Article having bond pattern

Abstract

To provide stretch laminates having improved patterns that provide suitable strength, stretchability and recovery.SOLUTION: An absorbent article includes: a first waist region, a second waist region, and a crotch region disposed between the first and second waist regions; and a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The article further includes a stretch laminate 10 having a bonding region 40. The bonding region has a plurality of ultrasonic bonds 30, a majority of the ultrasonic bonds are oriented in a stretch direction, and the bonding region has a hysteresis ratio of 2.5 or less.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to bonded laminates, particularly stretch laminates such as those found in absorbent articles. [Background technology]

[0002] It has been known for some time that absorbent articles, such as conventional absorbent articles (e.g., diapers, adult incontinence articles, feminine hygiene pads), provide the advantage of receiving and containing urine and / or other bodily exudates (e.g., feces, menses, feces and urine mixtures, menses and urine mixtures, etc.) To effectively contain bodily exudates, the articles need to fit snugly around the waist and legs of the wearer.

[0003] Manufacturers often use extensible regions, such as elastic side panels (i.e., ears), in articles to help achieve a comfortable fit. When worn, the elastic ears allow the article to stretch around the hips and waist of the wearer, securing the product in place during use while allowing the wearer to move comfortably. A fastening system is typically bonded to the ears to further secure the product around the wearer. Elastic ears are typically a laminate of a cover material (e.g., a nonwoven) and an elastomeric material.

[0004] It has been proposed to create stretch laminates using ultrasonic bonding. In such cases, a stretchable elastomeric material is combined with a nonwoven via ultrasonic bonding. After combination, the nonwoven forms corrugations when the laminate is in a relaxed state. In other examples, an elastomeric material is bonded in a relaxed state to a stretchable or elastic nonwoven via ultrasonic bonding. These laminates can produce highly stretchable ears (depending on the level of stretch imparted in the elastomeric material and / or the extensibility of the nonwoven) while avoiding the use of adhesives and mechanical activation. However, ultrasonically bonded ears may lack the strength of ears formed under different means (e.g., adhesive bonding, coextrusion). During use, if the ears lack the necessary strength, the ear components and / or the entire ear laminate may tear or delaminate, fasteners may come off the ear, and / or the ear may come off the rest of the article. Such failure renders the article itself unusable.

[0005] Thus, a suitable high bond strength is required. Likewise, it is important to balance such strength with the required extensibility. In other words, the number and positioning of bonds must not inhibit stretchability. Furthermore, the laminate must stretch sufficiently to allow easy application of the article while maintaining suitable integrity to stay in place during use. Furthermore, manufacturers also seek to vary patterns for comfort, breathability, aesthetic appeal, and product line differentiation. Summary of the Invention [Problem to be solved by the invention]

[0006] Thus, there is a continuing need for stretch laminates with improved patterns that provide suitable strength, stretch, and recovery. Additionally, there is a need for variability in the design of such patterns. There is also a need for bond patterns that can be used to create desired properties in a cost-effective and efficient manner. [Means for solving the problem]

[0007] The present invention includes the features of the independent claims herein. The absorbent article includes a stretch laminate including a nonwoven and an elastomeric layer. The stretch laminate includes a bonded region. The bonded region includes a first plurality of ultrasonic bonds, a majority of the bonds of the first plurality are oriented in the stretch direction, and each of the first plurality of ultrasonic bonds includes at least one dimension of 0.7 mm or greater. The bonded region includes a hysteresis ratio of 2.5 or less and an unload force at 50% of 0.44 MPa or greater, as measured by the Hysteresis Test Method herein.

[0008] The absorbent article includes a front waist region, a rear waist region, and a crotch region disposed between the first waist region and the second waist region, as well as a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The article further includes a stretch laminate. The stretch laminate includes a first bonded region having a plurality of ultrasonic bonds, a majority of the bonds of the first plurality oriented in a stretch direction, and a second bonded region having a second plurality of bonds, a majority of the bonds of the second plurality oriented in a second direction that is perpendicular to the stretch direction. The second bonded region includes a low stress region.

[0009] The absorbent article includes a chassis including a first waist region, a second waist region, and a crotch region disposed between the first waist region and the second waist region, as well as a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The article further includes a stretch laminate. The stretch laminate includes a nonwoven layer and an elastomeric layer. The stretch laminate may have bonded regions with ultrasonic bonds oriented in multiple stretch directions having a 10 hour force drop of less than 65% and an elongation at the opening of 50% or less after 10 hours. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is an exploded perspective view of an exemplary ear, according to a non-limiting embodiment of the present invention. [Figure 1A]FIG. 2 is a plan view of an exemplary ear according to one non-limiting embodiment of the present invention. [Diagram 2] FIG. 2 is a plan view of an exemplary laminate according to a non-limiting embodiment of the present invention. [Figure 2A] FIG. 2 is a plan view of an exemplary laminate according to another non-limiting embodiment of the present invention. [Diagram 3] FIG. 2 is a perspective view of an exemplary laminate according to another non-limiting embodiment of the present invention. [Figure 4A] 1 is a schematic representation of an exemplary prior art bonding pattern. [Figure 4B] 1 is a schematic representation of an exemplary bonding pattern, according to a non-limiting embodiment of the present invention. [Figure 4C] 1 is a schematic representation of an exemplary bonding pattern, according to a non-limiting embodiment of the present invention. [Figure 4D] 1 is a schematic representation of an exemplary bonding pattern, according to a non-limiting embodiment of the present invention. [Figure 4E] 1 is a schematic representation of an exemplary bonding pattern, according to a non-limiting embodiment of the present invention. [Figure 4F] 1 is a schematic representation of an exemplary bonding pattern, according to a non-limiting embodiment of the present invention. [Figure 4G] 1 is a schematic representation of an exemplary bonding pattern, according to a non-limiting embodiment of the present invention. [Figure 4H] 1 is a schematic representation of an exemplary bonding pattern, according to a non-limiting embodiment of the present invention. [Diagram 5] 1 is a chart showing load (N / in) versus strain (%) and associated force curves for a laminate in accordance with a non-limiting example of the present invention. [Figure 6] 1 is a chart showing load (N / in) versus strain (%) and associated force curves for a laminate in accordance with a non-limiting example of the present invention. [Figure 7] 1 is a chart showing load (N / in) versus strain (%) and associated force curves for a laminate in accordance with a non-limiting example of the present invention. [Figure 8]1 is a schematic plan view of an exemplary absorbent article according to one non-limiting embodiment of the present invention.The absorbent article is shown in a flat, uncontracted state. [Figure 9A] 1 is a schematic perspective view of an exemplary embodiment of an absorbent pant as detailed herein; [Figure 9B] 1 is a schematic plan view of an exemplary embodiment of an absorbent pant precursor structure prior to joining of the front and rear belt sections; FIG. [Figure 10] 1 is a schematic perspective view of a package according to one embodiment of the present invention; [Figure 11] FIG. 2 is a schematic plan view of an exemplary sample for use in the 10 Hour Force Drop / Elongation at Opening test method herein. [Figure 12] FIG. 1 is a schematic side view of a grip suitable for use in the 10 Hour Force Drop / Elongation at Opening Test Method herein. [Figure 13] FIG. 1 is a schematic perspective view of an exemplary apparatus for use in the 10 Hour Force Drop / Elongation at Opening test method. [Figure 14] FIG. 1 is a schematic perspective view of an exemplary apparatus for use in the 10 Hour Force Drop / Elongation at Opening test method. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] definition "Absorbent article" means a device that absorbs and contains bodily exudates, and more specifically, a device that is placed against or in close proximity to the wearer's body to absorb and contain various exudates discharged from the body. Examples of absorbent articles include diapers, training pants, pull-on pant diapers (i.e., diapers with preformed waist and leg openings, such as those exemplified in U.S. Pat. No. 6,120,487), refastenable or pant diapers, incontinence briefs and undergarments, diaper holders and liners, feminine hygiene garments such as panty liners, absorbent inserts, and the like.

[0012] As used herein, "aspect ratio" means the product of the major dimension (i.e., largest dimension) of a bond divided by the dimension of the bond perpendicular to that major dimension, as specified by the Bond Dimension Test Method herein.

[0013] "Elastic," "elastomeric," and "elastically extensible" refer to the ability of a material, or portion of a material, to stretch at least 50% without rupture or breakage at a given load in one of the directions according to the Hysteresis Test described herein, and when the load is removed, the elastic material or component exhibits at least 70% recovery (i.e., has less than 30% set). Stretchability, which may also be referred to as strain, percent strain, engineering strain, stretch ratio, or elongation, as well as recovery and set, may each be measured by the Hysteresis Test described in more detail below. Materials that are not elastic are referred to as nonelastic. As used herein, a laminate is elastic if at least 20% of the area of ​​the laminate meets the definition of elastic herein. In this context, the percentage of the area of ​​the laminate is determined when the laminate is in a fully stretched state.

[0014] "Extensibility" means the ability to stretch or elongate by at least 50% without rupture or breakage according to step 5(a) in the Hysteresis Test herein. As used herein, a laminate is extensible if at least 20% of the area of ​​the laminate meets the definition of extensibility herein. In this context, the percentage of the area of ​​the laminate is determined when the laminate is in a fully stretched state. If the laminate does not meet the definition of elasticity above, but meets the definition of extensibility provided within this paragraph, the laminate is a stretchable laminate.

[0015] "Disposable" in relation to absorbent articles means that the absorbent articles are generally not intended to be washed or otherwise restored or reused as absorbent articles (i.e., they are intended to be discarded after a single use, preferably recycled, composted, or disposed of in another environmentally friendly manner).

[0016] "Disposed" refers to an element being placed in a particular location or position.

[0017] "Joined" refers to a configuration in which an element is directly affixed to another element by directly attaching the element to the other element, and also to a configuration in which an element is indirectly affixed to another element by attaching the element to an intermediate member that is further affixed to the other element.

[0018] "Film" means a sheet-like material in which the length and width of the material significantly exceed (e.g., 10 times, 50 times, or even 1000 times) the thickness of the material. Films are typically liquid impermeable, but may be configured to be breathable.

[0019] "Fully stretched" in relation to a laminate means that (1) in the case of a corrugated laminate, the laminate is fully stretched when the corrugations are substantially flattened by stretching the laminate while ensuring that the nonelastic substrate of the laminate is not plastically deformed, and (2) in the case of a laminate without corrugations, the laminate is considered to be fully stretched without any such stretching (i.e., non-corrugated laminates are fully stretched in their relaxed state).

[0020] "Laminate" means two or more materials bonded together by any suitable method known in the art (e.g., adhesive bonding, thermal bonding, or high pressure bonding using unheated or heated patterned rolls).

[0021] As used herein, "longitudinal direction" refers to the maximum linear dimension of the absorbent article in the xy plane of the article. In the absorbent articles described herein, the longitudinal direction extends substantially perpendicularly from the waist edge to the opposing waist edge when the absorbent article is in a flat, uncontracted state, or from the waist edge to the crotch bottom of an article that is folded in half. The longitudinal direction of any component of the absorbent article (e.g., ears, waistband) is determined when the component is joined to the article.

[0022] "Lateral" generally means a direction perpendicular to the longitudinal direction. In the absorbent articles described herein, the lateral direction extends substantially parallel from one side edge to the other.

[0023] "Nonwoven" means a porous fibrous material made from continuous (long) filaments (fibers) and / or discontinuous (short) filaments (fibers), such as from processes such as spunbonding, meltblowing, airlaying, carding, co-forming, hydroentangling, etc. Nonwovens do not have a woven or knitted filament pattern. Nonwovens may be liquid permeable or impermeable.

[0024] "Relaxed" in relation to a laminate means a state in which, at rest, there are substantially no external forces acting on the laminate other than gravity.

[0025] As used herein, "stretch direction" refers to the intended direction of extensibility in the final product. For example, the back ears in an absorbent article may be intended to be stretchable in the lateral direction to fit around the waist of a wearer. The stretch direction of the laminate may be lateral and / or longitudinal. It is understood that the product may be stretchable in multiple directions. In such cases, the stretch direction is the originally intended direction of stretch in response to the expected application of forces required for use.

[0026] As used herein, "second direction" means a direction perpendicular to the stretch direction.

[0027] As used herein with reference to bonds that are oriented in a particular direction, "oriented" means that the bonds have an aspect ratio of at least 1.1 with a major dimension that forms an angle of 40 degrees or less with a line that extends in the particular direction. By way of example, a bond oriented in the stretch direction means that the bonds have a major dimension that forms an angle of 40 degrees or less with a line that extends in the stretch direction. A bond oriented in a second direction, or perpendicularly oriented, means that the bonds have an aspect ratio of at least 1.1 with a major dimension that forms an angle of 40 degrees or less with a line that extends in the second direction.

[0028] Laminate As shown in FIG. 1, the laminate 10 includes a first nonwoven 12 and an elastomeric layer 14. The laminate may include a second nonwoven 16, with the elastomeric layer 14 sandwiched between the first and second nonwovens. Additional layers may be included (e.g., additional nonwovens, nonelastic materials, elastic or extensible materials, etc.). The laminate may be extensible. In certain embodiments, the laminate is elastomeric. One or more of the laminate layers may be bonded by a plurality of ultrasonic bonds 30, as illustrated in FIG. 1A. The ultrasonic bonds may bond the nonwoven layers through the elastomeric layer. Ultrasonically bonded laminates may be formed by any suitable process, including, but not limited to, those described in commonly assigned U.S. Patent Application Nos. 62 / 374,010 and 62 / 419,515.

[0029] Any suitable nonwoven fabric may be used in the laminate 10. Suitable nonwoven fabrics may include basis weights of at least about 8 gsm, or up to about 30 gsm, or up to about 22 gsm, or up to about 17 gsm, or from about 10 gsm to about 22 gsm, with ranges listed for each increment within the range. Suitable nonwoven fabrics include, but are not limited to, spunbond, spunlaid, meltblown, spunmelt, solvent spun, electrospun, carded, film fibrillated, meltfilm fibrillated, air-laid, dry-laid, wet-laid staple fibers, and other nonwoven web materials formed in part or entirely from polymeric fibers as known in the art. In a non-limiting example, the nonwoven fabric includes a meltblown layer. Additionally or alternatively, the nonwoven fabric may include a spunbond layer. In a non-limiting example, the nonwoven fabric includes two or more spunbond layers. In further non-limiting examples, one or more of the nonwovens may include an SMS configuration. Alternatively, one or more of the nonwovens in the ears may not have a meltblown layer. Although meltblown layers have been found to enhance bonding in ears that require adhesion (given that meltblown layers inhibit the diffusion of adhesion through the porous nonwoven structure), meltblown layers often lack strength. In some embodiments, the nonwovens consist essentially of spunbond layers. In some non-limiting examples, both the first nonwoven and the second nonwoven include at least two spunbond layers, or three or more spunbond layers.

[0030] The nonwoven web may be formed primarily of polymeric fibers. In some embodiments, suitable nonwoven fiber materials may include, but are not limited to, polymeric materials such as polyolefins, polyesters, polyamides, or specifically polypropylene (PP), polyethylene (PE), polylactic acid (PLA), polyethylene terephthalate (PET), and / or blends thereof. In some embodiments, the fibers may be formed from PP / PE blends such as those described in U.S. Pat. No. 5,266,392. The nonwoven fibers may be formed from or include components such as aliphatic polyesters, thermoplastic polysaccharides, or other biopolymers as additives or modifiers. Further useful nonwoven fabrics, fiber compositions, fiber and nonwoven fabric formations, and related methods are described in U.S. Patent Nos. 6,645,569, 6,863,933, and 7,112,621, and U.S. Patent Application Nos. 10 / 338,603, 10 / 338,610, and 13 / 005,237. The individual fibers of the nonwoven layer may be monocomponent or multicomponent (including bicomponent). Multicomponent fibers can be bicomponent, for example, including various polymeric components in a core and sheath arrangement or a side-by-side arrangement. The individual components can include polyolefins, such as polypropylene or polyethylene, or copolymers thereof, or polyesters, thermoplastic polysaccharides, or other biopolymers. Additionally, the nonwoven fabric may include a blend of various fibers, for example, selected from the polymer fiber types listed above. In some examples, at least some of the fibers may exhibit a spiral crimp having a helical shape. According to one example, the fibers can include bicomponent fibers that are individual fibers, each of which includes different materials, typically a first polymeric material and a second polymeric material. The use of side-by-side bicomponent fibers is believed to be beneficial for imparting spiral crimp to the fibers.Examples of potentially suitable crimped or "drafted" bicomponent fibers and nonwovens formed therefrom are described in U.S. Patent Nos. 5,382,400, 5,418,045, 5,707,468, 6,454,989, 6,632,386, 5,622,772 and 7,291,239. For purposes of this specification, the use of nonwovens formed from bicomponent or multicomponent pleated fibers, such as those described in the immediately preceding cited patents and / or patent applications, may be desirable as one or both nonwoven layers, since they can feel particularly soft to the touch (providing a comfortable inner and aesthetically pleasing outer appearance to the wearer) and are generally quite flexible. In other non-limiting examples, the nonwoven may not have crimped fibers.

[0031] When laminate 10 includes two or more nonwovens, the nonwovens may have the same basis weight or different basis weights. Similarly, the nonwovens may include the same layer configuration (e.g., SSS) or different layer configurations (e.g., SMS).

[0032] The elastomeric layer 14 includes one or more elastomeric materials that provide elasticity to at least a portion of the layer 14. Non-limiting examples of elastomeric materials include films (e.g., polyurethane films, films derived from rubber and / or other polymeric materials), elastomeric coatings applied to another substrate (e.g., hot melt elastomers, elastomeric adhesives, printed elastomers, or elastomers coextruded onto another substrate), elastomeric nonwovens, scrims, etc. The elastomeric materials may be formed from any suitable known elastomer, including, but not limited to, elastomeric polymers including styrene derivatives, polyesters, polyurethanes, polyetheramides, polyolefins, combinations thereof, or coextruded VISTAMAXX®. Exemplary elastomers and / or elastomeric materials are disclosed in U.S. Pat. Nos. 8,618,350, 6,410,129, 7,819,853, 8,795,809, 7,806,883, 6,677,258, and U.S. Patent Publication No. 2009 / 0258210.Commercially available elastomeric materials include KRATON (styrenic block copolymer; available from Kraton Chemical Company, Houston, TX), SEPTON (styrenic block copolymer; available from Kuraray America, Inc., New York, NY), VECTOR (styrenic block copolymer; available from TSRC Dexco Chemical Company, Houston, TX), ESTANE (polyurethane; available from Lubrizol, Inc., Ohio), PEBAX (polyether-based block amide; available from Arkema Chemicals, Philadelphia, PA), HYTREL (polyester; available from DuPont, Wilmington, DE), VISTAMAXX (homopolyolefins and random copolymers, as well as blends of random copolymers, available from EXXON Mobile, Spring, TX), and VERSIFY (homopolyolefins and random copolymers, as well as blends of random copolymers, available from Dow Chemical Company, Midland, Michigan).

[0033] In a non-limiting example, elastomeric layer 14 comprises a film 15. The film may comprise a single layer or multiple layers. The film may be extensible or elastic in the transverse and / or longitudinal directions. The film may be pre-activated, for example, as disclosed in U.S. Patent No. 9,533,067.

[0034] The elastomeric layer may be shorter in one or more dimensions of the laminate than the laminate itself. For example, the elastomeric layer may include a first dimension Y, where Y is at least 10 mm less than a dimension W of the laminate in the same direction. In certain embodiments, Y is at least about 20%, or about 25% to about 100%, or about 35% to about 85%, or no more than about 80% of W, with each range being recited in 5% increments within this range. Additionally or alternatively, the elastomeric layer may have a dimension equal to one or more dimensions of the laminate. For example, the elastomeric layer may include substantially the same longitudinal length of the laminate across the entire lateral width of the laminate. In some embodiments, the elastomeric layer may have a basis weight of about 5 to about 150 gsm, or about 10 to about 100 gsm, or less than about 150 gsm, with each range being recited in 5 gsm increments within this range.

[0035] 2, the laminate 10 may include elasticized regions 18. The stretchable regions 18 are generally defined by the perimeter of the elastomeric material 14. In the elastic regions, the laminate is elastically extensible. In some embodiments, the area of ​​the elastic regions includes at least about 20%, or from about 30% to about 100%, or up to about 80%, of the total area of ​​the laminate, with ranges recited in 5% increments within this range.

[0036] The laminate may further include one or more inelastic regions. In certain embodiments, the laminate 10 includes a first inelastic region 20 that extends laterally outward from the first laminate edge 9 of the laminate and is adjacent to the elastic region 18 at the first elastomeric material edge 17. The ear may further include a second inelastic region 22 that may extend laterally inward from the second laminate edge 11 and is adjacent to the elastic region 18 at the second elastomeric material edge 19. The first and second inelastic regions may be made of the same material or different materials.

[0037] In certain embodiments, the laminate 10 includes a gathered laminate 24 in which one of the layers distorts more than the remaining layers during lamination. Thus, the less extensible layers (i.e., nonwovens 12, 16) form gathers when the laminate 24 is in a relaxed state. In some embodiments, at least a portion of the elastomeric layer distorts while the nonwoven is in a relaxed state during lamination. The elastomeric layer may be stretched in one or more directions. Corrugations are then formed in the nonwoven layer when the subsequently formed laminate 24 is in a relaxed state. When making the laminated laminate, the elastomeric layer is stretched in the stretch direction (i.e., the intended direction of stretch in the final product). The stretch direction may be the transverse direction. In a non-limiting example, the elastomeric layer is stretched in a direction that corresponds to the transverse direction of the article. In other words, when the laminate is joined to the chassis after lamination, the laminate is oriented such that the laminate is stretchable in the transverse direction of the article (i.e., the laminate is transversely extensible).

[0038] As shown in Figures 1A-3, two or more laminate layers are joined by one or more ultrasonic bonds 30. The ultrasonic bonds may join the nonwoven layers through an elastomeric layer. The bonds may be of any suitable shape or size. In some embodiments, the bonds are non-circular. Additionally, or alternatively, the bonds may have longitudinal dimensions greater than their lateral dimensions, or vice versa. At least a portion of the bonds may have an aspect ratio of at least 1.1, or at least about 1.25, or at least about 1.5, or from about 1.1 to about 10, or from about 1.25 to about 7.5, with each range recited in 0.01 increments within the range. The bonds can have a major dimension (i.e., largest dimension) of at least about 0.55 mm, or at least about 0.7 mm, or at least about 1 mm, or from about 0.55 mm to about 2.6 mm, or from about 1 mm to about 2.5 mm, with each 0.05 increment within the range being recited. In a non-limiting example, the major dimension is at least about 0.7 mm. The bonds can have a minor dimension of at least about 0.5 mm, or at least about 0.75 mm, or from about 0.5 mm to about 2.2 mm, with each range being recited for each 0.05 mm increment within the range. In a non-limiting example, the bonds have at least one dimension that is 0.7 mm or greater, which may be a dimension other than the minor or major dimension. One or more bonds can have a curvilinear shape, such as an elliptical, oval, or rod-like shape. Other non-limiting examples of bond shapes include rectangular, trapezoidal, diamond, S-shaped, and combinations thereof.

[0039] In addition to the above, one or more ultrasonic bonds 30 are stretch-direction oriented bonds 32 (i.e., oriented in the stretch direction). In non-limiting examples, a majority of the ultrasonic bonds are oriented in the stretch direction. In certain embodiments, at least about 20%, or at least about 30%, or at least about 40%, or at least about 50%, or at least about 55%, or about 20% to about 100%, or about 25% to about 80%, or about 30% to about 75% of the bonds may be oriented in the stretch direction, with the ranges recited in 1% increments within the range. Without being bound by theory, it is believed that a majority of the bonds oriented in the stretch direction provides a laminate that improves return (i.e., unloading) force, reduces tearing, and provides greater durability. When such a laminate stretches, the film between the bond sites stretches. Generally, in ultrasonically bonded laminates, each bond site includes an opening in the elastomeric material through which a nonwoven or other material layer is bonded. The bonds oriented in the second direction 34 have a relatively large bond length perpendicular to the stretch direction SD. This longer bond length results in a large amount of elastomeric material being cut in the stretch direction. Due to this lack of connectivity, when tension is applied in the stretch direction, a large opening is formed because the opening in the initial bond cannot resist the applied force. Conversely, the bonds 32 oriented in the stretch direction have a relatively small bond length perpendicular to the stretch direction SD. This small bond length results in a limited amount of elastomeric material being cut in the stretch direction. Due to the high connectivity, when tension is applied in the stretch direction, there is enough connected material to resist the applied force, resulting in minimal opening elongation. Smaller apertures can lead to improved stretchability and appearance without compromising the integrity of the laminate.

[0040] The laminate may be elastic in the stretch direction. The laminate may include an area A having a 10 hour force drop of about 65% or less, or about 60% or less, or about 40% to about 70%, recited in 0.5% increments therein, as measured by the Force Drop Test Method herein. Area A may be at least 25.4 mm wide and 25.4 mm long. Without being bound by theory, it is believed that a laminate having a 10 hour force drop as shown above has improved extensibility and integrity. The desired 10 hour force drop may be obtained by a combination of bond pattern, bond orientation, and material chemistry.

[0041] In non-limiting examples, the laminate may have no substantial elongation at the elastomeric material aperture, where the substantial elongation is greater than about 50% or the original aperture area. In non-limiting examples, the laminate film has an elongation at the aperture of about 50% or less, or about 25% or less after 10 hours according to the 10 hour force drop method.

[0042] Additionally or alternatively, the laminate 10 may include a bond density, as defined by the Bond Size Test Method, of at least about 1.5%, or at least about 2%, or from about 1.5% to about 12%, with ranges recited in 1% increments within the range. Bond density may vary depending on the components into which the laminate is incorporated.

[0043] Without being bound by theory, it is believed that the orientation, bond aspect ratio, bond area, bond size, including geometric shapes, and material compositions disclosed herein result in improved laminate performance. Although various shapes may be used, the bonds and substrates according to the teachings herein achieve the desired performance. In some embodiments, the laminate of the present invention includes bonded regions 40 having a hysteresis ratio of about 3 or less, or about 2.75 or less, about 2.65 or less, or about 2.5 or less, or about 2.4 or less, or about 1 to about 3. Thus, the laminate exhibits high elasticity. When incorporated into an absorbent article, the laminate with the hysteresis ratio of the present invention stretches easily for application and has sufficient ability to withstand forces when worn (e.g., after application, the stretch ears relax, allowing the product to fit snugly to the wearer). In other words, the laminate requires a relatively low force for application, but maintains a suitable higher return force, allowing it to withstand strain during wear without sagging or tearing.

[0044] Additionally, the bonded regions include an unload force at 50% of about 0.57 N / in or greater, or about 0.6 N / in or greater, or about 0.62 N / in or greater, or about 0.65 N / in or greater, in non-limiting examples. In some embodiments, it may be desirable to have a higher unload force even if a lower hysteresis ratio (3 or less) cannot be achieved. For such embodiments, the laminate includes an unload force at 50% of about 0.4 N / in or greater, or about 0.5 N / in or greater, or about 0.6 N / in or greater, or about 0.4 N / in to about 2 N / in, as measured by the Hysteresis Test Method herein, with the ranges recited in 0.1 N / in increments within this range.

[0045] The bonded regions include, in non-limiting examples, an unload force at 50% of about 0.42 MPa or greater, or about 0.44 MPa or greater, or about 0.45 MPa or greater, or about 0.48 MPa or greater. Additionally or alternatively, the laminate includes an unload force at 50% of 0.29 MPa or greater, or 0.37 MPa or greater, or 0.44 MPa or greater, or from about 0.29 to about 1.46 MPa, as measured by the Hysteresis Test Method herein, with the ranges recited in 0.05 MPa increments within the range.

[0046] In some embodiments, the laminate may include bonds 34 oriented in a second direction (also referred to herein as vertically oriented bonds 34). In non-limiting examples, at least 5%, or at least 25%, or at least 50%, or at least about 75%, or about 5% to about 75% of the bonds may be vertically oriented, with ranges recited in 5% increments within the range. In non-limiting examples, the average major dimension of the stretch-oriented bonds 32 may be higher than the average major dimension of the vertically oriented bonds 34. For example, one or more stretch-oriented bonds may have a major dimension (or collectively, an average major dimension) of about 1.5 mm, and one or more vertically oriented bonds may have a major dimension (or collectively, an average major dimension) of about 1.2 mm.

[0047] Additionally or alternatively, the laminate may include a first plurality of bonds 36, with a majority of the bonds 32 oriented in the stretch direction. The laminate may include a second plurality of bonds 38, with a majority of the bonds 34 oriented in the second direction. In this manner, bonds oriented in the second direction having a lower return force (lower pressure applied to the wearer) may be used while still maintaining the strength, higher return force and tear resistance advantages of the bonds oriented in the stretch direction. The first plurality may be disposed in a first bond region 40, as shown in Figures 2-2A, and / or the second plurality may be disposed in a second bond region 42. In a non-limiting example, the second bond region includes a low stress region 44. The low stress area has a load force at 50% that is at least 10% lower than the load force at 50% of the adjacent bond area (i.e., adjacent high stress area 46) as measured by the Hysteresis Test Method herein. In non-limiting examples, the low stress area can include a load force at 50% of about 2 N / in or less, or about 1.5 N / in or less, or about 1.3 N / in or less, or about 1 N / in or less, or from about 0.2 N / in to about 2 N / in, with ranges recited in 0.1 N / in increments within this range. The low stress area can include a load force at 50% of about 1.46 MPa or less, or about 1.10 MPa or less, or about 0.95 MPa or less, or about 0.73 MPa or less, or from about 0.15 MPa to about 1.46 MPa, with ranges recited in 0.05 MPa increments within this range. The higher stress region 46 may be disposed in the center of the laminate and may overlap with a lateral centerline 48 of the laminate. The low stress region may be disposed at least partially longitudinally outboard and / or longitudinally inboard of the higher stress region. In the non-limiting example shown in FIG. 2A, the laminate includes two low stress regions 44a and 44b, one disposed longitudinally outboard of the higher stress region and a second disposed longitudinally inboard of the higher stress region. The two low stress regions may include the same stress / strain profile or different stress / strain profiles.In a non-limiting example, the laminate may include a gradient in the percentage of bonds in the second direction. The aggregate area of ​​bonds oriented in the second direction and / or the number of bonds oriented in the second direction may increase further away from the most stressed point of the laminate. For example, in the most stressed area, the bonded region of the laminate may include only bonds oriented in the stretch direction or may include a majority of bonds oriented in the stretch direction. Longitudinally inward and / or longitudinally outward of the most stressed area, the bonded region of the laminate may gradually increase in the number of bonds oriented in the second direction, the aggregate area of ​​bonds oriented in the second direction, the average size of the bonds' dimension in the second direction, and / or the average aspect ratio of the bonds whose larger dimension is in the second direction.

[0048] In certain embodiments, the first plurality 36 may be in an at least partially interspersed and / or at least partially overlapping relationship with the second plurality 38, as illustrated in FIG.

[0049] The laminate 10 may further include reinforcing features 50 that help provide strength to the laminate. Non-limiting examples of reinforcing features include additional bonds 52, such as adhesives, heat or pressure bonds, additional substrate layers 54, including separate layers of material and / or folded materials, and combinations thereof, as shown in Figure 3. The additional substrate layer 54 may include a nonwoven, an elastomeric material, or combinations thereof. The additional substrate layer 54 may include the same material as the first nonwoven, the second nonwoven and / or the elastomeric layer, or the additional substrate layer 54 may include a different material than any of the foregoing layers.

[0050] In certain embodiments, the laminate has an air permeability of at least about 1 m according to the air permeability test method herein. 3 / m 2 / min, or about 1m 3 / m 2 / min ~ approx. 125m 3 / m 2 / min, or about 2m 3 / m 2 / min ~ approx. 50m 3 / m 2per minute per meter for each range. 3 / m 2 Enumerate every / minute increment.

[0051] In some embodiments, the laminate may be adhesive-free. EXAMPLES

[0052] The following laminate examples demonstrate the properties of the invention herein. The following examples are various combinations of three different laminates, which differ by their elastomeric layers and eight different patterns shown in Figures 4A-H.

[0053] Comparative Example 1A includes a first nonwoven and a second nonwoven, and an elastomeric film sandwiched between the first and second nonwoven. Each of the first and second nonwoven is a 19 gsm spunbond nonwoven available from Avgol, USA under the trade name AVMN3002394. The nonwoven has an average basis weight of about 19 gsm as measured by the basis weight test method herein. The elastomeric film is available from Berry Global under the trade name ELASTIPRO™ 4013 and has a basis weight of about 50 gsm. The nonwoven was cut into a rectangle having a stretch dimension of 95 mm and a second dimension of 141 mm. The film was cut into a rectangle having a stretch dimension of 44 mm and a second dimension of 140 mm. The laminate was assembled using an ultrasonic scanner available from Branson Ultrasonics under the trade name Branson 2000X and a bonding plate with the desired pattern. The film was stretched to 130% strain (i.e., 44 mm stretched to approximately 103 mm, with 7 mm inelastic zones on each side), and in the stretched state, the setting stretched the width to approximately 4 mm. A second nonwoven was then applied such that the film was sandwiched between the first and second nonwovens. The laminate was ultrasonically bonded while the film was stretched as described. The bonding pattern shown in FIG. 4A was used. Each nodule was 0.49 mm. 2 The bond area is

[0054] Comparative Example 2A is the same as Comparative Example 1, except the elastomeric film is available from EXTEN under the trade name EXTRETCH30 and has a basis weight of about 30 gsm.

[0055] Comparative Example 3A is the same as Comparative Example 1, except the elastomeric film is available from Tredegar Corp. under the trade name CEX802W and has a basis weight of about 50 gsm.

[0056] Inventive Examples 1B-1H are each the same as Comparative Example 1A, except that while the film was stretched as described, the laminates were ultrasonically bonded using the bonding patterns shown in Figures 4B-4H, respectively.

[0057] Inventive Examples 2B-2H are each the same as Comparative Example 2A, except that while the film was stretched as described, the laminates were ultrasonically bonded using the bonding patterns shown in Figures 4B-4H, respectively.

[0058] Inventive Examples 3B-3H are each the same as Comparative Example 3A, except that while the film was stretched as described, the laminates were ultrasonically bonded using the bonding patterns shown in Figures 4B-4H, respectively.

[0059] Table 1 below provides information regarding the bond dimensions and summarizes which patterns were provided for each laminate.

[0060] [Table 1]

[0061] As illustrated in Figures 5-7, when the bond area is kept consistent, the bond geometry of the present invention produced desirable strength, stretchability, and elasticity while providing flexibility in the bond design. Additionally, the laminate of the present invention provided improved tear resistance. The figures are charts of force loading and unloading curves for various laminates. The force loading curve illustrates the amount of force required for the laminate to achieve a particular stretch. In other words, the force loading curve relates to the force applied during stretching. The force loading curve is a proxy for the ease of stretching of the laminate during product application or otherwise. The force unloading curve illustrates the amount of force that the laminate can apply to the wearer while returning to its initial state (or as close to its initial state as possible). The force unloading curve is a proxy for the durability of the laminate after application and when worn. The closer the force loading curve is to the force unloading curve (i.e., the lower the hysteresis ratio), the more elastic the laminate is. Typically, elastic laminates are more expensive due to the more expensive materials required.However, the inventors have surprisingly found that by using the inventive bonding patterns and teachings disclosed herein, elastic laminates can be produced using lower cost high elastic materials.As mentioned above, in some embodiments, it may be desirable to have a higher unloading force even if a lower hysteresis ratio (3 or less) cannot be achieved.

[0062] Figure 5 compares Comparative Example 1A (having the pattern shown in Figure 4A) with Inventive Examples 1B and 1C (having the patterns of Figures 4B and 4C, respectively). The chart illustrates that the patterns of Figures 4B and 4C can approximate the force profile and resilience of a known pattern while providing variability in bond design. The chart in Figure 5 illustrates the laminates of Examples 1A-1C, but the same trends are seen in the data for Examples 2A-2C and 3A-3C.

[0063] FIG. 6 compares Comparative Example 1A and Inventive Examples 1D-1E. The chart illustrates that the pattern of FIG. 4D can approximate the force profile and resilience of the known pattern while providing flexibility in the bond design. Furthermore, the chart illustrates that the pattern of FIG. 4E performs better than the known pattern. In fact, the pattern approximates the load curve of the comparative example, but the pattern provides a better return curve. In comparing D and E, it can be seen that although the bond dimensions are the same, the bond oriented in the stretch direction (pattern of FIG. 4E) provides a better, higher return force. In fact, as shown in the table below, the pattern of FIG. 4E has a consistently higher return force.

[0064] FIG. 7 compares inventive Examples 1E-1H. As shown in the table below, the patterns of FIG. 4F-4G generally have lower load forces at 50% and lower unload forces at 50% than Comparative Example 1A. In fact, the force load curves are generally lower than those of the Comparative Example, as can be shown by comparing FIG. 6 and FIG. 7. Furthermore, FIG. 7 shows that the patterns of FIG. 4F-4H provide lower force load curves than the Comparative Example, and lower forces are required to achieve the same extension for at least a portion of the load curve. Furthermore, the chart demonstrates that laminates having bonds oriented in a second direction with a major dimension greater than 1.2 mm have reduced performance relative to the Comparative Example. In fact, the more bonds oriented in the second direction, the greater the reduction in force. The chart in FIG. 7 illustrates the laminates of Examples 1E-1H, but the same trends are shown in the data of Examples 2E-2H and 3E-3H.

[0065] Table 2 illustrates the hysteresis ratios of the examples as determined by the Hysteresis Test Method herein.

[0066] [Table 2]

[0067] [Table 3]

[0068] [Table 4]

[0069] Laminate examples were also tested in the force drop test method herein. Inventive Examples 1E, 2E, and 3E (all of which contain the pattern of FIG. 4E) showed no tearing after 8 hours of testing, while the remaining patterns had elongation at the opening of more than 50% after 8 hours, regardless of film. As shown in Table 5 below, inventive Examples 1-E, 2-E, and 3-E also exhibited a 10-hour force drop of 65% or less, more specifically 60% or less. This further demonstrates that under conditions representative of the wearing experience, stretch-oriented bonds can provide additional pattern and visual appearance improvements without compromising the fit / performance of the product.

[0070] [Table 5]

[0071] Articles containing laminates 8, the laminate 10 of the present invention may be incorporated into an absorbent article 100, such as a disposable absorbent article. The laminate may be attached to one or more layers of a chassis 120 by chassis attachment bonds 102. The chassis attachment bonds may include ultrasonic bonds, adhesive bonds, mechanical bonds, or combinations thereof.

[0072] 8 is a plan view of an exemplary, non-limiting embodiment of an absorbent article 100 of the present invention in a flat, uncontracted state. The body-facing surface 115 of the absorbent article 100 faces towards you. The absorbent article 100 includes a longitudinal centerline 105 and a lateral centerline 110.

[0073] The absorbent article 100 includes a chassis 120. The absorbent article 100 and chassis 120 are shown as having a first waist region 114, a second waist region 118 opposite the first waist region 114, and a crotch region 116 located between the first waist region 114 and the second waist region 118. The waist region 114 and the waist region 118 generally include those portions of the absorbent article that encircle the waist of the wearer when worn. The waist region 114 and the waist region 118 may include elastic members 155 that gather around the waist of the wearer to improve fit and containment. The crotch region 116 is the portion of the absorbent article that is generally positioned between the legs of the wearer when the absorbent article is worn.

[0074] The outer periphery of the chassis 120 is defined by longitudinal edges 112 and waist edges (i.e., a first waist edge 113 in the first waist region 114 and a second waist edge 119 in the second waist region 118). The chassis 120 may have opposing longitudinal edges 112 oriented generally parallel to the longitudinal centerline 105. However, for a better fit, the longitudinal edges 112 may be curved or angled to create an "hourglass" shaped article when viewed in plan view, for example, as shown in FIG. 8. The chassis 120 may have opposing lateral edges 113, 119 (i.e., a first waist edge 113 and a second waist edge 119) oriented generally parallel to the lateral centerline 110.

[0075] The chassis 120 may include a liquid permeable topsheet 124, a backsheet 126, and an absorbent core 128 between the topsheet 124 and the backsheet 126. The topsheet 124 may be joined to the core 128 and / or the backsheet 126. The backsheet 126 may be joined to the core 128 and / or the topsheet 124. It should be appreciated that other structures, elements, or substrates may be positioned between the core 128 and the topsheet 124 and / or between the core 128 and the backsheet 126. In some embodiments, an acquisition distribution system 127 is disposed between the topsheet 126 and the absorbent core 128.

[0076] In certain embodiments, the chassis 120 comprises the main structure of the absorbent article 100, with other features added to form a composite absorbent article structure. The topsheet 124, backsheet 126, and absorbent core 128 may be assembled in a variety of well-known configurations, although absorbent article construction is generally as described in U.S. Patent Nos. 3,860,003, 5,151,092, 5,221,274, 5,554,145, 5,569,234, 5,580,411, and 6,004,306.

[0077] Components of disposable absorbent articles can include, at least in part, biologically derived content as described in U.S. Patent Publication Nos. 2007 / 0219521 (A1), 2011 / 0139658 (A1), 2011 / 0139657 (A1), 2011 / 0152812 (A1), and 2011 / 0139659 (A1). These components include, but are not limited to, topsheets, backsheet films, backsheet nonwovens, ear / ear laminates, leg gasket systems, superabsorbents, acquisition layers, core wrap materials, adhesives, fastening systems, and landing zones. In at least one embodiment, the disposable absorbent article component comprises a biobased content value using ASTM D6866-10, Method B, of about 10% to about 100%, or about 25% to about 75%, or about 50% to about 60%. To apply the ASTM D6866-10 methodology to determine the biobased content of any component, a representative sample of the component must be obtained for testing. In at least one embodiment, the disposable absorbent article component may be ground into fine particles of less than about 20 mesh using well-known grinding methods (e.g., a WILEY® mill) and a representative sample of suitable mass may be removed from the randomly mixed particles.

[0078] The laminate 10 of the present invention may form or be a part of one or more components of an article, including, but not limited to, ears, waist features, belts, and combinations thereof.

[0079] Top sheet The topsheet 124 is generally the part of the absorbent article 100 that may be at least partially in contact with or more proximal to the wearer. Suitable topsheets 124 may be manufactured from a wide range of materials, such as porous foams, reticulated foams, perforated plastic films, or woven or nonwoven webs of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or a combination of natural and synthetic fibers. The topsheet 124 is generally supple, soft-feeling, and non-irritating to the wearer's skin. Generally, at least a portion of the topsheet 124 is liquid pervious, allowing liquids to easily penetrate through the thickness of the topsheet 124. The topsheet 124 may be perforated. The topsheet may be perforated by overbonding the material and then breaking the overbonds by ring rolling, as disclosed in U.S. Pat. No. 5,628,097.

[0080] Any portion of the topsheet may be coated with a skin care composition, an antimicrobial agent, a surfactant, and / or other benefit agent. The topsheet may be hydrophilic or hydrophobic, or may have hydrophilic portions or layers and / or hydrophobic portions or layers. If the topsheet is hydrophobic, there will typically be holes present to allow body exudates to pass through the topsheet.

[0081] Absorbent Core The absorbent core 128 may include a wide variety of liquid absorbent materials commonly used in disposable diapers and other absorbent articles. Examples of suitable absorbent materials include comminuted wood pulp, commonly referred to as airfelt crepe paper cotton, meltblown polymers including coforms, chemically stiffened, modified, or crosslinked cellulose fibers, tissue including tissue wrappers and tissue laminates, absorbent foams, absorbent sponges, superabsorbent polymers, absorbent gelling materials, or any other absorbent material or combination of materials. In one embodiment, at least a portion of the absorbent core is substantially cellulose-free, contains less than 10% by weight cellulose fibers, less than 5% by weight cellulose fibers, less than 1% by weight cellulose fibers, trace amounts of cellulose fibers, or contains no cellulose fibers. It should be understood that trace amounts of cellulosic materials do not substantially affect at least one of the thinness, flexibility, and absorbency of the substantially cellulose-free portion of the absorbent core. Among other advantages, when at least a portion of the absorbent core is substantially free of cellulose, this portion of the absorbent core is believed to be significantly thinner and more flexible than a similar absorbent core that contains more than 10% by weight of cellulose fibers. The amount of absorbent material, e.g., absorbent particulate polymer material, present in the absorbent core may vary, but in certain embodiments is present in the absorbent core in an amount greater than about 80% by weight of the absorbent core, or greater than about 85% by weight of the absorbent core, or greater than about 90% by weight of the absorbent core, or greater than about 95% by weight of the core. In some embodiments, the absorbent core may include one or more channels 129, which are substantially free of absorbent particulate polymer material. The channels 129 may extend in the longitudinal or transverse direction. The absorbent core may further include two or more channels. The channels may be straight, curved, angled, or any operable combination thereof. In a non-limiting example, two channels are symmetrically disposed about the longitudinal axis.

[0082] Back sheet The backsheet 126 is generally positioned such that it may be at least a portion of the garment that faces the surface of the absorbent article 100. The backsheet 126 may be joined to a portion of the topsheet 124, the absorbent core 128, and / or any other layers of the absorbent article by any attachment method known to one of skill in the art. The backsheet 126 may be designed to prevent exudates absorbed by and contained within the absorbent article 100 from soiling articles that may come in contact with the absorbent article 100, such as bed sheets and undergarments. In certain embodiments, the backsheet 126 is substantially water impermeable. The backsheet may be or include a thin plastic film, such as, for example, a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm. Other suitable backsheet materials may include breathable materials that allow vapors to escape from the absorbent article while still preventing or at least inhibiting body exudates from passing through the backsheet.

[0083] The backsheet 126 may also be comprised of two or more layers. The backsheet 126 may include an outer cover and an inner layer. The outer cover material 40 may include bond patterns, apertures, and / or three-dimensional features. The outer cover material 40 may be a nonwoven material, such as a hydroentangled nonwoven material. The inner layer may be made of a substantially liquid impermeable film, such as a polymeric film. The outer cover and inner layers may be joined together by adhesive or any other suitable material or method.

[0084] Ears / fasteners The absorbent article 100 may include one or more ears 130, including, for example, a front ear 132 disposed in a first waist region and / or a back ear 134 disposed in a second waist region. The ears 130 may be integral with the chassis or may be separate elements joined to the chassis 120 at chassis attachment bonds 102 that may join one or more layers of the ear to the chassis. The ears 130 may be extensible or elastic. The ears 130 may be formed from one or more nonwoven webs, woven webs, knit fabrics, polymeric and elastomeric films, perforated films, sponges, foams, scrims, or any combination and / or laminates thereof.

[0085] In some embodiments, the ears 130 may include an elastomer, which makes the ears stretchable. In certain embodiments, the ears 130 may be formed of a stretch laminate, such as a nonwoven / elastomeric laminate or a nonwoven / elastomeric / nonwoven laminate, which also makes the ears stretchable. The ears 120 may be stretchable in the cross direction of the article. In some embodiments, the ears are elastic in the cross direction. In further embodiments, the ears 130 may stretch more in the cross direction than in the longitudinal direction. Alternatively, the ears may stretch more in the longitudinal direction than in the cross direction. In certain non-limiting examples, the ears may include one or more inelastic regions along with separate elastic regions.

[0086] In some embodiments, the ears comprise a laminate of one or more nonwovens and one or more elastic materials, such as laminate 10 having any of the features or laminate layers described herein for the laminates of the present invention.

[0087] Any suitable nonwoven may be used in the ear 130. Suitable nonwovens may include a basis weight of at least about 8 gsm, or at least about 30 gsm, or up to about 17 gsm, or from about 10 gsm to about 17 gsm, with ranges recited in increments within the range. Typically, a lower basis weight nonwoven reduces the overall strength of the ear. However, the inventors have discovered that ears designed according to the principles herein can obtain high strength despite a lower basis weight nonwoven. When the ear 130 includes two or more nonwovens, the nonwovens may include the same basis weight or different basis weights. Similarly, the nonwovens may include the same layer configuration or different layer constructions. Additionally, the nonwovens in the ears may include nonwovens of the same or different features in the backsheet, topsheet, leg gasket system, and / or waist features.

[0088] The ears may include, for example, ultrasonically bonded ears as disclosed in U.S. Patent Application Serial No. 15 / 674559. The ears may be gathered laminate 24. Alternatively, the ears may be activated by the processes disclosed in U.S. Patent Publication No. 2013 / 0082418, U.S. Patent Nos. 5,167,897, 5,993,432, 5,156,793, 5,167,897, 7,062,983, and 6,843,134.

[0089] The ears may be joined to the chassis at chassis attachment bonds 102. In some non-limiting examples, the chassis attachment bonds are located in inelastic regions of the ears.

[0090] The absorbent article 100 may also include a fastening system 148 that, when fastened, interconnects the first waist region 116 and the rear waist region 118 to create a waist circumference that can encircle a wearer while the absorbent article 100 is being worn. The fastening system 148 may include fastening elements 150, such as, for example, tape tabs, hook-and-loop fastening components, interengaging fasteners such as tabs and slots, buckles, buttons, snaps, and / or hermaphroditic fastening components, although any other known fastening means are generally acceptable. The absorbent article may further include a landing zone where the fastening elements can be engaged and / or a release tape to protect the fastening elements from insults prior to use. Some exemplary surface fastening systems are disclosed in U.S. Patent Nos. 3,848,594, 4,662,875, 4,846,815, 4,894,060, 4,946,527, 5,151,092, and 5,221,274. An exemplary interengaging fastening system is disclosed in U.S. Patent No. 6,432,098. In some embodiments, the fastening system 148 and / or the elements 150 are foldable.

[0091] The fastening system 148 may be joined by any suitable means to any suitable portion of the article 100. The fastening system may be joined at the ears between layers.

[0092] Leg Gasket System The absorbent article 100 may include a leg gasket system 170 attached to the chassis 120, which may include one or more cuffs. The leg gasket system may include a pair of barrier leg cuffs 172. Each barrier leg cuff may be formed by a piece of material that is bonded to the absorbent article, and thus may extend upwardly from the wearer-facing surface of the absorbent article and may provide improved containment of fluids and other exudates near the junction of the wearer's torso and legs. The barrier leg cuffs are bounded by a proximal edge that is directly or indirectly joined to the topsheet 124 and / or backsheet 126, and a free edge 175 that is intended to contact the wearer's skin and form a seal. In some embodiments, the free edge 175 includes a folded edge. The barrier leg cuffs 172 extend at least partially between the front waist edge 113 and the back waist edge 119 of the absorbent article on either side of the longitudinal centerline 105 and are at least in the crotch region. The barrier leg cuffs may be joined to the chassis of the article at their proximal edges by a bond that may be achieved by a combination of adhesives, melt bonding, or other suitable bonding processes.

[0093] The barrier leg cuffs may be integral with the topsheet 124 or backsheet 126 or may be separate materials joined to the chassis of the article. Each barrier leg cuff 172 may include one, two or more elastic elements 155 adjacent its free edge 175 to provide a better seal.

[0094] In addition to the barrier leg cuffs 172, the article may include gasket cuffs 176 joined to the chassis of the absorbent article, particularly the topsheet 124 and / or backsheet 126, and positioned outwardly relative to the barrier leg cuffs 172. The gasket cuffs 176 may provide a better seal around the wearer's thighs. The gasket cuffs may include a proximal edge and a free edge 177. The free edge 177 may include a folded edge. Each gasket cuff may include one or more elastic elements 155 in the chassis of the absorbent article between the topsheet 124 and the backsheet 126 in the region of the leg openings. All or a portion of the barrier leg cuffs and / or gasket cuffs may be treated with a lotion or another skin care composition.

[0095] In a further embodiment, the leg gasketing system includes a barrier leg cuff integrated with the gasket cuff. Suitable leg gasketing systems that may be part of the absorbent article are disclosed in U.S. Patent Application Nos. 62 / 134,622, 14 / 077,708, U.S. Patent Nos. 8,939,957, 3,860,003, 7,435,243, and 8,062,279.

[0096] Elastic waist mechanism As shown in FIG. 8, the absorbent article 100 may include at least one elastic waist feature 180 that helps provide improved fit and containment. The elastic waist feature 180 is generally intended to stretch to dynamically fit the waist of the wearer. Elastic waist features include a waistband, a waist cuff with a pocket formed from a portion of the waist feature 180 that is detached from the chassis 120, and a waist panel designed to fit securely around the wearer's abdomen. Non-limiting examples of elastic waist features are disclosed in U.S. Patent Application Nos. 13 / 490,543, 14 / 533,472, and 62 / 134,622. The waist feature 180 may be joined to the chassis 120 at the first waist region 114 and / or the second waist region 118. The waist feature may be used in conjunction with ears 130 to provide the desired stretch and flexibility to properly fit the article to the wearer. The waist feature may include a laminate 10 having any of the features described herein with respect to the laminate. The waist feature may be extensible or elastic in the lateral and / or longitudinal directions. In some embodiments, the waist feature 180 includes a belt 220.

[0097] Adult or infant pants absorbent articles In some embodiments, the article 100 may include an absorbent pant 200 as shown in Figures 9A and 9B, which may include a chassis 122, a belt 220 positioned around the waist of the wearer, and, optionally, a leg gasket system 170. Figure 9B illustrates an exemplary precursor structure of the pant of Figure 9A in an open configuration laid out flat and laterally stretched for elastic induced contraction. In the final assembly of the pant, the front belt portion 222 is joined to the rear belt portion 223 at a seam 224, which may be permanent or refastenable. To form the pant 200, the precursor structure may be folded at or about the lateral centerline 110 with the topsheet 124 facing inward, and the longitudinal edges of the front 222 belt and rear 223 belt portions may be joined at the seam 224 to form a pant structure having leg openings, front waist edges, and rear waist edges. In this manner, the pant 200 may include a preformed continuous waist opening and preformed continuous leg openings for the wearer when the pant 200 is worn.

[0098] The front belt portion 222 and the back belt portion 223 may be the outermost structures forming the front and back regions of the pant 200. The pant may include an outer wrap 226 that envelops the entire front, crotch and back regions and forms the outermost pant-shaped structure. In some embodiments, the backsheet outer cover forms the outer wrap. The outer wrap 226 may be formed from one or more sections of a nonwoven web and, if desired, cut to a contour that provides a suitably adjusted leg opening edge contour.

[0099] The belt 220 may comprise a laminate 10 of the present invention having any of the features previously described, including one or more nonwoven layers and one or more elastomeric layers. The laminate layers may be joined by ultrasonic bonding.

[0100] According to some non-limiting examples, the nonwoven fabric used in the belt portions may include materials that provide good recovery when external pressure is applied and then removed.

[0101] An elastomeric layer of a waist feature, such as a belt portion, may include one or more elastic members 155. The elastic members 155 may be elastomeric fibers, such as LYCRA® fiber available from INVISTA (Wichita, KS), in various decitex levels. The elastic members 155 may also include any heat shrinkable elastic material known in the art. Other suitable elastics may be made from a variety of other materials, including, but not limited to, rubber, styrene ethylbutylene styrene, styrene ethylene propylene styrene, styrene ethylene propylene styrene, styrene butadiene styrene, styrene isoprene styrene, polyolefin elastomers, elastomeric polyurethanes, and other elastomeric materials known in the art, as well as combinations thereof. In some non-limiting examples, the elastic members may be extruded strand elastics having any number of strands (or filaments). In some embodiments, the elastic members may have a decitex in the range of 50-2000, or any integer value for any decitex value within this range. Those skilled in the art may select the appropriate decitex based on the desired amount of shrinkage and other principles discussed herein. In further embodiments, the elastic member may be in the form of a film. Examples of films are described in prior patent applications (see, for example, U.S. Patent Application Publication No. 2010 / 0040826). The film may be made with various resins combined in at least one of several sublayers, which provide the film with different benefits.

[0102] It should be noted that the elastic member 155 may take on a number of configurations: for example, the width may vary, a single strand or multiple parallel or non-parallel strands of elastic material may be used, a variety of shapes including straight and curved may be used, or a variety of cross-sectional shapes may be used (circular, rectangular, square, etc.).

[0103] The layers of the waist feature (e.g., belt portion) and / or chassis 120 may be joined together around the elastic strands 155 by adhesive deposited between the layers, by thermal bonding, by crimping, or a combination thereof. In other embodiments, one or more of the elastic members may be strips or sections of film formed from an elastomeric material. When the elastic members are elongated, it may be desirable for the strands 155 to be oriented with their longer dimension transversely, or even substantially aligned transversely, as shown, for example, in FIG. 9B.

[0104] Other configurations of the belt portion or waist feature may include at least 3 waist elastic members, at least 5 elastic members, at least 10 waist elastic members, or at least 15 waist elastic members, or from about 2 to about 35 waist elastic members, or from about 5 to about 25 waist elastic members, with each range recited in increments within the range.

[0105] In one embodiment, adjacent elastic members 155 are spaced from one edge of the member to the other edge of the member by a longitudinal distance of at least 3.5 mm, optionally at least 4 mm, optionally at least 4.5 mm, optionally at least 5 mm, optionally at least 5.5 mm, optionally at least 6 mm, optionally at least 6.5 mm, optionally at least 7 mm, optionally at least The elastic members may be spaced apart at a longitudinal distance of 7.5 mm, optionally at least 8 mm, optionally at least 8.5 mm, optionally at least 9 mm, optionally at least 9.5 mm, optionally at least 10 mm, optionally at least 10.5 mm, optionally at least 11 mm, optionally at least 11.5 mm, optionally at least 12 mm. The spacing between the elastic members may be the same or different along the longitudinal length of the waist feature. For example, the spacing between adjacent elastic members may be uniformly 7 mm, or may be varied (i.e., two adjacent elastic members are 3 mm apart and two are 6.5 mm apart, etc.).

[0106] During manufacture of the waist feature, the elastic members 155 may be pre-strained a desired amount for incorporation into the waist feature. Upon subsequent relaxation of the waist feature, the elastic members may contract laterally toward their unstrained lengths. This may cause the layers of the waist feature to crease and form pleats or creases having ridges and valleys generally transverse to the length of the elastic members 155 and extending in the z-direction.

[0107] In a further embodiment, the elastics may be individually coated with adhesive ("coated strands") prior to incorporation into the waist laminate for bonding components of the waist feature laminate. Various coating methods and techniques, including strand coating methods and techniques, are shown, for example, in U.S. Patent Nos. 5,340,648, 5,501,756, 5,507,909, 6,077,375, 6,200,635, 6,235,137, 6,361,634, 6,561,430, 6,520,237, 6,582,518, 6,610,161, 6,613,146, 6,652,693, 6,719,846, and 6,737,102. The adhesive used can be a resilient and flexible hot melt adhesive (such as OMNIMELT BLOCKS22H2401F available from Bostik, Inc., Wauwatosa, Wisconsin, or ZEROCREEP™ such as AVANCE) that is suitable for attaching pre-strained elastic materials to a substrate.

[0108] In certain embodiments, the corners of the front and / or rear belt portions may be cut, as suggested in FIG. 9B. The corners may be cut along straight lines, or along cut paths that are curved, either concave or convex, with respect to the remaining areas of the belt portions, as may be desired to provide a particular curved leg edge profile. In conjunction with such cuts and the configuration of the elastic strands described above, it may be desirable to provide a bond between the layers along the edges of the respective belt portions 222, 223. Such a bond may help to prevent any separation of the layers along the edges that may contribute to creating a ragged appearance, and may also help to efficiently pull the rear belt portions laterally inward toward the central chassis 120 under the contractile force of the elastic strands below the seam 224. The bond may be effected, for example, by mechanical bonding / crimping as described in U.S. Pat. Nos. 4,854,984 and 4,919,738, by thermal bonding or welding, or by the deposition of an adhesive between the layers. In a non-limiting example, such bonds may form a pattern along the edges. Such bonds may supplement any bonds between layers that generally hold each belt portion 222, 223 together as a laminate structure.

[0109] The side seams 224 may be permanent or refastenable. A permanent seam may be formed between the front and rear belt portions by any joining mechanism, which cannot be forcibly separated without significant damage to one or both of the front and rear belt portions or without including a mechanism that allows for substantial reattachment or refastening. Bonds that form a permanent seam may include crimping, heat bonding / welding, ultrasonic bonding, or adhesive bonding. A refastenable seam may be formed between the front and rear belt portions by any mechanism that is configured to allow for a substantially non-destructive forced separation of the front and rear belt portions and subsequent substantial reattachment or refastening in the same location. One example of such a mechanism is a hook and loop fastening system, e.g., a VELCRO fastening system. A hook component of suitable size and shape may be joined to one of the front or rear belt portions along its longitudinal edge and to the other of the front or rear belt portions along its longitudinal edge at a location where they may engage together to form seam 224. Examples are shown in U.S. Patent Application Nos. 61 / 787,416, 61 / 787,332, and 61 / 666,065.

[0110] Exemplary belt and absorbent pant constructions are disclosed in US patent application Ser. Nos. 14 / 598,783 and 14 / 032,595.

[0111] package The absorbent article 100 of the present disclosure may be disposed in a package. The package may include polymeric films and / or other materials. Graphics and / or indicia relating to the characteristics of the absorbent article may be formed, printed, positioned, and / or disposed on an exterior portion of the package. Each package may include multiple absorbent articles. The absorbent articles may be packaged under compression to reduce the size of the package while providing a sufficient amount of absorbent articles per package. Packaging the absorbent articles under compression allows the caregiver to easily handle and store the package, and also provides the manufacturer with reduced distribution costs due to the size of the package.

[0112] Thus, a package of absorbent articles of the present disclosure may have an In-Bag Stacking Height based on the In-Bag Stacking Height Test described herein 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, specifically reciting all values ​​in 0.1 mm increments within the specified ranges and all ranges therein or formed thereby. Alternatively, a package of absorbent articles of the present disclosure may have an In-Bag Stack Height according to the In-Bag Stack Height Test described herein of about 70 mm to about 110 mm, about 70 mm to about 105 mm, about 70 mm to about 100 mm, about 70 mm to about 95 mm, about 70 mm to about 90 mm, about 70 mm to about 85 mm, about 72 mm to about 80 mm, or about 74 mm to about 78 mm, specifically reciting all values ​​in 0.1 mm increments within the specified ranges and all ranges therein or formed thereby.

[0113] 10 illustrates an exemplary package 1000 including a plurality of absorbent articles 1004. The package 1000 defines an interior space 1002 into which the plurality of absorbent articles 1004 are placed. The plurality of absorbent articles 1004 are arranged in one or more stacks 1006.

[0114] Test Method Sample preparation Unless otherwise specified in the specific methods below, specimens are cut and prepared from the laminates or components as follows: For laminates / components with one bond pattern: A specimen of the desired size (as specified in the method) is cut from the bond pattern area in the elastic region. If the available bond pattern area and / or elastic region is smaller than that specified for the Hysteresis and Elongation at 10 Hour Force Drop / Opening test method, specimens as small as 10 mm wide (dimension perpendicular to the stretch direction) and 10 mm long (in the stretch direction) may be used. For laminates / components with more than one pattern: Identify one bond pattern of interest (i.e., a uniform bond pattern) in the elastic region. If the available bond pattern area is smaller than that specified for the Hysteresis and Elongation at 10 Hour Force Drop / Opening test method, specimens as small as 10 mm wide (dimension perpendicular to the stretch direction) and 10 mm long (in the stretch direction) may be used. Care should be taken to ensure that the gauge length is kept the same as the width of the specimen and that the test strain rate is kept the same as that specified in the method.

[0115] Weighing At least 1 cm 2 of sample is used to measure basis weight from uniform bond pattern area. Sample is weighed to within ±0.1 milligrams using a digital balance. Length and width of sample is measured using digital calipers, or equivalent to within ±0.1 mm. All tests are conducted at 22±2°C and 50±10% relative humidity. Basis weight is calculated using the following formula:

[0116]

number

[0117] 10 Hour Force Drop / Elongation at Opening Test Method The purpose of this test is to measure the "10 hour force drop" and "stretch at opening" for laminate samples. This test provides information regarding how the laminate secures the article to the wearer when held at 37.8°C and 100% engineering strain, i.e., the fit of the product during use.

[0118] setting Gauge length: 25.4mm Sample width: 25.4mm Test temperature: 37.8℃. Applied engineering strain: 100% (i.e., apply and hold a displacement of 25.4 mm. ) Direction of applied deformation: The direction of stretch of the laminate during normal use of the article

[0119] Sample preparation FIG. 11 is provided to illustrate a particular embodiment of sample preparation. On a cutting mat, the laminate material is sandwiched between sheets of photocopy paper. A sharp X-ACTO brand knife and a straight edge are used to prepare the sample 600. The sample is cut from the uniform bond pattern area of ​​the elastic region. The sample 600 is cut to have a width 615 and length 616 of 25.4 mm, suitable for loading the sample into the grips and sufficient to provide a gauge length of 25.4 mm without unnecessarily interfering with the test. In this particular example, the length 616 is longer than the width 615, and the length 616 is in the stretch direction.

[0120] grip Line contact grips 500 of the type shown in FIG. 12 are used for this test. The line grips 500 are selected to provide a well defined gauge and avoid excessive slippage. The sample is positioned to have minimal slack. The tops 507 of the grips 500 are grounded to give good gauge definition while avoiding breaking or cutting the sample. The tops are grounded to provide a radius in the range of 0.5-1.0 mm. A portion of one or both of the grips 500 may be constructed to include a material 507 that reduces the tendency of the sample to slip (e.g., a urethane or neoprene rubber strip having a Shore A hardness of 50-70). FIG. 13 shows a pair of opposing grips 700 suitable for use herein.

[0121] Device The grips are mounted in a frame (e.g., Chatillon MT150L or similar) that allows for hand-operated movement of one grip relative to the other. A gauge block is used to establish the load of the sample and the exact grip position for testing the sample. The entire frame is mounted in a chamber equipped with a temperature control device well suited to maintain the air temperature in the immediate vicinity of the sample at 37.8°C. FIG. 14 shows an exemplary apparatus 800 for performing the test. As shown in FIG. 14, the apparatus 800 is set up in a temperature controlled chamber and includes a top grip 701, a bottom grip 702, a gauge block 720 for precisely positioning at least the bottom grip 702, and a thermocouple 710 for monitoring the temperature within the chamber. A force transducer 715 is deployed in mechanical communication with the top grip 701. The force transducer 715 includes suitable quality signal conditioning to enable the desired force measurements without significant drift, noise, etc. The force transducer is selected to provide adequate resolution to identify when ultimate failure of the sample occurs. The output from the signal conditioner is connected to an analog-to-digital converter interfaced with a computer to allow data acquisition during the test. Force data is sampled while the sample is being stretched and during its initial force decay at a frequency of at least one data point per second. The frequency of subsequent data sampling must be sufficient to determine the force decay of the sample over the entire test period (10 hours for the "10 hour force drop" and at least 8 hours for the "stretch at opening"). Time zero is assigned to the first data point after the sample is stretched 100% (i.e., 1 second after stretching is completed).

[0122] test The grip separation (i.e., gauge length) is set to 25.4 mm and the sample is inserted so that the grips form a well-defined contact line on the sample. The grip bolts are tightened to provide a fixed grip without cutting the sample. The temperature chamber door is closed and the temperature is allowed to equilibrate at the target temperature for 2 minutes. Data acquisition is started. The desired displacement (25.4 mm, corresponding to 100% strain) is applied to the sample over 15 seconds. Force data is collected at 1 second intervals during the test. The force 1 second after the sample is strained to 100% is recorded as the force at time zero. The force after 10 hours of holding the sample at 100% strain is recorded as the force after 10 hours. The force drop at 10 hours refers to the decay in force from the force at time zero to the force after 10 hours. The force drop at 10 hours is calculated as follows:

[0123]

number

[0124] For the "stretch at opening" measurement, the sample is loaded as described above for at least 8 hours and not more than 10 hours. The "base opening area" is calculated at the beginning of the test. When the sample is fully stretched to 100%, the dimensions of the smallest three openings are measured to within 0.1 mm using calipers. The area of ​​the openings in the film is measured, not the area of ​​the bond site. These three openings are referred to as the base openings. Once the measurements are complete, the chamber door is closed and the remainder of the test may be performed at 37.8 degrees Celsius. To calculate the base opening area, an area is calculated for each of the openings using the mathematical area formula that best fits the shape of the opening (rectangle, square, circle, oval, etc.). The three calculated areas are then averaged to calculate the "base opening area." At the end of the test (after 8 hours), the maximum opening dimension is measured to within 0.1 mm using a caliper while the sample is still stretched to 100%. The "maximum opening area" is the area of ​​the largest opening in the film of the sample calculated using the mathematical area formula that best fits the shape of the opening. The "stretch at opening" is calculated using the following:

[0125]

number

[0126] Joint Dimension Test Method Bond Dimension Test is used to measure various dimensions of bonds in laminates and bond density of laminates. Bond Dimension Test is performed on reflected light microscope images generated using a stereoscopic optical microscope (such as Zeiss V20 Stereoscope) and a mounted camera (such as Carl Zeiss AxioCam MRc5). Measurements are performed using Image Pro Plus software (Version 7.0.0.591, Media Cybernetics (USA)) calibrated against a ruler placed in the image when it is acquired. For the purposes of this method, a bond is an intentional joining of two or more layers and a deformed area that occurs during the bonding process (e.g., reduced caliper at the bonding site).

[0127] Identify multiple bonds of interest from the uniform bond pattern area and expand the resulting perimeter to at least 1 cm 2A linear specimen of area is collected by outlining and cutting along the perimeter. Care must be taken to avoid collecting specimens from adjacent areas if they are different (e.g. areas that are non-bonded, inelastic, or have different bonding patterns). Specimens must be cut to a minimum of 1 cm. 2 The collected particles are collected in a substantially rectangular shape having an area of ​​0.1 mm. If a sufficiently large sample is not available, a smaller sample having at least one repeat unit of the repeating bond pattern can be used, and the measured bond area value will be less than 1 cm 2 The images are normalized to the specimen area of ​​100 nm. If the pattern is too large for stereoscopic imaging, images should be collected using an SLR camera (such as the Pentax R20D) or a scanner (such as the Epson Perfection V750 Pro Flatbed Scanner) with a black background behind the sample.

[0128] The specimen is fully stretched. For corrugated laminates, the specimen is fully stretched when the corrugations are substantially flattened by stretching the laminate while ensuring that the inelastic substrate of the laminate is not plastically deformed. For laminates without corrugations, the specimen is considered to be fully stretched without such stretching.

[0129] As the images are acquired, a ruler is placed parallel to the long axis of the bond in each image. The dimensions of the discontinuous bonds and the area of ​​the discontinuous bonds are measured with the irregular area tool in Image Pro Plus software by selecting only the bonded area.

[0130]

number

[0131] All discontinuous bonded areas within the specimen are added to calculate the total bonded area for the specimen, and then the total bonded area is divided by the area of ​​the specimen (as measured in the fully stretched state) to determine the bond density, which can be expressed as the following formula:

[0132]

number

[0133] Hysteresis Test Method Hysteresis testing can be used for a variety of specified strain or load values. Hysteresis testing utilizes a commercially available tensile testing machine (e.g., from Instron Engineering Corp., Canton, MA, SINTECH-MTS Systems Corporation, Eden Prairie, MN, or equivalent) interfaced with a computer. The computer is used to control the test speed and other test parameters and to collect, calculate, and report the data. Testing is performed under laboratory conditions at 23° C.±2° C. and 50%±2% humidity. Test specimens are conditioned for 24 hours prior to testing.

[0134] Test specimens are cut to the dimensions listed in the table below for the test being performed.

[0135] Testing Protocol 1. Select the appropriate line grips (similar to those disclosed above in the Grip section of the Elongation at 10 Hour Force Drop / Opening Test Method) and load cell. The grips must have one flat surface and be wide enough to grip the specimen along its entire width. The grips must also provide sufficient force and a suitable surface to ensure that the specimen will not slip during testing. The load cell is selected so that the tensile response from the specimen being tested is 25%-75% of the load cell capacity being used. Calibrate the testing machine according to the manufacturer's instructions. 2. Set the distance between the grips (gauge length) for each test performed (table below). 3. Place the specimen in the flat of the grips so that the uniform width lies along a direction perpendicular to the gauge length. Clamp the specimen in the upper grip, allowing the specimen to hang slackly, and then close the lower grip. 4. Preload: Set the preload with 0.05 N slack and set the preload crosshead speed of 13 mm / min. This means that data collection begins when the slack is removed with a force of 0.05 N (at a constant crosshead speed of 13 mm / min). The strain is measured as a function of the adjusted gage length (l ini ), where the adjusted gage length is the length of the specimen between the grips of the tensile tester at a force of 0.05 N. This adjusted gage length is taken as the initial specimen length, which corresponds to 0% strain. The percent strain at any point in the test is defined as the change in length relative to the adjusted gage length divided by the adjusted gage length multiplied by 100. 5(a) First Cycle Load: Pull the specimen to a given load or strain at a constant crosshead speed as defined in the table below for the test. The elongated specimen length between the grips is defined as l max Report as. 5(b) First Cycle Unloading: The specimen is held at the load or strain of step 5(a) for 30 seconds, then the crosshead is moved to its starting position (0% strain or initial specimen length, l) at the constant crosshead speed defined in step 5(a) above. ini ) again. 5(c) Hold the test specimen in the relaxed position for 1 minute. 5(d) Second cycle: Repeat steps 5(a) and 5(b).

[0136] [Table 6]

[0137] A computer data system records the force applied to the sample during the test as a function of the applied strain. From the resulting data generated, the following quantities are reported:

[0138] i. The length of the specimen between the grips at a preloaded sag of 0.05 N (l ini ). ii. The length of the specimen between the grips on the first cycle at a given strain (lmax ). iii. The length of the specimen between the grips at the second cycle load force of 0.07 N (l ext ). iv. The force at 50% strain during the first load cycle (reported as load force at 50%), rounded to the nearest 0.01 N / in. v. Force at 50% strain during the second unloading cycle (reported as unloading force at 50%), rounded to the nearest 0.01 N / in

[0139] The reported load and unload force values ​​are converted to MPa using the following formula if the basis weight of the elastomeric layer is known or has been calculated from other known information:

[0140]

number

[0141] If the density of the elastomer layer is unknown, it is assumed to be 0.93 g / cm 3 The density value is used.

[0142] If the average elastomer layer thickness can be assessed via any experimental method (such as SEM), the reported load and unload force values ​​can be converted to MPa using the following equation:

[0143]

number

[0144] Air Permeability Test Method The air permeability of an ear laminate or substrate (e.g., a film, nonwoven, or article component) is determined by measuring the flow rate through a sample of standard conditioned air driven by a specified pressure drop. This test is particularly suitable for materials with relatively high gas permeability, such as nonwovens, perforated ear laminates, etc. ASTM D737 was used with the following modifications:

[0145] Use a Textest FX 3300 instrument or equivalent available from Textest AG, Switzerland or Advanced Testing Instruments ATI, Spartanburg SC, USA. Carry out the procedures described in the TEXTEST FX 3300 Air Permeability Tester manual under Operating Instructions, Airtightness Test and Function and Calibration Checks. If a different instrument is used, follow the same regulations regarding airtightness and calibration according to the manufacturer's instructions.

[0146] The sample is tested while in the relaxed state.

[0147] Set the test pressure drop to 500 Pa and 1 cm 2 Use an areal test head (FX3300-5 model) or equivalent. Record the results to three significant figures. Calculate the average of the five samples and obtain the air permeability value (m 3 / m 2 / min).

[0148] Bag stacking height test method The stack height of a package of absorbent articles within a bag is measured as follows.

[0149] device A thickness tester is used that has a flat rigid horizontal sliding plate. The thickness tester is configured such that the horizontal sliding plate is free to move vertically while always maintaining a horizontal orientation just above a flat rigid horizontal base plate. The thickness tester includes a device suitable 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 of the absorbent article package that contacts each plate (i.e., each plate extends beyond the contact surface of the absorbent article package in all directions). The horizontal sliding plate applies a downward force of 850±1 grams force (8.34 N) to the absorbent article package, which may be achieved by placing a suitable weight in the center of the top surface of the horizontal sliding plate that does not contact the package, such that the total mass of the sliding plate plus the additional weight is 850±1 grams.

[0150] Test procedure The absorbent article packages are equilibrated at 23±2° C. and 50±5% relative humidity prior to measurement.

[0151] Raise the horizontal sliding plate and center the absorbent article package under the horizontal sliding plate with the absorbent articles in the package in a horizontal orientation (see Figure 10). Any handles or other packaging mechanisms on the surface of the package that would contact any of the plates are folded flat against the surface of the package to minimize their effect on the measurement. Slowly lower the horizontal sliding plate until it touches the top surface of the package and then release it. 10 seconds after releasing the horizontal sliding plate, measure the gap between the horizontal plates to within ±0.5mm. Five identical packages (same size package and same number of absorbent articles) are measured and the arithmetic average is reported as the package width. Calculate "in-bag stack height" = (package width / number of absorbent articles per stack) x 10 and report within ±0.5mm.

[0152] Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0153] All documents cited herein, including any cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest or disclose such invention, either alone or in combination with any other reference(s). Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0154] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. An absorbent article (100), a topsheet (124), a backsheet (126), and an absorbent core (128) disposed between the topsheet and the backsheet; An elastic laminate (10), Nonwoven fabric (12), An elastomeric layer (14), and and a stretch laminate (10) comprising a bonded region (40), said bonded region comprising a first plurality (36) of ultrasonic bonds, a majority of bonds of said first plurality being oriented in a stretch direction (32), each ultrasonic bond comprising at least one dimension that is 0.7 mm or greater, said bonded region having a hysteresis ratio of 2.5 or less, more preferably 2.4 or less, and an unload force at 50% of 0.44 MPa or greater, as measured by the Hysteresis Test Method described herein.

2. 10. The absorbent article of claim 1, wherein said stretch laminate comprises a bond density of at least 1.5% when measured according to the Bond Dimension Test Method described herein.

3. 3. The absorbent article of claim 1 or 2, wherein a majority of said stretch-oriented bonds comprise an aspect ratio of at least 1.

25.

4. 4. The absorbent article of any one of claims 1 to 3, further comprising a second bond area (42) having a second plurality of ultrasonic bonds (38), a majority of said second plurality of bonds being oriented in a second direction (34), said second direction being perpendicular to said stretch direction, and said second bond area comprising a low stress area (44).

5. 5. The absorbent article of claim 4, wherein said low stress area has a load at 50% of less than or equal to about 1.46 MPa.

6. 6. The absorbent article of claim 4 or 5, wherein each of said bonds oriented in said second direction (34) has a major dimension length of 1.2 mm or less.

7. The absorbent article of any one of claims 4 to 6, wherein said second plurality is at least partially interwoven with said first plurality.

8. The absorbent article of any one of claims 4 to 7, wherein said second plurality is in at least partial overlapping relationship with said first plurality.

9. The absorbent article of any one of claims 1 to 8, wherein one or more of the bonds oriented in the stretch direction have an elliptical shape.

10. 10. The absorbent article of claim 9, wherein each of said stretch-oriented bonds has an elliptical shape.

11. 11. The absorbent article of any one of claims 1 to 10, wherein the laminate comprises a 10 hour force drop of 65% or less and an elongation at opening of 50% or less according to the 10 hour force drop / elongation at opening test method described herein.

12. 12. The absorbent article of any one of claims 1 to 11, wherein said stretch laminate comprises one or more reinforcement features (50), said reinforcement features being selected from the group consisting of additional bonds, layers, folds, substrates, and combinations thereof.

13. The absorbent article according to any one of claims 1 to 12, wherein the stretch laminate is disposed within a component selected from the group consisting of ears (130), waistbands (180), belts (220), and combinations thereof.

14. The absorbent article of claim 13, wherein the components are ears disposed in the rear waist region (118).

15. The absorbent article according to any one of the preceding claims, wherein said elastomeric layer comprises a film (15).

Images