flat, or in other words, without embossing, as the equipment is unable to uniformly apply pressure sensitive adhesive on products with topographical variations [on the cover or body-facing side of the product, and / or potentially within at least a portion of the intermediate layer or core of the product]. Such products lack features such as protrusions and channels that can increase the comfort of the user while wearing the product, improve mechanical properties, and improve the absorbent properties of the product. Such products are unable to have embossing, so they rely on visual cues to communicate the intended benefits to the consumer. To summarise the foregoing, current absorbent products can be difficult and / or costly to manufacture, requiring multiple components that are often produced by different manufacturers. There is a need to reduce the complexity and cost while maximising the comfort and / or performance characteristics of these products and improving their environmental impact where possible. Summary of the Invention

[0004] Absorbent articles for sanitary or incontinence such as napkins including pads, liners, maxi or ultra-thin products are provided. The absorbent articles have a cover layer, an absorbent core structure, and a backsheet that is generally hydrophobic, so that moisture is prevented from migrating through the absorbent article onto the underlying garment (undergarments, pants, etc.). The absorbent articles optionally include a transfer layer. In other embodiments, the properties of the transfer layer are designed into the cover layer and / or the absorbent core. In such latter embodiments, the overall thickness of the pad is optionally reduced. In such latter embodiments, the overall thickness of at least one of the cover layer and the absorbent core is increased to achieve a product with a layer thickness greater than the prior art products, but still reduced thickness. Such embodiments as contemplated throughout this disclosure can be used in many forms to achieve reduced thickness, although ultra-thin is preferred.

[0005] The absorbent article has a length, width, and thickness, the length being about 150 mm to about 330 mm, and the width being about 45 mm to about 150 mm (at the widest part). The total thickness of the cover, optional transfer layer, and absorbent core is about 0.9 mm to about 5 mm, or about 1.5 mm to about 3.3 mm, more preferably about 2.5 mm to about 3.3 mm. The total weight of the cover, optional transfer layer, and absorbent core is about 1.3 g to about 23 g, or about 1.3 g to about 6 g, or about 1.3 g to about 2.8 g, or about 7 g to about 23 g, or about 7 g to about 10 g. The cover, optional transfer layer, and absorbent core have a total basis weight (gsm) of less than about 240 gsm, or about 170 gsm to about 220 gsm, or about 180 gsm to about 200 gsm.

[0006] Optionally, the cover layer is embossed to have one or more protrusions separated by one or more channels. The cover layer has a first body-facing height and a second body-facing height different from the first body-facing height. The cover layer optionally comprises a honeycomb embossed cover, where the honeycomb is a repeating pattern of protrusions and channels across at least a portion of the absorbent article, such as a first end region, a second end region, and / or a central region, and / or a first side region, a central length region, and / or a second side region opposite the first side region.

[0007] The absorbent core has a total weight of about 2g to about 5g, or about 3g to about 4g, or about 3.3g to about 3.5g. Having a more robust core material is preferred when the cover material is reduced in weight, and such a core and cover combination allows for an absorbent article with reduced thickness. For example, the total thickness of the absorbent article is less than about 3mm. Such thickness, in combination with structures and materials, allows and provides the advantageous properties and characteristics contemplated throughout this disclosure.

[0008] The superabsorbent material comprises about 10% to about 50% of the total absorbent core, or about 15% to about 50% of the total absorbent core, or about 15% to about 25% of the total absorbent core. The pulp or cellulosic fiber content is about 50% to about 90%, or about 50% to about 85% of the total absorbent core.

[0009] The absorbent article includes a positioning adhesive applied to a backsheet (such as a wrapper, outer packaging, or release paper) and / or a release material. The terms "positioning adhesive", "pressure sensitive adhesive" and "removable adhesive" are interchangeable for purposes of this disclosure. The positioning adhesive includes, but is not limited to, a pattern such as multiple stripes (or lines) that are covered with one or more release papers until the absorbent article is ready to be applied to a garment for use. In some embodiments, 1 to 50 adhesive stripes are applied to extend parallel to the length of the absorbent article or perpendicular to the length of the absorbent article. In certain embodiments, 12 to 50 adhesive stripes are applied perpendicular to the length of the absorbent article.

[0010] In some embodiments, 1 to about 50 adhesive stripes are applied such that the stripes run parallel to the length of the absorbent article or perpendicular to the length. In some embodiments, 2 to 5 lines of adhesive are applied. In some embodiments, 2 lines of adhesive are applied. In alternative embodiments, the positioning adhesive is applied in a rectangular or square pattern around at least both ends of the absorbent article. In certain embodiments, 20 to 28 stripes are applied perpendicular to the length of the absorbent article or at an angle to the length of the absorbent article. In certain embodiments, 30 to 38 stripes are applied perpendicular to the length of the absorbent article. In certain embodiments, 40 to 48 stripes are applied perpendicular to the length of the absorbent article. The stripes or lines can include multiple individual segments. In such embodiments, the at least two adhesive stripes have a stripe width of 4 mm to about 40 mm, or about 4 mm to about 18 mm. In such embodiments, the at least two adhesive stripes have a stripe length of about 180 mm to about 290 mm, or about 180 mm to about 200 mm, or about 190 mm, or about 220 mm to about 250 mm, or about 240 mm, or about 250 mm to about 290 mm, or about 270 mm.

[0011] In alternative embodiments, the positioning adhesive is applied in a rectangular or square pattern around at least both ends of the absorbent article. In some embodiments, stripes of adhesive are applied, with at least one of the stripes having a different length than at least one other of the stripes of adhesive. In some embodiments, the stripes are oriented perpendicular to the length of the absorbent article, with a first stripe located most proximal to the top edge of the absorbent article being shorter than a stripe located inboard of the first stripe. In some embodiments, the stripes are oriented perpendicular or diagonal to the length of the absorbent article, with a last stripe located most proximal to the bottom edge of the absorbent article being shorter than a stripe located inboard of the last stripe.

[0012] The adhesive stripes are spaced apart from one another by portions of the backing layer of the absorbent article. Such areas free of adhesive are referred to as adhesive-free areas. The adhesive-free areas can have a length less than the length of the adhesive stripes (if the lines are arc-shaped or include the intersection of two or more lines), equal to the length of the adhesive stripes, or greater than the stripes. The adhesive-free areas can have a width of about 1 mm to about 10 mm, or about 2 mm to about 7 mm, or about 2 mm to about 6 mm, or about 4 mm to about 6 mm.

[0013] In some embodiments, the adhesive is applied to the backing layer of the absorbent article in an amount of about 20% to about 50% of the total surface area of ​​the backing layer of the absorbent article.

[0014] In some embodiments, the adhesive is applied to the article-facing side of the wrapper or to the release material in an amount of about 20% to about 50% of the total surface area of ​​the article-facing side of the wrapper.

[0015] In some embodiments, the adhesive is applied in stripes onto the release material (e.g., wrapper, outer packaging, or release paper) of the absorbent article as taught in this disclosure. The wrapper is then applied to the backing layer of the absorbent article.

[0016] In some embodiments, the cover layer and the absorbent core are assembled using a laminating adhesive, in other embodiments, a laminating adhesive is not required for such assembly, rather the product is assembled by heat and / or mechanical compression.

[0017] The absorbent article optionally has a simplified manufacturing process. In some embodiments, the absorbent article does not require a release paper. Therefore, only one release material (i.e., only the wrapper or outer packaging, and not the release paper) needs to be applied, and is discarded after the user puts the product into the user's underwear. Such a simple structure is advantageous in terms of cost.

[0018] The embodiments of the absorbent article as taught in the present disclosure have advantages over the prior art, for example, some embodiments of the absorbent article have embossing, which is difficult to achieve with a single release material, the wrapper (and not a release paper).

[0019] Absorbent articles according to the present disclosure have an adhesive strength of at least 100 gf, or from about 100 gf to about 300 gf, or from about 100 gf to about 250 gf.

[0020] A method is provided for applying adhesive to a packaging material and onto the backside of an absorbent article. The method provides a packaging material and an absorbent article. The absorbent article is formed from at least a cover layer, a core, and a backsheet together and assembled together by either pressure, heat, adhesive, or a combination thereof. The cover layer can be formed against the backsheet and / or each layer can be directly attached to its immediate neighbor. The absorbent article has an embossing such that the absorbent article has one or more protrusions separated by one or more channels.

[0021] The release material (e.g., wrapper, outer packaging, or release paper) is coated with adhesive in a pattern according to the present disclosure. The adhesive is applied by one or more nozzles. The nozzles are configured to spray one or more lines or patterns of adhesive onto the wrapper or release paper material according to the present disclosure. After the adhesive application step, the wrapper material or release paper material is conveyed by at least a transfer drum into a nip having a gap size of about 0.5 mm to about 4 mm, or about 0.5 mm to about 3 mm, or about 1 mm. The wrapper material or release paper material is conveyed such that its width corresponds to the length of at least one absorbent article. The gap size can be adjusted to fit the size (i.e., thickness) of the absorbent article. The gap size can be adjusted to accommodate different sizes of rollers suitable for different sizes of absorbent articles.

[0022] At the same time, at least one absorbent article is conveyed to the nip, and the at least one absorbent article is flat (or not yet folded). In some embodiments, the length of the at least one absorbent article is aligned with the width of the belt or rotating drum. In certain embodiments, the at least one absorbent article is transported by the belt or by vacuum. In one embodiment, the rotating transfer drum applies vacuum pressure to the at least one absorbent article.

[0023] Once the at least one absorbent article is applied to the adhesive on the release material in the nip, pressure is applied by the lobed roller such that a fixed but releasable connection is provided between the release material and the backside of the at least one absorbent article. The at least one absorbent product and the release material engage and pass through the nip created by the lobed roller and the transfer roller, the transfer roller being generally opposite the lobed roller such that each of the two rollers is opposite the at least one absorbent product and wrapper. The at least one absorbent product and the release material engage the lobed roller at a first portion of the lobed portion. The lobed portion of the roller is sized to be approximately the width of the absorbent article. The first portion of the lobed roller has a lead-in that mitigates the at least one absorbent article from bunching and not properly seating or mating with the adhesive applied to the release material. The lobed rollers have a pitch of about 120 mm to about 150 mm, or about 130 mm to about 140 mm, or about 131 mm to about 136 mm.

[0024] The lobed roller rotates at a speed substantially equal to the conveying speed of the packaging material or release paper. In embodiments where at least one absorbent article is conveyed on a belt, the lobed roller rotates at a speed substantially equal to the conveying speed of the at least one absorbent article. In embodiments where at least one absorbent article is conveyed by a transfer drum (using a vacuum), the rotational speed of the lobed roller is equal to the rotational speed of the transfer drum.

[0025] A lobed roller is a structure having a first circumference and a second circumference, the first circumference having the maximum diameter of the lobed portion of the roller and the second circumference having the minimum diameter of the trough. The first circumference forms a circumscribing circle around the entire roller, which includes at least one lobed portion and at least one trough. The second circumference forms a circle inscribed around the entire roller. In some embodiments, there are at least two lobed portions and at least two troughs, with the troughs separating each of the lobed portions.

[0026] An apparatus for applying a wrapper or release paper to an absorbent article is provided. The apparatus includes a drum having a rolling surface. The rolling surface is non-circular, with a portion of the rolling surface having a maximum diameter that defines a circumscribing circle. The rolling surface is optionally lobed, such that the portion of the rolling surface has a diameter less than the maximum diameter of the rolling surface defined by a lobed portion of the rolling surface. The rolling surface is optionally cammed, such that the portion of the rolling surface has a diameter less than the maximum diameter of the rolling surface defined by a cammed portion of the rolling surface.

[0027] The process and apparatus of the present disclosure provide improved consistency of adhesive within the adhesive stripes of the embossed absorbent article. Prior processes and apparatus have been unable to consistently apply adhesive in the configuration of one or more stripes that the present disclosure is able to achieve. Thus, the absorbent article of the present disclosure includes one or more adhesive stripes having a substantially uniform amount of adhesive applied throughout each individual adhesive stripe in at least one of the length and thickness of the adhesive stripe. Thus, the absorbent article of the present disclosure includes one or more adhesive stripes having a substantially uniform amount of adhesive applied throughout all of the one or more adhesive stripes on the absorbent article in at least one of the length and thickness of such one or more adhesive stripes.

[0028] Other exemplary embodiments of the present disclosure are provided below.

[0029] 1. An absorbent article having a length, a width, and a thickness, the length and width being in an xy plane,

[0030] a cover layer having a body facing surface and a lower cover surface opposite the body facing surface;

[0031] an absorbent core adjacent the lower cover surface;

[0032] a backsheet layer having a backsheet upper surface and a garment-facing surface opposite the backsheet upper surface, the garment-facing surface being at least a portion of the backsheet layer covered with a releasable adhesive;

[0033] at least one of the cover layer and the absorbent core is embossed to create a first body-facing height that is greater than the second body-facing height;

[0034] the garment-facing surface is coated with a plurality of stripes of a releasable adhesive;

[0035] The multiple stripes can range from 2 stripes to 50 stripes.

[0036] a release material comprising a semi-siliconized or fully siliconized film material;

[0037] The absorbent article is embossed to have at least one channel and up to about 25 channels;

[0038] the cover layer is embossed to have embossed protrusions on the body-facing surface relative to a cover layer base height;

[0039] the embossed protrusions have a protrusion height of about 0.020 inches (0.5 mm) to about 0.040 inches (1.0 mm) and a protrusion width of about 0.020 inches (0.5 mm) to about 0.040 inches (1.0 mm);

[0040] The absorbent article further comprising at least one channel separating the embossed projections, the channel having a channel width of about 0.0125 inches (0.31 mm) to about 0.0375 inches (0.95 mm).

[0041] 1. An absorbent article having a length, a width, and a thickness, the length and width being in an xy plane,

[0042] a cover layer having a body facing surface and a lower cover surface opposite the body facing surface;

[0043] an absorbent core adjacent the lower cover surface;

[0044] a backsheet layer having a backsheet upper surface and a garment-facing surface opposite the backsheet upper surface, the garment-facing surface being at least partially covered with a releasable adhesive;

[0045] the release material is generally rectangular and has a top edge, a left most edge, a right most edge generally opposite the left most edge, and a bottom edge generally opposite the top edge, the release material has an article facing side and an outer side opposite the article facing side, the article facing side and the outer side being defined by the top edge, side edges, and bottom edge, the release material has a release material length that is greater than or equal to the length of the absorbent article, the release material has a release material width that is greater than or equal to the width of the absorbent article, the release material comprises a semi-siliconized or fully siliconized material or coating,

[0046] At least one of the cover layer and the absorbent core is embossed to create a first body-facing height that is greater than the second body-facing height;

[0047] The release material is applied in a plurality of stripes of a releasable adhesive;

[0048] the plurality of stripes is at least 2 and at most about 50;

[0049] the plurality of stripes having an adhesive surface area of ​​about 20% up to about 50% of the total surface area of ​​the article-facing side of the release material;

[0050] The plurality of stripes have a bonded area of ​​about 20% up to about 50% of the total surface area of ​​the garment-facing surface.

[0051] 1. A method for applying an adhesive to at least one ultra-thin absorbent article, comprising:

[0052] Assembling at least one ultra-thin absorbent article from at least a cover layer, a core having one or more portions or layers, and a backsheet, the backsheet having a garment-facing surface that provides a back surface of the absorbent article;

[0053] a cover layer is applied to and adjacent to the core, the core is applied to and adjacent to the backsheet, and the cover layer, the core, and the backsheet are assembled into at least one ultra-thin absorbent article by at least one of pressure, heat, adhesive, or combinations thereof;

[0054] At least one ultra-thin absorbent article is constructed such that the cover layer (11) has a varied topography having one or more protrusions and one or more channels;

[0055] a release material is provided and conveyed past one or more nozzles that spray adhesive onto the release material in one or more lines or patterns as the release material is conveyed;

[0056] conveying the release material by at least a transfer drum into a nip having a gap size of about 0.5 mm to about 5 mm;

[0057] The release material is delivered such that the width of the release material corresponds to the length of the at least one ultra-thin absorbent article;

[0058] and simultaneously conveying at least one ultra-thin absorbent article into the nip on the conveyor belt, the at least one ultra-thin absorbent article being generally and substantially flat or unfolded;

[0059] The length of the at least one ultra-thin absorbent article is aligned with the width of the transport belt or rotating drum;

[0060] When the at least one ultrathin absorbent article is applied to the adhesive on the release material in the nip, pressure is applied by the lobed roller such that a fixed but releasable connection is provided between the release material and the backside of the at least one ultrathin absorbent article;

[0061] At least one ultra-thin absorbent article and release material are engaged and passed through a nip created by a lobed roller and a transfer drum;

[0062] the transfer drum is generally opposite the lobed roller such that the transfer drum and the lobed roller are each opposite the at least one ultra-thin absorbent article and the release material;

[0063] at least one of the ultra-thin absorbent article and the release material engages the lobed roller at a first portion of the lobed portion;

[0064] the lobed portion of the lobed roller is sized to be approximately the width of at least one ultra-thin absorbent article;

[0065] a first portion of the lobed roller having a lead-in portion that reduces bunching of the at least one ultra-thin absorbent article and prevents the at least one ultra-thin absorbent article from properly seating on or engaging with an adhesive applied to the release material;

[0066] The method wherein the lobed roller rotates at a speed substantially equal to the speed of transport of the release material. [Brief description of the drawings]

[0067] [Figure 1] FIG. 1 illustrates an angled top view of one embodiment of the present disclosure. [Figure 1A] FIG. 2 is a detailed schematic diagram of one embodiment of a cover layer of the present disclosure. [Diagram 2] 2 through 5 are top views of an embodiment of the present disclosure. [Diagram 3] FIG. 1 is a top view of an embodiment of the present disclosure. [Figure 4] FIG. 1 is a top view of an embodiment of the present disclosure. [Diagram 5] FIG. 1 is a top view of an embodiment of the present disclosure. [Figure 6] FIG. 1 illustrates an exploded angled top view of one embodiment of the present disclosure. [Figure 7] FIG. 2 is a bottom view of one embodiment of an absorbent article of the present disclosure. [Figure 8] FIG. 2 is a bottom view of one embodiment of an absorbent article of the present disclosure. [Figure 9] FIG. 2 is a bottom view of one embodiment of an absorbent article of the present disclosure. [Figure 10] FIG. 2 is a bottom view of one embodiment of an absorbent article of the present disclosure. [Figure 11] FIG. 2 is a bottom view of one embodiment of an absorbent article of the present disclosure. [Figure 12] FIG. 2 is a bottom view of one embodiment of an absorbent article of the present disclosure. [Figure 13] 1 is a flow diagram of a manufacturing method according to one embodiment of the present disclosure. [Figure 14] 1 is a flow diagram of a manufacturing method according to one embodiment of the present disclosure. [Figure 15] FIG. 1 is a schematic diagram of a prior art device according to one embodiment of the present disclosure. [Figure 16] FIG. 1 is a schematic diagram of an apparatus according to one embodiment of the present disclosure. [Figure 17A] FIG. 1 is an angled view of an apparatus according to one embodiment of the present disclosure. [Figure 17B] FIG. 17b is a side view of the device of FIG. 17a. [Figure 18] FIG. 18 is a perspective view of an apparatus according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0068] As illustrated in FIG. 1, an absorbent article (10) is provided. Coordinates are shown in the x, y, and z directions to provide a basis for understanding the subject matter discussed herein. The absorbent article has a length (14), a width (15), and a thickness (16), and generally includes a top (or body-facing) surface (11), often referred to as a cover layer (11). The absorbent article (10) has a back sheet (or back surface, or barrier layer) (18) opposite the cover layer (11), generally facing the garment worn by the user. The absorbent article has an absorbent core (20) structure between the cover layer (11) and the back sheet (18). Optionally, the absorbent article (10) has a transfer layer (22) between the cover layer (11) and the absorbent core (20).

[0069] The absorbent article (10) may have many shapes, but as shown and preferably for at least ultra-thin and liner products, dog-bone, peanut, hourglass, and / or barbell shapes are provided. Alternative shapes include generally cylindrical, pointed (such that the sides are not parallel but taper toward each other from the rear portion (or first end region 43) to the front portion (or second end region 44), and / or hybrids thereof. The absorbent article (10) optionally has winged portions (58) that join around the waist of the user and facilitate attachment to an undergarment or to itself (one or more pairs of winged portions emanating from the lateral sides of the central region (45) or the lateral side edges (42) of the second or rear region (44)). The absorbent article (10) optionally has a gathered waist region for pant-like or undergarment-style absorbent articles (not shown).

[0070] Optionally, the absorbent article (10) included colored portions (28) and non-colored portions (24) to indicate absorbent areas on the product, to enhance the perception of depth of the absorbent article, and / or to help mask liquids attempting to penetrate the product. The colored portions (28) are on the top surface (12) of the cover layer (11), on the bottom surface (13) of the cover layer (11) (opposite the top surface (12)), or on / in the absorbent core (20). The colored portions (28) can be of various colors, but are preferably darker colors that are more visible and, optionally, mask bodily fluid discharge. Such colors are red, blue, purple, and / or green.

[0071] The cover layer (11) has a body facing surface (12) and a lower cover surface (13) opposite the body facing surface (12). The body facing surface (12) is oriented towards the body of the user such that, when in use, the body facing surface (12) is at least partially in contact with the user's body, or at a minimum, is the first portion of the absorbent article (10) that accommodates bodily exudates such as fluids. Such fluids may include, for example, urine and / or menses.

[0072] In some embodiments, the cover layer (11) is a spunbound or spunlace material. The cover layer (11) comprises nonwoven fibers and / or synthetic fibers. The cover layer (11) optionally has bicomponent fibers of PE / PP. In one embodiment, the cover layer (11) comprises a blend of fibers. In some embodiments, polypropylene, polyester, and / or polyethylene fibers are blended. For example, polyester fibers and polypropylene fibers are blended, or polyethylene fibers and polypropylene fibers are blended. The ratio of such fibers can be about 1:3 to about 3:1, respectively, or alternatively about 25% to about 75%, and about 75% to about 25%, respectively. In some embodiments, the ratio of fibers can be about equal, about 1:1, or about 50% each. In some embodiments, the cover layer (11) has a basis weight that is about 20 gsm to about 50 gsm, or about 25 gsm to about 30 gsm, or about 27 gsm. In some embodiments, the cover layer (11) is hydroentangled imaged spunlace. In some embodiments, the cover layer (11) has a uniquely configured image or pattern. Cover materials are manufactured by manufacturers such as Suominen, Fitesa, and Shalag.

[0073] In some embodiments, the cover layer (11) is embossed. The embossment has one or more protrusions (26) separated by one or more channels (27). The one or more protrusions (26) have a protrusion height (38) and a protrusion width (or diameter) (39). The protrusion (27) honeycomb (25) structure is raised on the body-facing surface (12) relative to the cover layer base height (36). The protrusion height (38) is a first body-facing height (38), and these terms are used interchangeably throughout. The base height (36) is a second body-facing height (36), and these terms are used interchangeably throughout. In some embodiments, the embossment forms a pattern. In some embodiments, the cover layer (11) has an embossed pattern, and the one or more protrusions (26) and one or more channels (27) of such embossed pattern are a repeating pattern across at least a portion of the absorbent article, such as the first end region (43), the second end region (44), and / or the central region (45), and / or the first side region (46), the central length region (48), and / or the second side region (47) opposite the first side region (46). In some embodiments, the embossed pattern is a repeating pattern across substantially the entire absorbent article (10).

[0074] In some embodiments, the cover layer (11) has protrusions (26) and channels (27) that form a honeycomb (25) embossed pattern, and the honeycomb-shaped protrusions (26) (separated by channels (27)) are a repeating pattern across at least a portion of the absorbent article, such as the first end region (43), the second end region (44), and / or the central region (45), and / or the first side region (46), the central length region (48), and / or the second side region (27) opposite the first side region (46). In some embodiments, the honeycomb (25) pattern is a repeating pattern across substantially the entire absorbent article (10). The individual hexagonal structures that are the protrusions (26) in the cover layer (11) are separated by channels (27) that are between about 0.0125 inches and about 0.0375 inches, or 0.0125 inches apart. Each individual hexagonal structure in the cover layer (11) has a projection height (38) (or the difference between the first body-facing height (38) and the second body-facing height (36)) of about 0.020 inches to about 0.040 inches, more preferably about 0.030 inches. The distance between the first body-facing height (38) and the second body-facing height (36) is at least 0.010 inches and up to about 1 mm. Each side (49) of the projections (26), i.e., in an exemplary embodiment, the side (49) of each individual hexagonal projection (26), has a projection length (50) of about 0.080 inches to about 0.10 inches, or about 0.090 inches. The overall projection length (51) of each hexagonal projection (26) as defined by the midpoint of an outer side to the midpoint of the opposite outer side such that a perpendicular bisector is formed between the sides is about 0.15 inches to about 0.20 inches, more preferably about 0.16 inches to about 0.18 inches, or about 0.17 inches. The width / diameter (39) of each hexagonal projection (26) is about 0.20 inches to about 0.30 inches, or about 0.21 inches to about 0.28 inches.

[0075] The absorbent core (20) includes one or more layers called stratum (30). The absorbent core (20) is optionally an airlaid structure, where the material is deposited on a substrate. The absorbent core (20) has an upper core surface (21) adjacent the lower cover surface (13), and a lower core surface (23) adjacent the backsheet upper surface (17). Absorbent core structures can be purchased from manufacturers such as EAM and Glatfelterb.

[0076] The absorbent core (20) comprises one or more of the following: nonwoven, fiber, pulp, absorbent material, and optionally adhesive material. The fiber or pulp material is about 40% to about 95% of the total weight of the absorbent core (20). In some embodiments, the fiber material is about 60% to 90% of the total weight of the absorbent core (20). In some embodiments, the fiber material is about 80% to 90% of the total weight of the absorbent core (20).

[0077] In an absorbent core (20) having both pulp and bicomponent fibers and / or one or more layers (30) therein, the ratio of pulp to bicomponent fibers is about 3.5:1 to about 30:1. In a first embodiment, the ratio of pulp to bicomponent fibers is about 3.5:1 to about 8:1. In a second embodiment, the ratio of pulp to bicomponent fibers is about 10:1 to about 40:1. In such embodiments, the pulp material is about 40% to about 75% of the total weight of the absorbent core (20). In some embodiments, the pulp material is about 40% to about 60% of the total weight of the absorbent core (20). In some embodiments, the pulp material is about 55% to about 75% of the total weight of the absorbent core (20). In such embodiments, the bicomponent fibers are 1% to 15% of the total weight of the absorbent core (20). In some embodiments, the bicomponent fibers are 1% to 10% of the total weight of the absorbent core (20).

[0078] In some embodiments, the absorbent core (20) comprises an adhesive that is from about 0.5% to about 10% of the total weight of the absorbent core (20).

[0079] In some embodiments, the ratio of pulp to bicomponent fibers is from about 10:1 to about 40:1, the pulp material is from about 55% to about 75% of the total weight of the absorbent core (20), and the bicomponent fibers are from 5% to 15% of the total weight of the absorbent core (20).

[0080] The pulp in the absorbent core 20 may be treated, untreated, or a mixture of both treated and untreated. Such pulps are sold, for example, by the manufacturers GP Cellulose or International Paper.

[0081] The bicomponent fibers are PE-PET, for example, as sold by GP Cellulose or International Paper.

[0082] Adhesives are used as binders for the absorbent core (20). One type of binder is a dispersion binder. Dispersion binders are latex, vinyl acetate and / or ethylene. Some of the dispersion binders of the present disclosure are aqueous polymer dispersions.

[0083] Highly absorbent materials used in the absorbent core (20) are sold by Sumitomo Corporation, Nippon Shokubai, BASF, and Evonik. For example, some superabsorbent polymer grades sold by Sumitomo include SA55, SA60, SA60N Type II, SA65, SA65s, and SA70. The superabsorbent material is about 5% to about 40% of the total weight of the absorbent core (20).

[0084] The backsheet (18) has a backsheet upper surface (17) opposite a backsheet garment-facing surface (19). The backsheet upper surface (17) is adjacent to the absorbent core (20), and more specifically, the core lower surface (23) of the absorbent core (20). The backsheet garment-facing surface (19) is typically positioned adjacent to an undergarment worn by a user. The backsheet garment-facing surface (19) has a releasable adhesive that allows for temporary attachment to the undergarment so that the backsheet garment-facing surface (19) can be separated from the undergarment when the absorbent article (10) needs to be changed.

[0085] The positioning adhesive is applied in at least one stripe (32) to the garment-facing surface (19) of the backsheet, which is optionally the backsheet, [which may be the back layer (34) of the absorbent article (10)]. More specifically, the garment-facing surface (19) of the backsheet (18) is applied with adhesive in a pattern, such as at least one stripe (or line) (32). Optionally, the positioning adhesive comprises a plurality of stripes (32) that are covered by one or more pieces of release material (52), such as release paper, outer packaging, or wrapper, until the absorbent article (10) is ready to be applied to a garment for use. In some embodiments, one to about fifty lines (or stripes) (32) of adhesive are applied such that the stripes (32) run parallel to the length (14) of the absorbent article (10) or run perpendicular to the length (14). In some embodiments, two to about five lines (32) of adhesive are applied such that the stripes (32) extend parallel to the length (14) of the absorbent article (10) or such that the lines (32) extend perpendicular to the length (14). In some embodiments, two lines (32) of adhesive are applied such that the lines (32) extend parallel to the length (14) of the absorbent article (10). In some embodiments, two to about five lines (32) of adhesive are applied such that the stripes (32) extend parallel to the length (14) of the absorbent article (10) or such that the lines (32) extend perpendicular to the length (14). In some embodiments, two lines (32) of adhesive are applied such that the lines (32) extend parallel to the length (14) of the absorbent article (10). In an alternative embodiment, the positioning adhesive is applied in a rectangular or square pattern around at least both ends of the absorbent article. In certain embodiments, between 20 and 28 stripes (32) are applied perpendicular to the length (14) of the absorbent article (10). In certain embodiments, between 30 and 38 stripes (32) are applied perpendicular to the length (14) of the absorbent article (10). In certain embodiments, between 40 and 48 stripes (32) are applied perpendicular to the length (14) of the absorbent article (10).In certain embodiments where more than one nozzle is used, it is preferred to apply an even number of stripes (32) such that each nozzle is configured to spray the same pattern or amount of adhesive. In certain embodiments, 2 to 20 vertical stripes (32) extending parallel to the absorbent article (10) for the length (14) are preferred. In certain embodiments, the length of the stripes (32) is uniform such that all stripes (32) have the same length. In certain embodiments, the stripes (32) have the same width such that all stripes (32) are uniform. In certain embodiments, the spacing (40) between the stripes (32) is 1 mm to about 12 mm, or 2 mm to about 10 mm, or 2 mm to about 4 mm. In certain embodiments, the stripes (32) extend to within ¼ inch and about 2.5 inches from the edge of the absorbent article (10). In certain embodiments, the amount of adhesive applied to the backing layer (34) of the absorbent article (10) is from about 20% to about 60%, or from about 25% to about 45%, or from about 25% to about 35% of the total surface area of ​​the backing layer (34). In certain embodiments, the length of the stripes (32) is varied such that a first nozzle applies stripes (32) of a first length and a second nozzle applies stripes (32) of a second length that is different from the first length.

[0086] The absorbent article (10) with the adhesive on the adhesive stripes (32) has an adhesive strength of from 100 gf to 300 g, or at least about 120 gf to a maximum of about 300 gf, or at least about 150 gf to a maximum of about 300 gf, or from about 120 gf to about 200 gf.

[0087] The mass of the applied adhesive is from about 0.1 g to about 0.5 g, or from about 0.1 g to about 0.3 g, or from about 0.12 g to about 0.25 g, or from about 0.12 g to about 0.21 g.

[0088] In some embodiments, one or more wings (58) extend outwardly from the lateral edges (42) and are attachable to an undergarment. The wings (58) have a releasable adhesive that allows the wings (58) to be temporarily attached to the undergarment so that the wings (58) can be separated from the undergarment when the absorbent article (10) needs to be changed. In embodiments having a releasable or pressure sensitive adhesive on the garment facing surface (19) of the backsheet and / or on the wings (58), the releasable adhesive is covered by a release material (52), such as a release paper and / or an outer covering or wrapper (52), to prevent the absorbent article (10) from adhering to other articles prior to use.

[0089] The absorbent article (10) has a length (14), a width (15), and a thickness (16), with the length (14) being from about 150 mm to about 330 mm and the width (at its widest point) varying from about 45 mm to about 150 mm. The total thickness (15) of the cover (11), optional transfer layer (22), and absorbent core (20) is from about 0.9 mm to about 5 mm, or from about 1.5 mm to about 3.3 mm, more preferably from about 2.5 mm to about 3.3 mm. The cover (11), optional transfer layer (22), and absorbent core (20) have a total weight of from about 1.3 g to about 23 g, or from about 1.3 g to about 6 g, or from about 1.3 g to about 2.8 g, or from about 7 g to about 23 g, or from about 7 g to about 10 g. The cover (11), optional transfer layer (22), and absorbent core (22) have a total basis weight (gsm) of less than about 240 gsm, or from about 170 gsm to about 220 gsm, or from about 180 gsm to about 200 gsm.

[0090] The absorbent core (20) has a total weight of about 2 g to about 5 g, or about 3 g to about 4 g, or about 3.3 g to about 3.5 g. Having a more robust core material is preferred if the cover material is to be reduced in weight, and such a combination of absorbent core (20) and cover layer (11) allows for an absorbent article (10) with reduced thickness. For example, the absorbent article (10) has a total thickness (15) of less than about 3 mm. Such thicknesses (15), in combination with structures and materials, allow for and provide the advantageous properties and characteristics contemplated throughout this disclosure.

[0091] Table 1 below illustrates the improved properties achieved by the teachings of the present disclosure using procedures generally consistent with those described above. TIFF2024544793000002.tif148155

[0092] As shown, by eliminating the need for a central release paper (and thus by having only the absorbent article (10) and its wrapper (52)), the total mass (shown on the bottom row of Table 1) is reduced by up to about 10%, or about 5% to 10%, or about 8% to 10%. The reduction in material and mass results in cost improvements as well as a positive impact on the environment, since raw materials do not have to be harvested and / or manufactured and / or processed, raw materials do not have to be packaged and shipped, less energy is required to fully assemble the absorbent article (10), and less mass is required for shipment to distribution centers, customers, and / or consumers.

[0093] In another aspect of the present disclosure, the process and apparatus of the present disclosure provide improved consistency of adhesive within the adhesive stripes (32) for embossed absorbent articles (10). Whereas prior processes and apparatus have been unable to consistently apply adhesive in the configuration of one or more stripes (32), the present disclosure is able to do so. Thus, the absorbent article (10) of the present disclosure includes one or more adhesive stripes (32) having a substantially uniform amount of adhesive applied throughout each individual adhesive stripe (32) in at least one of the length (33) and thickness (31) of the adhesive stripe (32). Thus, the absorbent article (10) of the present disclosure includes one or more adhesive stripes (32) having a substantially uniform amount of adhesive applied throughout all of the one or more adhesive stripes (32) on the absorbent article (10) in at least one of the length (33) and thickness (31) of such one or more adhesive stripes (32). In some embodiments, the amount of surface area of ​​the adhesive stripe (32) that is covered by adhesive (as viewed by viewing the adhesive stripe (32) when positioned on the backing layer (34) of the absorbent article (10), such as in Figures 6-8) is greater than 75%, or greater than about 80%, or greater than about 90%, or greater than about 95%, or greater than about 97%, or greater than about 98% of the overall size of the adhesive stripe (32) (such that any of the backing layer (34) is covered within the adhesive stripe (32)). Figure 8 illustrates portions of the stripe (32) that are not covered with adhesive, designated by reference numeral (35), while the stripe (32) is otherwise covered with adhesive. In some embodiments, the amount of total surface area of ​​one or more adhesive stripes (32) (as viewed by viewing the adhesive stripe (32) when positioned on the back surface of the absorbent article (10) (so that any of the back surface layer (34) is covered within the adhesive stripe (32)), as in Figures 6 to 8) is greater than about 75% of the overall size of the adhesive stripe (32), or greater than about 80%, or greater than about 90%, or greater than about 95%, or greater than about 97%, or greater than about 98%.Such measurements can be made with computer software and a high resolution camera or microscope to measure the total surface area of ​​the adhesive stripes 32. Also, the surface area of ​​the adhesive stripes 32 that is covered with adhesive can be measured, or alternatively, the surface area of ​​the adhesive stripes 35 that is not covered with adhesive can be measured. The percentage of the surface area of ​​the adhesive stripes 32 that is covered with adhesive can be calculated by dividing (a) the surface area of ​​the adhesive stripes 32 that is covered with adhesive by (b) the total surface area of ​​the adhesive stripes 32.

[0094] The absorbent article (10) according to the present disclosure is made possible by a unique manufacturing apparatus that includes a lobed roller (82). Currently, ultra-thin absorbent articles (10) having embossed cover sheets or otherwise having ribs, channels, and / or protrusions that create a variety of topographies on the cover sheet (11) are sprayed with a positioning adhesive on either the back sheet (18) of the pad or the release paper. In either case, the absorbent article (10) and the release paper are then assembled such that the release paper is adhered onto the back sheet of the ultra-thin article by the nip (76) defined by the two rollers. Applicants have discovered that applying a positioning adhesive in a desired shape or pattern on the ultra-thin absorbent article (10) (having the aforementioned embossing or other topographical variations) and achieving a consistent spread of adhesive along the entirety (width and length) of each portion of the adhesive shape or pattern after it has been applied to a film material, such as a film material in a package or outer packaging, is not achievable with current rollers having a uniform circumference. Applicants have surprisingly realized that applying uniform pressure (by a cover layer) to a structure with variable topography results in inconsistent application of positioning adhesive. Counterintuitively, Applicants have created an asymmetric, i.e., lobed, roller (82) that would allow for discontinuous pressure over the length (14) of the absorbent article (10), where release of pressure during assembly of the release material (52) allows material to be applied and modified to alleviate inconsistent application of adhesive from the release material (52) to the absorbent article (10).

[0095] A method is provided for applying a release material (52), such as a wrapper, outer packaging, or release paper, onto the backing layer (34) of an absorbent article (10). Each of these variations is described in turn below, beginning with applying an adhesive to the release material (52), and then subsequently applying the adhesive to the backing layer (34) of the absorbent article (10). Figures 15-18 show embodiments of the method, product, and apparatus.

[0096] As illustrated in FIG. 13, the first step (60) of the method provides a release material (52) and an absorbent article (10). The absorbent article (10) is formed from at least a cover layer (11), a core (20), and a backsheet (19) together and assembled together by either pressure, heat, adhesive, or a combination thereof. The cover layer (11) can be formed against the backsheet (19) and / or each layer can be directly attached to its immediate neighbor. The absorbent article (10) can be embossed to have one or more protrusions (26) separated by one or more channels (27). Alternatively, the absorbent article (10) can have a variety of topographies on the cover layer (11) and therefore also have protrusions (26), channels (27), ribs, recesses, etc.

[0097] The next step (62) of the method includes applying adhesive in a pattern to the release material (52) according to the present disclosure. The adhesive is applied by one or more nozzles. The nozzles are configured to spray one or more lines or stripes or patterns (32) of adhesive onto the release material (52) according to the present disclosure. After the adhesive application step, step (66) includes conveying the release material (52)i by at least a transfer drum (90) to a nip (76) having a gap size of about 0.5 mm to about 4 mm, or about 0.5 mm to about 3 mm, or about 1 mm. The release material (52) is conveyed such that the width of the material corresponds to the length (14) of at least one absorbent article (10). The gap size can be adjusted to fit the size (i.e. thickness) of the absorbent article (10). The gap size can be adjusted to accommodate different sized rollers suitable for different sized absorbent articles (10).

[0098] At the same time, step (64) occurs, where the absorbent article (10) is conveyed into the nip (76), where the absorbent article (10) is flat (or not yet folded). In some embodiments, the length (14) of the absorbent article (10) is aligned with the width of the belt (78) or rotating drum (80). In certain embodiments, the absorbent article (10) is transported by the belt (78) or by vacuum. In one embodiment, the rotating transfer drum (90) applies vacuum pressure to the absorbent article (10).

[0099] Once the absorbent article (10) is applied to the adhesive on the release material (52) within the nip (76) (step 68), pressure is applied by a lobed roller (82) such that a fixed but releasable connection is established between the release material (52) and the back surface (34) of the absorbent article (10), step (70). The release material (52) attached to the absorbent article (10) is then passed through a cutter (or slitting machine) whereby the individual absorbent articles (10) [with the release material (52)] are cut and separated for packaging (step 72).

[0100] As illustrated in FIG. 14, the first step (60) of the method provides a release material (52) and an absorbent article (10). The absorbent article (10) is formed from at least a cover layer (11), a core (20), and a backsheet (19) together and assembled together by either pressure, heat, adhesive, or a combination thereof. The cover layer (11) can be formed against the backsheet (19) and / or each layer can be directly attached to its immediate neighbor. The absorbent article (10) can be embossed to have one or more protrusions (26) separated by one or more channels (27). Alternatively, the absorbent article (10) can have a variety of topographies on the cover layer (11) and therefore also have protrusions (26), channels (27), ribs, recesses, etc.

[0101] The next step (62) in the method involves applying adhesive to an absorbent article (10) according to the present disclosure in a pattern. The adhesive is applied by one or more nozzles. The nozzles are configured to spray one or more lines or stripes or patterns (32) of adhesive onto the back surface (34) of the absorbent article (10) according to the present disclosure. After the adhesive application step, step (66) involves conveying the absorbent article (10) by at least a transfer drum (90) to a nip (76) having a gap size of about 0.5 mm to about 4 mm, or about 0.5 mm to about 3 mm, or about 1 mm. The absorbent article (10) is conveyed such that the length (14) of at least one absorbent article (10) corresponds to the width of the release material (52). The gap size can be adjusted to fit the size (i.e. thickness) of the absorbent article (10). The gap size can be adjusted to accommodate different sized rollers suitable for different sized absorbent articles (10).

[0102] At the same time, step (64) is performed, the release material (52) is conveyed into the nip (76) while the absorbent article (10) (or the release material (52)) is flat (or not yet folded). In some embodiments, the width of the release material (52) is aligned with the width of the belt (78) or rotating drum (80). In certain embodiments, the release material (52) is conveyed by the belt (78) or by vacuum. In one embodiment, the rotating transfer drum (90) applies vacuum pressure to the release material (52).

[0103] Once the absorbent articles (10) have been applied to the adhesive on the backside (34) of the absorbent articles (10) in the nip (76) (step 68), pressure is applied by the lobed roller (82) such that a fixed but releasable connection is made between the backside (34) of the absorbent articles (10) and the release material (52), step (70). The release material (52) attached to the absorbent articles (10) is then passed through a cutting (or slitting) machine whereby the individual absorbent articles (10) [with the release material (52)] are cut and separated for packaging (step 72), resulting in packaged absorbent articles (10a).

[0104] The absorbent article (10) and release material (52) engage and pass through a nip (76) formed by a lobed roller (82) and a transfer roller (90), the transfer roller (90) being generally opposite the lobed roller (82) such that each of the two rollers (82, 90) is on an opposite side of the absorbent article (10) and release material (52). The absorbent article (10) and release material (52) engage the lobed roller (82) at a first portion (88) of the lobed portion (86). The lobed portion (86) of the lobed roller (82) is sized to be approximately the width (15) of the absorbent article (10). The first portion (88) of the lobed roller (82) has a lead-in that mitigates the absorbent articles (10) from bunching and not properly seating on or mating with the adhesive applied to the release material (52). The lobed roller (82) has a pitch of about 120 mm to about 150 mm, or about 130 mm to about 140 mm, or about 131 mm to about 136 mm. As illustrated in Figure 17b, the lobed roller (82) follows a cam path (74) that is offset from a central axis (84) of the lobed roller (82).

[0105] The lobed roller (82) rotates at a speed substantially equal to the conveying speed of the release material (52). In embodiments where the at least one absorbent article (10) is conveyed on the belt (78), the lobed roller (86) rotates at a speed substantially equal to the conveying speed of the at least one absorbent article (10) [of the belt (78)]. In embodiments where the at least one absorbent article (10) is conveyed by a vacuum-assisted transfer drum (90), the rotational speed of the lobed roller (86) is equal to the rotational speed of the transfer drum (90).

[0106] The lobed roller (86) is configured to have a first circumference (94) and a second circumference (96), where the first circumference (94) has a maximum diameter of the lobed portions (86) of the roller and the second circumference (96) has a minimum diameter of the troughs. The first circumference (94) forms a circumscribing circle around the entire lobed roller (82), including at least one lobed portion (86) and at least one trough (92). The second circumference (96) forms an inscribing circle around the entire lobed roller (82). In some embodiments, there are at least two lobed portions (86) and at least two troughs (92), with the troughs (92) [forming the basis of the second circumference (96)] separating each of the lobed portions (86).

[0107] An apparatus for applying a release material (52) to an absorbent article (10) is provided. The apparatus includes a drum having a rolling surface. The rolling surface is non-circular, a portion of the rolling surface having a maximum diameter at a first circumference (94) that defines a circumscribing circle. The rolling surface optionally has a lobed portion (86) such that the portion of the rolling surface has a second circumference (96) having a minimum diameter smaller than the first circumference (94) having the maximum rolling surface diameter defined by the lobed portion (86) of the rolling surface. The rolling surface is optionally cammed such that the portion of the rolling surface has a second circumference (96) having a minimum diameter smaller than the first circumference (94) having the maximum rolling surface diameter defined by the cammed portion of the rolling surface.

[0108] As is common in patent documents, the terms "a" or "an" are used herein to include one or more. As used herein, the term "or" means a non-exclusive "or" unless otherwise indicated. It should be understood that the above description is intended to be illustrative and not limiting. For example, the above-described embodiments (and / or aspects thereof) can be used in combination with each other. Many other embodiments will be apparent to those of ordinary skill in the art upon reviewing the above description. The scope of the present disclosure should therefore be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms "including" and "in which" are used as the plain English equivalents of the terms "comprising" and "wherein," respectively. Moreover, in the following claims, the terms "first," "second," "third," etc. are used merely as labels and are not intended to impose numerical requirements on their subject matter. In the above detailed description, various features may be grouped together to streamline the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may reside in less than all features of a single disclosed embodiment. Accordingly, the following claims are hereby incorporated into this specification, with each claim standing on its own as a separate embodiment.

Claims

1. An absorbent article (10) having a length (14), a width (15) and a thickness (16), said length (14) and width (15) lying in the xy plane, a cover layer (11) having a body-facing surface (12) and a lower cover surface (13) opposite the body-facing surface (12); an absorbent core (20) adjacent said lower cover surface (13); a backsheet layer (18) having a backsheet upper surface (17) and a garment-facing surface (19) opposite the backsheet upper surface (17), the garment-facing surface (19) having at least a portion covered by a releasable adhesive; Equipped with At least one of the cover layer (11) and the absorbent core (20) is embossed to create a first body-facing height (38) that is greater than a second body-facing height (36); The releasable adhesive on the garment-facing surface (19) is applied in a plurality of stripes (32); The absorbent article (10), wherein the plurality of stripes (32) is from 2 stripes to 50 stripes.

2. 10. The absorbent article (10) of claim 1, further comprising a release material (52) comprising a semi-siliconized or fully siliconized film material.

3. 10. The absorbent article of claim 1, wherein said absorbent article (10) is embossed to have at least one channel (27) and up to about 25 channels (27).

4. 4. The absorbent article (10) of claim 3, wherein the cover layer (11) is embossed (25) such that there are embossed protrusions (25) on the body-facing surface (12) relative to a cover layer base height (36).

5. 5. The absorbent article (10) of claim 4, wherein the embossed projections (25) have a projection height (38) of about 0.020 inches (0.5 mm) to about 0.040 inches (1.0 mm) and a projection width (39) of about 0.020 inches (0.5 mm) to about 0.040 inches (1.0 mm).

6. 6. The absorbent article (10) of claim 5, further comprising at least one channel (27) separating said embossed protrusions (25), said channel (27) having a channel width (37) of about 0.0125 inches (0.31 mm) to about 0.0375 inches (0.95 mm).

7. An absorbent article (10) having a length (14), a width (15) and a thickness (16), said length (14) and width (15) lying in the xy plane, a cover layer (11) having a body-facing surface (12) and a lower cover surface (13) opposite the body-facing surface (12); an absorbent core (20) adjacent said lower cover surface (13); a backsheet layer (18) having a backsheet upper surface (17) and a garment-facing surface (19) opposite the backsheet upper surface (17), the garment-facing surface (19) having at least a portion covered by a releasable adhesive; a release material (52) having a generally rectangular shape and having a top edge, a leftmost edge, a rightmost edge generally opposite the leftmost edge, and a bottom edge generally opposite the top edge, the release material (52) having an article-facing side (98) and an outer side (100) opposite the article-facing side (98), the article-facing side (98) and the outer side (100) being defined by the top edge (55), side edges (42), and bottom edge (56), the release material (52) having a release material length that is equal to or greater than the length (14) of the absorbent article (10), the release material (52) having a release material width that is equal to or greater than the width (15) of the absorbent article (10), and the release material (52) comprising a semi-siliconized or fully siliconized material or coating; Equipped with At least one of the cover layer (11) and the absorbent core (20) is embossed to create a first body-facing height (38) that is greater than a second body-facing height (36); The releasable adhesive of the release material (52) is applied to a plurality of stripes (32); the plurality of stripes (32) being at least 2 stripes (32) and at most about 50 stripes (32); the plurality of stripes (32) having an adhesive surface area of ​​at most about 20% to at most about 50% of the total surface area of ​​the article-facing side (98) of the release material (52); the plurality of stripes (32) having an adhesive surface area of ​​from about 20% to a maximum of about 50% of the total surface area of ​​the garment-facing surface (19); An absorbent article (10).

8. A method for applying adhesive to at least one ultra-thin absorbent article (10), comprising: assembling said at least one ultra-thin absorbent article (10) from at least a cover layer (11), a core (20) having one or more portions or layers, and a backsheet (18), said backsheet (18) having a garment-facing surface (19) that provides a back surface (34) of said absorbent article (10); the cover layer (11) is applied to the core (20) and adjacent to the core (20), the core (20) is applied to the backsheet (18) and adjacent to the backsheet (18), and the cover layer (11), the core (20), and the backsheet (18) are assembled into the at least one ultra-thin absorbent article (10) by at least one of pressure, heat, adhesive, or a combination thereof; said at least one ultra-thin absorbent article (10) is assembled such that said cover layer (11) has a varied topography with one or more protrusions (26) and one or more channels (27); providing a release material (52) and conveying it past one or more nozzles that spray adhesive onto the release material (52) in one or more lines or patterns (32) as the release material (52) is conveyed; conveying said release material (52) by at least a transfer drum (90) into a nip (76) having a gap size of about 0.5 mm to about 5 mm; the release material (52) is conveyed such that the width of the release material (52) corresponds to the length (14) of the at least one ultra-thin absorbent article (10); At the same time, conveying the at least one ultra-thin absorbent article (10) to the nip (76) on a conveyor belt (78), wherein the at least one ultra-thin absorbent article (10) is generally and substantially flat or unfolded; Including, the length (14) of the at least one ultra-thin absorbent article (10) is aligned with the width of the transfer belt (78) or rotating drum (90); when the at least one ultra-thin absorbent article (10) is applied to the adhesive on the release material (52) within the nip (76), pressure is applied by a lobed roller (82) to provide a fixed but releasable connection between the release material (52) and the back surface (34) of the at least one ultra-thin absorbent article (10); the at least one ultra-thin absorbent article (10) and the release material (52) are engaged and passed through the nip (76) created by the lobed roller (82) and the transfer drum (90); the transfer drum (90) is generally opposite the lobed roller (82) such that the transfer drum (90) and the lobed roller (82) are each opposite the at least one ultra-thin absorbent article (10) and the release material (52); the at least one ultra-thin absorbent article (10) and the release material (52) engage the lobed roller (82) at a first portion (88) of a lobed portion (86); the lobed portion (86) of the lobed roller (82) is sized to be approximately the width (15) of the at least one ultra-thin absorbent article (10); the first portion (88) of the lobed roller (82) has a lead-in portion that mitigates bunching of at least one ultra-thin absorbent article (10) so that the at least one ultra-thin absorbent article (10) does not properly seat on or engage with the adhesive applied to the release material (52); The lobed roller (82) rotates at a speed substantially equal to the conveying speed of the release material (52); method.

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