Absorbent article having a laminate bonding pattern

Abstract

The absorbent article includes a first waist region and a second waist region, and a crotch region disposed between the first waist region and the second waist region. The absorbent article includes a chassis having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. At least one elastic ear including a laminate is joined to the chassis. The laminate is an ultrasonic bonded laminate of an elastomer layer and a nonwoven layer. The bonding pattern includes a plurality of separate primary ultrasonic bonds and a plurality of secondary ultrasonic bonds. The primary bonds permanently attach the layers of the laminate, and the secondary bonds releasably attach the layers of the laminate. The secondary bonds release when the laminate is stretched in the longitudinal direction.

Description

Technical Field

[0001] The present disclosure relates to an absorbent article having a stretchable laminate with a bonding pattern. More specifically, the present disclosure relates to a stretchable laminate including one or more permanent joints and one or more releasable joints.

Background Art

[0002] Elastomeric laminates are used in various products including absorbent articles (e.g., diapers, incontinence articles, feminine hygiene pads). Such laminates typically include an elastomeric layer that provides stretchability to the laminate and an outer layer that is less stretchable but suitable for providing durability and desirable tactile properties. In this way, the laminate provides a desirable appearance quality while allowing the components of the article to closely contact and comfortably touch the wearer.

[0003] The layers of an elastomeric laminate can be combined by various means including, for example, thermal bonding in a gathered laminate configuration where one or more layers have a corrugation. When bonding the layers, the manufacturer must balance considerations of strength, stretchability, and comfort. However, these considerations often counteract each other. For example, while more bonds can provide greater laminate strength, it can impair stretchability. Similarly, a more elastic material can provide greater tear resistance but lower flexibility or breathability.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Accordingly, there remains a continuing need to balance the strength, comfort, and stretchability of a stretchable laminate. There is also a need to provide a bonding pattern that maximizes the desired laminate properties while minimizing undesirable properties. Further, there is a need to provide laminate properties due to the bonding pattern.

Means for Solving the Problems

[0005] An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The absorbent core includes at least one elastic ear having a laminate. The laminate includes an elastomer layer and a nonwoven layer. The laminate may include a plurality of separate primary ultrasonic bonding portions and a plurality of secondary ultrasonic bonding portions. The elastomer layer and the nonwoven layer are permanently attached by the primary ultrasonic bonding portions and remain releasably attached by the secondary ultrasonic bonding portions. The secondary ultrasonic bonding portions release when the laminate is stretched more than about 5 mm in the stretch direction.

[0006] An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The absorbent core includes at least one elastic ear having a laminate. The laminate includes an elastomer layer and a nonwoven layer. The laminate may include a plurality of separate primary ultrasonic bonding portions and a plurality of secondary ultrasonic bonding portions. The elastomer layer and the nonwoven layer are permanently attached by the primary ultrasonic bonding portions and remain releasably attached by the secondary ultrasonic bonding portions. The secondary ultrasonic bonding portions release when the laminate is stretched with a force of at least 0.5 N / in in the stretch direction.

[0007] An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The absorbent core includes at least one component having a laminate. The laminate includes an elastomer layer and a nonwoven layer. The laminate may include a plurality of separate primary ultrasonic bonding portions and a plurality of secondary ultrasonic bonding portions. The elastomer layer and the nonwoven layer are permanently attached by the primary ultrasonic bonding portions and remain releasably attached by the secondary ultrasonic bonding portions. The secondary ultrasonic bonding portions release when the laminate is stretched more than about 5 mm in the stretch direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above and other features and advantageous aspects of the present disclosure, and the manner in which they are realized, will become more apparent by referring to the following description of the exemplary forms of the present disclosure in conjunction with the accompanying drawings, and the understanding of the present disclosure itself will be deepened.

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Best Mode for Carrying Out the Invention

[0009] Definitions "Absorbent article" refers to an instrument for absorbing and containing body excreta, and more specifically, a device that contacts the wearer's body or is placed proximal to the wearer's body and absorbs and contains various excreta discharged from the body. Examples of absorbent articles include diapers, training pants, pull-on pant-type diapers (i.e., diapers having pre-formed waist openings and leg openings as illustrated in U.S. Patent No. 6,120,487), re-fastenable diapers or pant-type diapers, incontinence briefs and underwear, diaper holders and liners, feminine hygiene garments such as pantiliners, absorbent inserts, and the like.

[0010] "Elasticity", "elastomeric property", and "elastic extensibility" mean the ability of a material or a portion of a material to stretch at least 50% without rupture or breakage at a given load in one of the directions by the hysteresis test described herein, and upon release of the load, the elastic material or component exhibits at least 70% recovery (i.e., has less than 30% permanent strain). The stretchability, sometimes also referred to as strain, percent strain, engineering strain, draw ratio, or elongation, may be measured by the hysteresis test described in more detail below, similar to recovery and permanent strain. Materials that are not elastic are referred to as inelastic. As used herein, a laminate is elastic if at least 20% of the area of the laminate meets the definition of elasticity herein. In this context, the percent of the area of the laminate is determined when the laminate is in a fully stretched state.

[0011] "Extensibility" means the ability to stretch or elongate at least 50% without rupture or breakage by step 5(a) of 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 percent of the area of the laminate is determined when the laminate is in a fully stretched state. If the laminate does not meet the above definition of elasticity but meets the definition of extensibility presented in this paragraph, the laminate is an extensible laminate.

[0012] As for "fully stretchable" related to the laminate, in the case of a corrugated laminate, when the corrugation is substantially flattened by stretching the laminate while confirming that the inelastic base material of the laminate is not plastically deformed, the laminate is fully stretchable. In the case of a non-corrugated laminate, the laminate is considered to be fully stretchable without any such stretching (i.e., the non-corrugated laminate is fully stretchable in its relaxed state). "Relaxed" with respect to the laminate means that the laminate is stationary in a state where there is substantially no external force acting on the laminate other than gravity.

[0013] A "unit" is the smallest building block of a pattern, the geometric arrangement of which defines the characteristic image of the pattern, and the repetition of which in space is necessary to reconstruct the pattern. A pattern can be formed from one or more units. A "repeating unit" is a unit that exists multiple times within a pattern, and the unit can be reoriented by rotation, mirroring, or other methods.

[0014] An "independent bubble unit" means a distinguishable unit having a surrounding, and the surrounding is formed by at least five joints that substantially surround a region not including permanent joints. The surrounding can be formed by discontinuous joints. For example, separate joints that are small enough and / or close together cause an observer to see a shape substantially surrounded by the surrounding. Independent bubble units can share bonding sites with each other to form independent bubbles.

[0015] A "releasable joint" related to the laminate means that when the laminate is stretched in the stretching direction during use from its relaxed state, the joint will be released. Release includes at least partial separation of the joint. For example, one or more fibers of the non-woven portion of the laminate may remain bonded at the bonding site when the laminate is stretched. However, even though these one or more fibers remain bonded, the bonding site will be considered to be released.

[0016] The "permanent joint" regarding the laminate means that when the laminate is stretched and contracted by at least 15 mm in the transverse direction from the relaxed state of the laminate according to the laminate stretching test method, the joint remains as it was.

[0017] "Joined" refers to a configuration in which one element is directly attached to another element so that the element is directly adhered to the other element, and a configuration in which the element is attached to an intermediate member and the intermediate member is further adhered to the other element so that the element is indirectly adhered to the other element.

[0018] Overview As shown in FIG. 1, the laminate 10 includes a first cover material layer 12 and an elastomer layer 14. The laminate can include a second cover material layer 16, and the elastomer layer 14 can be sandwiched between the first cover material layer and the second cover material layer. The cover material layer material can be inelastic. Additional layers may be included. The layers can be non-woven fabrics, inelastic materials, elastic, or stretchable materials. The laminate can be stretchable. In certain embodiments, the laminate is elastomeric. Two or more laminate layers can be joined by a plurality of joints 30, as shown in FIG. 2A. The joint can be an ultrasonic joint 31 that can join the non-woven fabric layer through the elastomer layer. The ultrasonic bonded laminate can be formed by any suitable process, including but not limited to those described in U.S. Pat. Nos. 10,568,775, 10,568,776, and 10,575,993 by the same applicant. The joint can be of any suitable shape or size such that two or more laminate layers are joined.

[0019] As illustrated in FIGS. 2A-2C, the laminate may include a plurality of joints 30, which may be ultrasonic joints 31. The plurality of joints may be arranged in a joint pattern. The joint pattern may include a plurality of joints arranged in a lattice configuration or a shaped configuration such that groups of joints form one or more shapes. For example, as illustrated in FIG. 2A, the laminate includes a first joint pattern 200. The first joint pattern 200 includes closed cell units 204. The laminate may include one or more joint patterns, and these joint patterns may be different.

[0020] The joints of the joint pattern may include a joint separation distance of from about 0.1 mm to about 15 mm, or from about 1.2 mm to about 10 mm, or from about 1.5 mm to about 5 mm, or less than about 5 mm, according to the joint measurement test method of this specification. Each joint of the permanent joint and the releasable joint may have a joint size of 0.5 mm to 10 mm or about 0.7 mm to 3 mm in one or more directions according to the joint dimension test method. The permanent joint may be larger in size than the releasable joint. The permanent joint and the releasable joint may have any shape, such as rectangular, circular, hexagonal, elliptical, diamond-shaped, or any other shape that enables the laminate to be joined.

[0021] Referring to FIG. 2B, the joint pattern 200 may be a plurality of joints 30 arranged in a lattice configuration. As illustrated in FIG. 2C, the joint pattern 200 may be a plurality of joints 30 arranged in an offset configuration such that rows of joints are offset from adjacent rows of joints. It should be understood that the joint pattern may be an irregular pattern and the density of joints within the joint pattern may vary in different regions of the laminate. Further, the plurality of joints may not be from a joint pattern, but rather may be unevenly spaced on the laminate.

[0022] In addition to the above, the joining pattern 200 may include a plurality of distinct primary joining portions 30, also referred to herein as permanent joining portions, and a plurality of secondary joining portions 32, also referred to herein as releasable joining portions. The primary ultrasonic joining portion may be such that the laminate 10 is permanently attached in the region of the primary joining portion 30. The secondary joining portion 32 may be such that when the laminate is stretched in the stretching direction, these joints are released, allowing two or more layers of the laminate to separate. The primary joining portion 30 may be a permanent joining portion 34, and the secondary joining may be a releasable joining portion 36. The releasable joining portion 36 is configured to join two or more layers of the laminate 10 together before the joining portion is released. When the releasable joining portion 36 is released, two or more layers of the laminate are partially or completely separated. The releasable joining portion 36 may be configured to release when the laminate is stretched in one or more directions. For example, the laminate may be an elastic ear portion. Before the elastic ear portion is stretched and contracted, the releasable joining portion attaches each layer of the elastic ear portion. When the elastic ear portion is stretched, the releasable joining portion 36 is released, allowing two or more layers of the laminate of the elastic ear portion to separate. The releasable joining portion 36 allows the laminate to be in a relatively flat state before stretching and contracting, and then, when stretched to release the releasable joining portion, allows it to be relatively tall and pillow-shaped. The permanent joining portion 34 prevents the laminate from separating when the laminate is stretched. Both the permanent joining portion and the releasable joining portion may be ultrasonic joining portions. The permanent joining portion and the releasable joining portion may be different types of joining portions.

[0023] These features and other features will be described in more detail below. The ear portion 130 and / or waistband 180 and / or leg cuff of the absorbent article may include the laminate described herein.

[0024] Laminate As described above, laminate 10 includes one or more coverstock layers 12, 16, and an elastomer layer 14. The coverstock layer material can be selected from nonwoven fabrics, films, and / or any other type of web-based material. In various embodiments, one or more coverstock layers include nonwoven fabrics. Any suitable nonwoven fabric may be used in laminate 10. Suitable nonwoven fabrics can have a basis weight of at least about 8 gsm, or at least about 10 gsm, or at least about 15 gsm, or at least about 40 gsm, or 30 gsm or less, or 22 gsm or less, or 17 gsm or less, or from about 10 gsm to about 22 gsm. Suitable nonwoven fabrics include, but are not limited to, spunbond, spunlace, meltblown, spunmelt, solvent spun, electrospun, carded, film fibrillation, melt film fibrillation, airlaid, dry laid, wet laid, hydroentangled, spunlace, air-through bonded, and other nonwoven web materials formed in part or entirely of 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 can include a spunbond layer. In a non-limiting example, the nonwoven fabric includes two or more spunbond layers. In a further non-limiting example, one or more nonwoven fabrics can include an SMS (spunbond-meltblown-spunbond) configuration. In a further non-limiting example, one or more nonwoven fabrics can include an SPS (spunbond-pulp-spunbond) configuration. Alternatively, one or more of the nonwoven fabrics in the ear region of the absorbent article may not include a meltblown layer. Although the meltblown layer has been found to enhance the bond in the ear region where bonding is required (in view of the meltblown layer inhibiting the diffusion of adhesion through the porous nonwoven fabric structure), the meltblown layer often lacks strength. In some embodiments, the nonwoven fabric consists essentially of a spunbond layer. In some non-limiting examples, both the first nonwoven fabric and the second nonwoven fabric include at least two layers of spunbond layers, or three or more layers of spunbond layers. The fibers of the nonwoven fabric can be joined by multiple thermal spot bonds, as known in the art.In a non-limiting example, the nonwoven fabric may include a bonding area of about 20% or less (with respect to their thermal point bonding).

[0025] This nonwoven web may be mainly formed of polymer fibers. In some examples, suitable nonwoven fiber materials may include, but are not limited to, polyolefins, polyesters, polyamides, nylons, or specifically, polymer materials such as polypropylene (PP), polyethylene (PE), polylactic acid (PLA), polyethylene terephthalate (PET), and / or blends thereof. In some examples, the fibers may be formed from a PP / PE blend such as those described in U.S. Patent No. 5,266,392. The nonwoven fibers may be formed from components such as aliphatic polyesters, thermoplastic polysaccharides, or other biopolymers, or may contain those components as additives or modifiers. Further useful nonwovens, fiber compositions, fiber and nonwoven formation, and related methods are described in U.S. Patent Nos. 6,645,569, 6,863,933, and 7,112,621, and U.S. Patent Applications Nos. 10 / 338,603, 10 / 338,610, and 13 / 005,237. The individual fibers of the nonwoven layer may be single-component or multi-component (including two-component). The multi-component fibers can be, for example, two-component, including various polymer components in a core and sheath arrangement or a parallel arrangement. The individual components may include polyolefins such as polypropylene or polyethylene, or their copolymers, or polyesters, thermoplastic polysaccharides, or other biopolymers, or recycled or recyclable polymer resins. Further, this nonwoven fabric may include, for example, a blend of different fibers selected from the types of polymer fibers described above.

[0026] The individual fibers of the nonwoven fabric may also include natural fibers. The natural fibers may be fibers derived from plant sources or natural sources such as plants and / or wood. Suitable sources for this application include wood pulp, cotton, rice, wheat, bamboo, and seaweed. The fiber web may include fibers from any of these natural sources, fiber components (linter, seed hair, trichome, straw), or spun fibers, or combinations thereof. The most common and suitable spun fibers for this application are made from spun wood pulp and bamboo.

[0027] The nonwoven fabric may include a combination of vegetable fibers and synthetic fibers that are not vegetable. For example, the nonwoven fabric can include both polypropylene fibers and cotton fibers, see, for example, U.S. Patent Application Publication No. 2017 / 0203542. The cotton content can range from about 3 wt%, 5 wt%, 10 wt%, or 15 wt% to about 50 wt% of the nonwoven fabric. When synthetic fibers such as polypropylene are used, the polypropylene is preferably a non-phthalate catalyst polypropylene fiber.

[0028] In some examples, at least a portion of those fibers may exhibit a spiral crimp having a helical shape. According to one example, those fibers can include bicomponent fibers that are individual fibers, each including a different material, typically a first polymeric material and a second polymeric material. The use of side-by-side bicomponent fibers is thought to be beneficial for imparting a spiral crimp to those fibers. Examples of potentially suitable crimped or "drawn" bicomponent fibers and nonwovens formed therefrom are described in U.S. Pat. Nos. 5,382,400, 5,418,045, 5,707,468, 6,454,989, 6,632,386, 5,622,772, and 7,291,239. For the purposes of this specification, the use of nonwovens formed from bicomponent or multicomponent crimped fibers, such as those described in the immediately preceding patents and / or patent applications, for example, may be desirable as one or both nonwoven layers because they can feel particularly soft to the touch (comfortable on the inside for the wearer and aesthetically pleasing on the outside) and are generally quite flexible. In other non-limiting examples, the nonwoven may not have crimped fibers.

[0029] If laminate 10 includes more than one nonwoven, the nonwovens can have the same basis weight or different basis weights. Similarly, the nonwovens can have the same layer configuration (e.g., SSS) or different layer configurations (e.g., SMS, SPS).

[0030] The elastomeric layer 14 includes one or more elastomeric materials that provide elasticity to at least a portion of layer 14. Non-limiting examples of elastomeric materials include films (e.g., films derived from polyurethane films, rubbers and / or other polymeric materials), elastomeric coatings applied to another substrate (e.g., hot melt elastomers, elastomeric adhesives, printed elastomers, or elastomers coextruded with another substrate), elastomeric nonwovens, scrims, strands (including one or more strands), and the like. The elastomeric material can be formed from an elastomeric polymer that includes a styrene derivative (e.g., a styrenic block copolymer material), polyester, polyurethane, polyetheramide, polyolefin, combinations thereof, or any suitable known elastomer including coextruded VISTAMAXX®. Exemplary elastomers and / or elastomeric materials are disclosed in U.S. Patent 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 (styrene block copolymer; available from Kraton Chemical Company (Houston, TX)), SEPTON (styrene block copolymer; available from Kuraray America, Inc. (New York, NY)), VECTOR (styrene block copolymer; available from TSRC Dexco Chemical Company (Houston, TX)), ESTANE (polyurethane; available from Lubrizol, Inc. (Ohio)), PEBAX (polyether block amide; available from Arkema Chemicals (Philadelphia, PA)), HYTREL (polyester; available from DuPont (Wilmington, DE)), VISTAMAXX (homopolyolefin and random copolymer, and blends of random copolymers; available from EXXON Mobile (Spring, TX)), VERSIFY (homopolyolefin and random copolymer, and blends of random copolymers; available from Dow Chemical Company (Midland, Michigan)), and INFUSE (block copolymer available from Dow Chemical Company).

[0031] In a non-limiting example, the elastomeric layer 14 includes a film 15. The film can be a single layer or multiple layers. The film can be stretchable or elastic in the transverse and / or longitudinal directions. The film can be pre-processed, for example, pre-activated, as disclosed in U.S. Patent No. 9,533,067. Additionally, or alternatively, the elastomeric layer 14 can be perforated.

[0032] The elastomeric layer may be shorter than the laminate itself in one or more dimensions of the laminate. For example, as illustrated in FIGS. 2A-2C, the elastomeric layer may include a maximum dimension Y in the stretch direction, and the laminate may include a maximum dimension W in the stretch direction. In various embodiments, the stretch direction is the lateral direction. The maximum dimension is measured when the laminate is in a relaxed state. In a non-limiting example, Y may be at least about 10 mm smaller than W. In certain embodiments, Y is at least about 20%, or about 25% to about 100%, or about 35% to about 85%, or about 80% or less of W. In various embodiments, the stretch direction is the lateral direction. 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 a 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.

[0033] Referring to FIGS. 2A-2C, the laminate 10 may include a primary region 18 defined by the perimeter of an elastomeric material 14 and one or more inelastic regions 20, 22. The primary region 18 includes an elastic region 26 and one or more non-stretch zones 28. In the elastic region 26, the laminate 10 is elastically stretchable. In the non-stretch zones 28, the laminate 10 may not be elastic despite the presence of the elastomeric layer. In some embodiments, the area of the primary region 18 includes at least about 20%, or about 30% to about 100%, or about 80% or less of the total area of the laminate. The laminate 10 may include one or more inelastic regions 20, 22. In certain embodiments, the laminate 10 includes a first inelastic region 20 that extends laterally outward from a first laminate edge 9 of the laminate and is adjacent to the elastic region 18 at a first elastomeric material edge 17. The laminate may further include a second inelastic region 22 that may extend laterally inward from a second laminate edge 11 and may also be adjacent to the elastic region 18 at a second elastomeric material edge 19. The first inelastic region and the second inelastic region may be made of the same material or different materials.

[0034] In certain embodiments, laminate 10 includes a gathered laminate 24, and one of the layers is distorted at a greater angle than the remaining layers during lamination. Thus, low-ductility layers, such as coverstock layers 12, 16, will form gathers when the gathered laminate 24 is in a relaxed state. In some embodiments, at least a portion of the elastomeric layer is distorted while the coverstock layer (including one or more nonwovens) is in a relaxed state during lamination. The elastomeric layer can be stretched and contracted in one or more directions. Then, when the subsequently formed laminate 24 is in a relaxed state, waveforms are formed within the nonwoven layer. The laminate may have a waveform regularity greater than about 50%, such that when measured perpendicular to the flat surface of the laminate, as illustrated in FIG. 14, about 50% of the waveforms have substantially the same amplitude. The laminate may have a waveform regularity greater than about 75%, such that when measured perpendicular to the flat surface of the laminate, as illustrated in FIG. 14, about 75% of the waveforms have substantially the same amplitude. When making a gathered laminate, the elastomeric layer is stretched in the stretch and contract direction (i.e., the intended direction of stretch and contract in the final product). The stretch and contract direction may be the lateral direction. In a non-limiting example, the elastomeric layer is stretched and contracted in a direction corresponding to the lateral 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 lateral direction of the article (i.e., the laminate is extensible in the lateral direction).

[0035] For example, as illustrated in FIG. 2A, the layers of the laminate are joined by one or more joints 30. The joints may be of any suitable shape, and multiple shapes may be utilized within the laminate. In various embodiments, the joint may be an ultrasonic joint 31. The joint may be disposed within one or more patterns 200. Each pattern may include one or more closed cell units 204. Repeated closed cell units form one or more repeating units 202. The repeating units are the same or substantially the same closed cell units that repeat in the bonding pattern. Thus, the first repeating unit includes first closed cell units having substantially the same shape, and the second repeating unit includes second closed cell units having substantially the same shape, but the first closed cell units and the second closed cell units are of different shapes. It should be understood that the closed cell units of different repeating units may differ in at least one of shape and size. The bonding pattern may include closed cell units that are the same or substantially the same in shape and / or size. The bonding pattern may include closed cell units that are different, for example, of different shapes and / or sizes. A particular closed cell unit may be the same or substantially the same as a particular other closed cell unit in the bonding pattern, and the particular other closed cell unit may be different. For example, the bonding pattern may include only closed cell units having a hexagonal shape, or the bonding pattern may include some closed cell units having a hexagonal shape and some closed cell units having a triangular shape. The laminate may include a first bonding pattern 200a having one or more repeatable closed cell units 204. The first bonding pattern may at least partially overlap with the primary region 18.

[0036] Furthermore, the bonding pattern 200 may include a permanent bonding portion 34. The permanent bonding portion 34 enables the laminate to remain bonded in the region of the permanent bonding portion 34 while the laminate is stretched and contracted. The bonding pattern 200 may also include a releasable bonding portion 36. The permanent bonding portion 34 may be referred to as a primary bonding portion 29, and the releasable bonding portion 36 may be referred to as a secondary bonding portion 32. The releasable bonding portion refers to an ultrasonic bonding portion that is breakable (or releasable) when stretched. FIG. 2D is a schematic view of a stretchable laminate 10 including an elastomeric film layer 14 sandwiched between a first cover layer 12 and a second cover layer 16. The layers are held together by a plurality of ultrasonic bonding portions 31. The stretchable laminate 10 may be subjected to a lateral tensile force in the stretching and contracting direction. FIGS. 2E to 2G are schematic views of the stretchable laminate 10 of FIG. 2D having various types of releasable bonding sites 36 after being subjected to a lateral tensile force. In FIG. 2E, the releasable bonding site 36 separates from both the first cover layer 12 and the second cover layer 14 in the separation region 702. In FIG. 2F, the releasable bonding site 36 separates from either the first cover layer 12 or the second cover layer 14 in the separation region 702. In FIG. 2G, the releasable bonding site 36 separates only partially from either the first cover layer 12 or the second cover layer 14 in the separation region 702.

[0037] The releasable bonding portion 36 may be disposed within and / or outside the closed-cell unit, as illustrated in FIG. 2A. The releasable bonding portion 36 is releasable when the laminate is stretched by more than about 5 mm in the stretching and contracting direction according to the laminate stretching test method. For example, the bonding portion is released when at least one of the bonded layers within the region of the releasable bonding portion is separated from one or more other layers, or is at least partially separated from one or more layers within the region of the releasable bonding portion. In some embodiments, the releasable bonding portion is released when the laminate is stretched by about 5 mm to about 12 mm, or about 5 mm to about 10 mm, or about 5 mm to about 8 mm according to the laminate stretching test method. The permanent bonding portion remains bonded when the laminate is stretched up to 15 mm.

[0038] According to the peel strength test method, the secondary releasable joint can be released when the laminate peel strength (the peel strength applied to the laminate) is 0.3 N / cm or more. In another embodiment, the permanent joint may remain bonded, but according to the peel strength test method, when each joint receives a force of 0.06 N / joint or less, the releasable joint is released. In another embodiment, the permanent joint may remain bonded, but according to the laminate stretching test method, when the laminate is stretched by a force of 0.5 N / in or more in the stretching and contracting direction, the releasable joint is released. In some embodiments, the releasable joint of the laminate can be released when the laminate is stretched by a force of about 0.4 N / in to about 0.7 N / in, or about 0.4 N / in to about 0.5 N / in according to the laminate stretching test method.

[0039] It should be understood that one or more of the releasable joints may be released before the laminate is stretched 5 mm in the stretch direction. For example, the second or releasable joint may be such that when the laminate is stretched by a first stretch that is less than 5 mm in the stretch direction, one or more of the releasable joints are released, and when the laminate is stretched by a second stretch that is 5 mm or more in the stretch direction, a plurality of the second releasable joints are released. For example, a laminate stretched by a first stretch of approximately 5 mm in the stretch direction results in either partial or complete release of the first portion of the releasable joint, and a laminate stretched by a second stretch of approximately 10 mm in the stretch direction results in either partial or complete release of the remaining or second portion of the releasable joint. Similarly, one or more of the releasable joints may be released before the laminate is stretched with a force of 0.5 N / in in the stretch direction, while additional joints may not be released until the laminate is stretched with a force of 0.5 N / in or more in the stretch direction. It should also be understood that according to the peel force test method, one or more of the releasable joints may not be released if an individual releasable joint receives a peel force of 0.06 N / joint or less. Thus, as more force is applied to the releasable joints, additional releasable joints may be released. For example, all of the releasable joints are released when an individual releasable joint receives a force of 1.2 N / joint or less. In a preferred embodiment, substantially all of the releasable joints are configured to be released when an individual releasable joint receives a force of approximately 0.06 N / joint or less, which is approximately the force applied by the user when applying an absorbent article including the laminate as disclosed herein.

[0040] The release of the releasable joint enables the joint region to undergo a change from a relatively compressed region to a more pillow-like region. For example, the releasable joint or the secondary joint may be present in the ear portion of the disposable absorbent article, and the secondary joint or the releasable joint may be released when the absorbent article is first applied to the wearer. The release of the releasable joint can enable the presence of ears having a relatively more pillow-like feel, higher breathability, and / or increased air flow when the absorbent article is in use or disposed on the wearer. Further, the release of the releasable joint can result in a change in opacity, graphic visibility, and / or color intensity. The release of the releasable joint can also result in an increase in the thickness of the laminate.

[0041] To achieve a more pillow-like region, the number of primary joints 29 is greater than the number of secondary joints 32. In other words, the number of permanent joints 34 may be greater than the number of releasable joints. The permanent joints 34 and the releasable joints 36 can have a bonding ratio. The bonding ratio is the ratio of the permanent joints 34 to the releasable joints 36. The number of permanent joints and releasable joints can be determined by a bonding ratio test method. The laminate has a bonding ratio of 1, or greater than about 1, or greater than about 1.1, or greater than about 1.3, or greater than about 1.5, or greater than about 1.7, or greater than about 2, or greater than about 5, or greater than about 8, or greater than about 10 according to the bonding ratio test method. Having a bonding ratio greater than 1 enables the laminate to remain sufficiently attached for use and allows the releasable joints to be separated during use. Further, the bonding ratio enables the laminate to be sufficiently compressed before use, such as while in a packaged state, and to become relatively pillow-like while maintaining a sufficient amount of attachment between the layers during use after stretching.

[0042] As illustrated in FIG. 2A, the releasable coupling 36 may be disposed within the closed cell unit formed from the permanent coupling 34. The releasable coupling 36 may enable the closed cell unit to maintain a more compressed state prior to use or expansion / contraction of the laminate. Upon release of the releasable coupling 36, the laminate in the region of the releasable coupling 36 may be released such that the releasable coupling 36 no longer joins the laminate or only partially joins the laminate such that one or more fibers remain joined. The permanent couplings remain recognizable by the user upon release of the releasable coupling.

[0043] The releasable coupling 36 may be part of a bonding pattern that does not include closed cells, as illustrated in FIGS. 2B and 2C. The secondary or releasable couplings may be distributed uniformly or non-uniformly across the laminate. As illustrated in FIGS. 2A, 2B, and 2C, the releasable couplings may form a secondary bonding pattern across the laminate. It should be understood that the first bonding pattern formed by the permanent couplings may not be fully recognizable by the user until the second bonding pattern formed by the releasable couplings is released. Further, the first bonding pattern formed by the permanent couplings and the second bonding pattern formed by the releasable couplings may form a cooperative bonding pattern prior to release of the releasable couplings, and the first bonding pattern may become visible upon release of the second bonding pattern.

[0044] Each of the primary bonding portion and the secondary bonding portion (which may also be referred to as a welding portion in this specification) may be formed by one or more methods including ultrasonic bonding, adhesive bonding, mechanical bonding such as heat and pressure or a combination of heat and pressure, and electrostatic bonding. The primary bonding portion may be formed by a first bonding method, and the secondary bonding portion may be formed by a second bonding method. The first bonding method may be different from the second bonding method. In some embodiments, the primary bonding portion and the secondary bonding portion may be formed by the same bonding method but may have different bonding strengths. For example, in order to vary the bonding strength, the bonding portions may be of different sizes, may include different materials, or may be of different shapes. Further, the bonding portions may be formed by the same method but may have different bonding strengths due to different structures of the nonwoven fibers such as the cross-sectional area of the fibers, and / or different elastic film properties or coatings.

[0045] As previously discussed, the permanent bonding portion and the releasable bonding portion may form one or more bonding patterns. These bonding patterns can include bonds that are uniformly or non-uniformly distributed. These bonding patterns may also form one or more independent bubble units. Further, the permanent bonding portion may form a first bonding pattern, and the releasable bonding portion may form a second bonding pattern. When the releasable bonding portion is released, the second bonding pattern may be removed from the laminate, and the first bonding pattern may remain. Still further, the permanent bonding portion may form a first bonding pattern, and the releasable bonding portion may form a second bonding pattern. When the releasable bonding portion is released, the second bonding pattern may be removed from the laminate, and the permanent bonding portion may form a third bonding pattern different from the first bonding pattern.

[0046] Figures 3A - 5B provide examples of bonding patterns having permanent joints and releasable joints. For example, FIGS. 3A - 3C illustrate a bonding pattern having closed - cell units including a perimeter 206 formed by one or more permanent joints 34 and releasable joints 36. For example, FIGS. 3A and 3B illustrate a plurality of closed - cell units 204 forming a first bonding pattern 200 and a second bonding pattern 201. The first bonding pattern 200 and the second bonding pattern 201 may be formed by one or more permanent joints 34 and one or more releasable joints 36. FIG. 3B illustrates a portion of the bonding pattern illustrated in FIG. 3A and the perimeters 206 formed by each of the closed - cell units. The perimeters 206 are shown as dashed lines for purposes of illustration and to better understand the present disclosure, but the dashed lines do not form part of the bonding pattern. The perimeters 206 are formed by connecting adjacent individual joints. It should be understood that the perimeter of the first closed - cell unit may form part of the perimeter of the second closed - cell unit. Further, the perimeter 206 may be formed by connecting one or more permanent joints and releasable joints.

[0047] Referring to FIG. 3C, when the laminate is stretched in the stretch - shrink direction, the releasable joint 36 releases and the permanent joint 34 remains. The permanent joints 34 remaining after the release of the releasable joint 36 reveal a third bonding pattern that is different from both the first bonding pattern and the second bonding pattern. Further, the release of the releasable joint 36 provides a larger area of the laminate that is not restricted by the bonding, resulting in a more pillow - like or cushioned appearance of the laminate.

[0048] The discrete bubble units can be of any shape that can be specified as a shape having a perimeter that substantially surrounds the region. For example, the discrete bubble units can be of various shapes including polygons, hearts, circles, ellipses, and combinations thereof. The bonding patterns can include discrete bubble units each having the same shape. The bonding patterns can include discrete bubble units having different shapes. Some bonding patterns can include two or more discrete bubble units having different shapes. For example, as illustrated in FIGS. 3A and 3B, the bonding pattern can include a first discrete bubble unit 204a and a second discrete bubble unit 204b. The first discrete bubble unit 204a can be a hexagonal discrete bubble unit, and the second discrete bubble unit 204b can be a triangular discrete bubble unit. Also, it should be understood that the various discrete bubble units can be of substantially the same shape but different sizes. The discrete bubble units can form patterns as previously discussed.

[0049] Bonding patterns having discrete bubble units, as discussed herein, allow for a relatively large area of the nonwoven fabric to come together when the laminate is in a contracted state, for example, without the risk of having an uncontrolled area of unbonded regions that could tear. Further, these bonding patterns having discrete bubble units allow for a more cushioned feel against the wearer's skin and will likely result in less pressure and skin marking for the wearer. The bonding patterns discussed herein can also allow for relatively greater breathability.

[0050] Figures 4A - 4D illustrate another bonding pattern of the laminate. The bonding pattern includes both permanent bonding portions 34 and releasable bonding portions 36. Figures 4A and 4B illustrate the laminate before stretching in the stretching direction, including both permanent bonding portions 34 and releasable bonding portions 36 that bond two or more layers of the laminate. The permanent bonding portions 34 and the releasable bonding portions 36 may be positioned to form independent bubble units. Further, the permanent bonding portions 24 and the releasable bonding portions 36 may be positioned to form a first bonding pattern 200 that forms a hexagonal region and a second bonding pattern 201 that forms a triangle. When the laminate is stretched in the stretching direction, the releasable bonding portions 36 are released, and two or more layers of the laminate can be separated from each other. As illustrated in Figures 4C and 4D, with the release of the releasable bonding portions, additional independent bubble units of the laminate come into existence. The laminate includes a first independent bubble unit in the shape of a hexagon of a first size and a second independent bubble unit in the shape of a hexagon of a second size different from the first size. It should be understood that in some embodiments, the shapes of the first independent bubble unit and the second independent bubble unit may be of the same size. In other words, the shape of the pattern formed by the bonding portions may be the same or different in size.

[0051] Also, it is contemplated that the first bonding pattern may include independent bubble units and the area of the bonding pattern that is not enclosed. For example, as illustrated in Figure 5A, the bonding pattern may include separate independent bubble units 204. Each of the separate independent bubble units has a perimeter that does not share the perimeter of another independent bubble unit. Referring to Figure 5A, for example, the bonding pattern may include independent bubble units and individual linearly arranged bonding portions. It should also be understood that the bonding pattern may include one or more independent bubble units that share a perimeter with each other and the area of the bonding pattern that is not enclosed. The independent bubble units may be formed by permanent bonding. The individual linear bonding portions may be formed by the releasable bonding portions 36. Thus, as illustrated in Figure 5B, when the releasable bonding portions are released, the independent bubble units are independent of each other such that the bonding portions from the first independent bubble unit do not share the bonding portion with another independent bubble unit.

[0052] In some embodiments, the laminate may have a first cover stock layer 12 including a first outer surface 210 and a second cover stock layer 16 including a second outer surface 212, as illustrated in FIG. 6. The first cover stock layer and the second cover stock layer may be made of different materials and may have different basis weights, layer configurations, and stretchabilities. For example, the first cover stock layer includes a nonwoven fabric, and the second cover stock layer includes a nonwoven fabric. Alternatively, the first cover stock layer includes a first nonwoven fabric, and the second cover stock layer includes a second nonwoven fabric, such that at least one of the basis weight, layer configuration (e.g., SS, SMS, SPS, etc.), and stretchability of the first nonwoven fabric and the second nonwoven fabric is different. In another non-limiting example, the first cover stock layer and the second cover stock layer have the same constituent materials, but one of the two layers includes a surface treatment or coating that causes a change in material properties such as stretchability, tensile strength, flexibility, or a combination thereof. In embodiments where the first and second cover stock layers are different, the same bonding pattern 200 may result in different appearances and / or different bonding strengths. As illustrated in FIG. 7, for example, the bond is relatively darker and more visibly apparent on the second outer surface 212 than on the first outer surface 210.

[0053] The region of the laminate including the bonding pattern may have a 50% unloading force of about 0.2 N / in or more, or about 0.3 N / in or more, or about 0.35 to about 1 N / in, in accordance with the hysteresis test method of the present specification, and is listed herein in increments of 0.01 N / in for this range.

[0054] The laminate may include, for example, a first bonding pattern 200a and a second bonding pattern 200b as illustrated in FIGS. 8 and 9. The second bonding pattern differs from the first bonding pattern in at least one of the shape of the bond, the number of bonds, the number of closed-cell units (or the absence of closed-cell units), the shape of the repeating unit, the enclosed area of the closed-cell unit, the bond density, the bond area, and combinations thereof. The second bonding pattern may be positioned outside the first bonding pattern, such that the two patterns may be in a non-overlapping relationship. As illustrated in FIGS. 8 and 9, the second bonding pattern may be disposed along one or more edges of the laminate. In this way, the second bonding pattern can at least partially surround or frame at least a portion of the first bonding pattern or the entire first bonding pattern. The second bonding pattern may at least partially overlap with the non-stretch region 34, the non-elastic region 20, the fastening system 148, and / or the reinforcing layer 160 (e.g., a folded substrate or an additional substrate added to the laminate to enhance integrity).

[0055] The first bonding pattern and the second bonding pattern may overlap in a transition zone. The overlap between the first bonding pattern and the second bonding pattern in the transition zone may be less than about 5 mm, or less than about 3 mm, or less than about 1 mm.

[0056] The bonding pattern may include one or more releasable bonds and one or more permanent bonds. As illustrated in FIGS. 8 and 9, the first bonding pattern 200a includes a releasable bond 36 and a permanent bond 34. The releasable bond 34 may be disposed within the closed-cell unit of the first bonding pattern 200a. The second bonding pattern 200b may also include at least one of a permanent bond 34 and a releasable bond 36 in a grid pattern.

[0057] The second bonding pattern 200b may not include closed-cell units. Alternatively, the second bonding pattern may include one or more closed-cell units having any of the features described herein.

[0058] In certain embodiments, the laminate has an air permeability value of at least about 1 m 3 / m 2 / min, or about 1 m 3 / m 2 / min to about 125 m 3 / m 2 / min, or about 2 m 3 / m 2 / min to about 50 m 3 / m 2 / min.

[0059] The bonding pattern of the laminate can be coordinated with other parts of the absorbent article. For example, the bonding pattern of the laminate can be coordinated with the bonding pattern on the chassis such as the topsheet and / or backsheet, ears, fasteners, and / or waist features. The coordination pattern can be a pattern formed by mechanically changing the structure of the material or by adding material to form a pattern such as by printing. The bonding pattern of the laminate may be coordinated with the bonding pattern included in another part of the absorbent article such that the bonding patterns are the same, or the bonding patterns may differ in size, for example, such that one bonding pattern is larger or smaller than the other. The bonding patterns may be coordinated such that the bonding patterns have the same geometric shape.

[0060] The laminate can include additional materials such as inks, discoloring indicators, and skin compositions such as humectants, fragrances, lubricants, antibacterial substances, insect repellents, and UV protecting substances. The additional materials may be disposed on one or more layers of the laminate. The additional materials may be disposed on the surface of one or more layers of the laminate. For example, ink may be applied to the laminate by printing. The ink can provide the user with a visual signal such as the location of a releasable bond or a bonding pattern or graphic.

[0061] As described above, laminates can be manufactured using a variety of methods. For example, a method for manufacturing an elastic laminate may include the following steps. A first substrate and a second substrate may be provided. The first substrate and the second substrate may be any of the materials considered above, such as nonwoven fabrics. Each of the first substrate and the second substrate may include a first surface and a second surface opposite thereto, and define a width in the transverse direction. The first surface of the first substrate may be wound around the outer peripheral surface of an anvil. An elastic film or other elastomeric substrate may be advanced in the machine direction.

[0062] The elastic film may be pre-activated in the machine direction, the transverse direction substantially perpendicular to the machine direction, or both. With respect to the pre-activation process, the elastomeric film may be guided through a system of meshing shape rollers, each roller including a disk packet having a plurality of meshing disks disposed on the axis. This process is generally referred to as a ring rolling process. In this case, the elastomeric film is stretched and contracted in the transverse direction by the meshing disk packet.

[0063] The stretching and contraction may be uniform or may vary across the width of the film. The pre-activation process may be performed with a varying pitch and / or a varying engagement depth. The pre-activation process may be performed in the machine direction or any other direction. Pre-activation by ring rolling creates visible lines on the film by local mechanical deformation caused by the meshing disks, and these lines are also known as activation stripes. The activation stripes formed on the elastic film can be seen with the naked eye.

[0064] Pre-activation of the elastomeric film has a positive effect on the stretch force profile, thereby facilitating the stretching and contracting operation of the stretchable laminate produced over a large expansion area. Further, the recovery of the stretchable laminate can also be improved by pre-activating the elastomeric film. Recovery is the ability of the stretchable laminate to return to its original dimensions after being stretched to its expansion limit. The improvement in the recovery of the elastomeric film after the pre-activation process is due to the removal of the amount of permanent strain in the film. The pre-activation of the elastomeric film is disclosed in U.S. Patent No. 11135100, which is incorporated by reference.

[0065] The elastomeric film further includes at least one film disposed on an elastically stretchable material, the film forming at least one of the film surfaces. Such a film is a stretchable material that provides the outer surface of the elastomeric film, which is less sticky than the underlying elastically stretchable material. In some embodiments, the film may also be eligible as an elastically stretchable material, but will be less stretchable than the underlying elastically stretchable material. Thus, when compared to the elastically stretchable material, the film has a lower degree of recovery from the same amount of stretch. In other words, when compared to the elastically stretchable material, the film has a greater percentage of permanent strain from the same percentage of strain. The film can assist in the processability of the elastomeric film, and the thickness is about 1 μm to about 10 μm, or about 3 μm to about 7 μm, or in some embodiments, about 5 μm. In certain embodiments, the film overlapping the elastically stretchable material in the elastomeric film is a polyolefin. Non-limiting examples of useful film materials include metallocene polyethylene, low density polyethylene, high density polyethylene, linear low density polyethylene, ultra low density polyethylene, polypropylene homopolymer, plastomeric random polypropylene / olefin) copolymer, syndiotactic polypropylene, metallocene polypropylene, polybutene, impact copolymer, polyolefin wax, and combinations thereof. Exemplary elastomeric films useful for the stretchable laminate described in detail herein (i.e., an elastically stretchable material having at least one film disposed on the surface of the elastically stretchable material) include the M18-1117 and M18-1361 elastomeric films commercially available from Clopay Corporation, Cincinnati, Ohio, the K11-815 and CEX-826 10 elastomeric films commercially available from Tredegar Film Products, Richmond, Va., and the elastomeric films commercially available from Mondi Gronau GmbH, Gronau, Germany. These exemplary elastomeric films include a single layer of elastically stretchable material with a 15 μm film disposed on both surfaces of the material.

[0066] A film suitable for this application has a film providing a first surface and a second film providing a second surface. During pre-activation, the film and the elastically stretchable material are stretched and contracted in the same manner (i.e., placed under the same strain). However, after stretching and contracting, the film and the elastically stretchable material will contract and recover differently (i.e., have different permanent strain values). Compared to the elastically stretchable material, the film has lower elasticity, so there is less recovery after stretching and contracting, i.e., the permanent strain value is larger. Also, since the film is much thinner than the elastically stretchable material, when the thicker elastically stretchable material contracts and recovers after pre-activation stretching, the attached film will also be forced to contract together. However, since the film cannot recover as well as the elastically stretchable material, the film bends and wrinkles. In the case without pre-activation, the film, and thus the outer surface of the elastomeric film, is substantially smooth in cross-section. As disclosed in U.S. Patent No. 10,485,713, due to pre-activation, the film, and thus the outer surface of the elastomeric film, is substantially wrinkled in cross-section.

[0067] The pre-activated elastic film may be advanced to a spreader mechanism including an engagement portion. The elastic film may be stretched in the transverse or machine direction to a first elongation in the spreader mechanism. Next, the elastic film is advanced from the spreader mechanism to the anvil. The anvil may include an active vacuum zone having a maximum width in the transverse direction. The elastic film is positioned in contact with the second surface of the first substrate on the anvil, and the second substrate is advanced to a position where the first surface of the second substrate contacts the elastic film and the second surface of the first substrate on the anvil. With the elastic material positioned between the first substrate and the second substrate, the first substrate is ultrasonically bonded together with the second substrate. A sonotrode may be used to ultrasonically bond the laminate. The ultrasonic bonding of the laminate imparts one or more bonding patterns as previously discussed herein. The method of manufacturing the laminate is disclosed in co-owned publications U.S. Patent Nos. 10,561,537, 10,568,776, U.S. Patent Publication No. 2021 / 0401638, and U.S. Application No. 17 / 493,098 filed on October 4, 2021, which are incorporated herein by reference.

[0068] The releasable joint may be made through various means, including reduction of joint size, reduction of joint pressure, reduction of joint nub height, and reduction of energy transfer through nub shape or geometry. The change in joint nub height can be achieved by laser metal deposition as disclosed in U.S. Patent Publication No. 2020 / 0180025.

[0069] An article comprising a laminate Referring to FIG. 10, the laminate 10 of the present disclosure 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 the chassis 120 by a chassis attachment joint 102. The chassis attachment joint may include an ultrasonic joint, an adhesive joint, a mechanical joint, or a combination thereof.

[0070] Figure 10 is a plan view of an exemplary and non-limiting embodiment of an absorbent article 100 in a flat, non-contracted state. The body-facing surface 115 of the absorbent article 100 faces the observer. The absorbent article 100 includes a longitudinal centerline 105 and a lateral centerline 110.

[0071] The absorbent article 100 includes a chassis 120. The absorbent article 100 and the chassis 120 are shown as having a first waist region 114, a second waist region 118 on the opposite side of 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 regions 114 and 118 generally include those portions of the absorbent article that surround the wearer's waist when worn. The waist regions 114 and 118 may include elastic members 155 that form gathers around the wearer's waist so as to improve the fit and containment. The crotch region 116 is the portion of the absorbent article that is generally positioned between the wearer's legs when the absorbent article is worn.

[0072] The outer peripheral portion of the chassis 120 is defined by longitudinal edges 112 and waist edges (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 that are generally oriented parallel to the longitudinal centerline 105. However, for a better fit, the longitudinal edges 112 may be curved or angled such that, for example, an article shaped like an hourglass is produced when viewed in plan view as shown in FIG. 10. The chassis 120 may have opposing lateral edges 113, 119 (i.e., the first waist edge 113 and the second waist edge 119) that are generally oriented parallel to the lateral centerline 110.

[0073] 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 the backsheet 126. In some embodiments, a capture distribution system 127 is disposed between the topsheet 126 and the absorbent core 128.

[0074] In certain embodiments, the chassis 120 includes the primary structure of the absorbent article 100, along with other features added to form a composite absorbent article structure. The topsheet 124, the backsheet 126, and the absorbent core 128 may be assembled in various well-known configurations, although the construction of absorbent articles is generally 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.

[0075] The components of the disposable absorbent article may at least partially contain a bio-source 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, a topsheet, a backsheet film, a backsheet nonwoven fabric, an ear / ear laminate, a leg gasket system, a superabsorbent, a capture layer, a core wrap material, an adhesive, a fastening system, and a landing zone. In at least one embodiment, the components of the disposable absorbent article contain a bio-based content value of about 10% to about 100%, or about 25% to about 75%, or about 50% to about 60% when using Method B of ASTM D6866-10. To determine the bio-based content of any component by applying the methodology of ASTM D6866-10, a representative sample of the component must be obtained for testing. In at least one embodiment, the components of the disposable absorbent article can be ground into particles less than about 20 mesh using a known grinding method (e.g., WILEY® mill), and a suitable mass of a representative sample can be taken from the randomly mixed particles.

[0076] The laminate 10 of the present disclosure can form one or more components of the article, including but not limited to ears, waist features, belts, and combinations thereof, or can be a part thereof.

[0077] Topsheet The topsheet 124 is generally a part of the absorbent article 100 that at least partially contacts the wearer or can be positioned more proximally. Suitable topsheets 124 can be made from a wide range of materials such as porous foams, reticulated foams, perforated plastic films, or woven or non-woven webs of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or combinations of natural and synthetic fibers. The topsheet 124 generally has a compliant and soft feel against the wearer's skin and is non-irritating. Generally, at least a portion of the topsheet 124 is liquid permeable and can easily permit liquids to permeate through the thickness of the topsheet 124. The topsheet 124 may be perforated. The topsheet may be perforated by over-bonding the material and then breaking the over-bond with a ring roll as disclosed in U.S. Patent No. 5,628,097.

[0078] Any portion of the topsheet can be coated with a skin care composition, an antibacterial agent, a surfactant, and / or other beneficial agents. The topsheet can be hydrophilic or hydrophobic, or can have hydrophilic portions or layers and / or hydrophobic portions or layers. If the topsheet is hydrophobic, there will typically be pores so that body excretions can pass through the topsheet.

[0079] Absorbent core The absorbent core 128 can include a wide variety of liquid-absorbent materials commonly used in disposable diapers and other absorbent articles. Examples of suitable absorbent materials generally include ground wood pulp, commonly referred to as airfelt crepe paper, meltblown polymers including coform, chemically hardened, modified, or crosslinked cellulose fibers, tissue paper including tissue wrappers and tissue laminates, absorbent foams, absorbent sponges, superabsorbent polymers, absorbent gelling materials, or any other known absorbent material or combination of materials. In one embodiment, at least a portion of the absorbent core is substantially free of cellulose, containing less than 10% by weight of cellulose fibers, less than 5% by weight of cellulose fibers, less than 1% by weight of cellulose fibers, trace amounts of cellulose fibers, or no cellulose fibers. It should be understood that trace amounts of cellulosic materials do not substantially affect at least one of the thickness, flexibility, and absorbency of the portion of the absorbent core that is substantially free of cellulose. Among other advantages, when at least a portion of the absorbent core is substantially free of cellulose, this portion of the absorbent core is considered to be significantly thinner and more flexible than a similar absorbent core containing more than 10% by weight of cellulose fibers. The amount of absorbent material present in the absorbent core, for example, the absorbent particulate polymer material, may vary, but in certain embodiments, it 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.

[0080] The absorbent material may be deposited as an absorbent layer having a generally rectangular profile. The layer of absorbent material may also have a non-rectangular outer perimeter ("formed" core), and in particular, the absorbent material may define a tapered (or "dogbone") shape along its width towards the central region of the core. In this way, the absorbent material deposition area may have a relatively narrow width in the area of the core intended to be disposed within the crotch region of the absorbent article. This can, for example, result in better wearing comfort. Other shapes such as a "T", or "Y", or "hourglass" can also be used for the area of the absorbent material.

[0081] In some embodiments, the absorbent core may include one or more channels 129 that are substantially free of absorbent particulate polymer material. The channels 129 may extend longitudinally or transversely. The absorbent core may further include two or more channels. The channels may be straight, curved, angled, or any possible combination thereof. By way of non-limiting example, two channels are symmetrically disposed about the longitudinal axis.

[0082] Backsheet The backsheet 126 is generally positioned such that it can be at least a portion of the surface of the absorbent article 100 facing the garment. The backsheet 126 may be joined to the topsheet 124, the absorbent core 128, and / or portions of any other layer of the absorbent article by any attachment method known to those skilled in the art. The backsheet 126 may be designed to prevent excrement absorbed by and contained within the absorbent article 100 from soiling articles, such as bedsheets and undergarments, that can come into contact with the absorbent article 100. In certain embodiments, the backsheet 126 is substantially impermeable to liquids. The backsheet may be, for example, a thin plastic film such as a thermoplastic film having a thickness of from about 0.012 mm to about 0.051 mm, or may include the same. Other suitable backsheet materials may include breathable materials that allow vapor to escape from the absorbent article while still preventing or at least inhibiting body excrement from passing through the backsheet.

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

[0084] Ear / Fastener Absorbent article 100 may include one or more ears 130, such as a front ear 132 disposed in a first waist region and / or a rear ear 134 disposed in a second waist region. The ear 130 may be integral with the chassis or may be a separate element joined to the chassis 120 at a chassis attachment joint 102 that can join one or more layers of the ear to the chassis. It should be understood that the front ear 132 and the rear ear 134 may be attached to different layers of the chassis. The ear 130 may be stretchable or elastic. The ear 130 may be formed from one or more nonwoven webs, woven webs, knitted fabrics, polymer films and elastomeric films, perforated films, sponges, foams, scrims, or any combination and / or laminate of the foregoing.

[0085] In some embodiments, the ear 130 may include an elastomer, whereby the ear is stretchable or extensible. In certain embodiments, the ear 130 may be formed of a stretchable laminate such as a nonwoven / elastomeric material laminate or a nonwoven / elastomeric material / nonwoven laminate, which also results in the ear being extensible. The ear 120 may be extensible in the lateral direction of the article. In some embodiments, the ear is elastic in the lateral direction. In further embodiments, the ear 130 may be more extensible in the lateral direction than in the longitudinal direction. Alternatively, the ear may be more extensible in the longitudinal direction than in the lateral direction. In certain non-limiting examples, the ear may include one or more inelastic regions along separate elastic regions.

[0086] In some embodiments, the ear includes a laminate of one or more nonwovens and one or more elastic materials, such as a laminate 10 having any of the features or laminate layers described herein.

[0087] Any suitable nonwoven fabric may be used in the ear portion 130. Suitable nonwoven fabrics may have a basis weight of at least about 8 gsm, or less than about 30 gsm, or about 17 gsm or less, or about 10 gsm to about 17 gsm. Typically, nonwoven fabrics with a lower basis weight reduce the overall strength of the ear portion. However, the ear portions designed in accordance with the principles herein can achieve high strength despite the lower basis weight nonwoven fabric. If the ear portion 130 includes two or more nonwoven fabrics, the nonwoven fabrics may have the same or different basis weights. Similarly, the nonwoven fabrics may have the same or different layer structures. Further, the nonwoven fabric in the ear portion may have the same or different characteristics of the nonwoven fabric in the backsheet, topsheet, leg gasket system, and / or waist features.

[0088] The ear portion may be, for example, an ultrasonic bonded ear portion as disclosed in U.S. Patent Application No. 15 / 674,559. The ear portion may be a gathered laminate 24. Alternatively, the ear portion may be activated, for example, 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 ear portion may be joined to the chassis at the chassis attachment joint 102. In some non-limiting examples, the chassis attachment joint is located in a non-elastic region of the ear portion.

[0090] Absorbent article 100 may also include a fastening system 148. When fastened, the fastening system 148 interconnects the first waist region 116 and the rear waist region 118, creating a waist perimeter that can surround the wearer during use of the absorbent article 100. The fastening system 148 may include fastening elements 150 such as, for example, tape tabs, hook and loop fastening components, tab and slot mating fasteners, buckles, buttons, snaps, and / or hermaphroditic fastening components, although any other known fastening means are generally acceptable. The absorbent article may include a landing zone where the fastening elements can engage and / or a release tape that protects the fastening elements from damage 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 mating 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 to any suitable portion of the article 100 by any suitable means. The fastening system may be joined to the ears between layers.

[0092] Leg gasket system Absorbent article 100 may include a leg gasket system 170 attached to chassis 120, and the leg gasket system 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 of a single piece of material coupled to the absorbent article, and thus can extend upwardly from the surface facing the wearer of the absorbent article and can provide improved containment of fluids and other bodily excretions near the junction of the wearer's torso and legs. The barrier leg cuff is bounded by a proximal edge directly or indirectly joined to topsheet 124 and / or backsheet 126 and a free edge 175 intended to contact the wearer's skin and form a seal. In some embodiments, free edge 175 includes a folded edge. Barrier leg cuff 172 extends at least partially between front waist edge 113 and rear waist edge 119 of the absorbent article on opposite sides of longitudinal centerline 105 and is at least present within the crotch region. The barrier leg cuff may be joined to the chassis of the article at the proximal edge by a join that can be effected by adhesion, heat sealing, or a combination of other suitable joining processes.

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

[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 the 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 absorbent article chassis between the topsheet 124 and the backsheet 126 at the area of the leg opening. All or a portion of the barrier leg cuffs and / or the gasket cuffs may be treated with a lotion or another skin care composition.

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

[0096] Elastic Waist Feature As shown in FIG. 10, the absorbent article 100 may include at least one elastic waist feature 180 that serves to provide an improved fit and containment. The elastic waist feature 180 is generally intended to contract and dynamically fit the wearer's waist. The stretchable waist feature includes a waistband, a waist cuff having a pocket formed from a portion of the waist feature 180 that is removed from the chassis 120, and a waist panel designed to fit snugly around the wearer's abdomen. Non-limiting examples of stretchable 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 in the first waist region 114 and / or the second waist region 118. The waist feature may be used in combination with the ear 130 to provide the desired stretch and flexibility for properly fitting the article to the wearer. The waist feature may include a laminate 10 having any of the features described herein. The waist feature may be extensible or elastic in the transverse and / or longitudinal directions. In some embodiments, the waist feature 180 includes a belt 220. The waist feature may be attached to the chassis at the waist feature junction 182.

[0097] Absorbent article for adult or infant pants In some embodiments, article 100 may include absorbent pant 300 as shown in FIGS. 11A and 11B. The absorbent pant may include chassis 120, belt 320 positioned around the wearer's waist, and optionally leg gasket system 170. FIG. 11B depicts an exemplary front body structure of the pant of FIG. 11A in an open configuration that is laid flat and stretched laterally against elastic induced contraction. In the final assembly of the pant, the front belt portion 322 is joined to the rear belt portion 323 at seam 324, which may be permanent or re - fastenable. To form pant 300, the front body structure is folded at or around the lateral centerline 110 such that the topsheet 124 faces inward, and the longitudinal edges of the front 322 and rear 323 belt portions are joined at seam 324 to form a pant structure having leg openings, a front waist edge, and a rear waist edge. Thus, pant 300 may include a pre - formed continuous waist opening and a pre - formed continuous leg opening for the wearer when the pant 300 is worn.

[0098] Front belt portion 322 and rear belt portion 323 may be the outermost structures that form the front and rear regions of pant 300. The pant may include outer wrap 326 that wraps around the entire front region, crotch region, and rear region and forms the outermost pant - shaped structure. In some embodiments, the outer cover of the backsheet forms the outer wrap. Outer wrap 326 may be formed from one or more sections of non - woven web and, if desired, may be cut into a contour that provides a preferably adjusted contour of the leg opening edge.

[0099] Belt 320 may include laminate 10 of the present disclosure having any of the aforementioned features including one or more non - woven layers and one or more elastomeric layers. The laminate layers may be joined by ultrasonic bonding.

[0100] According to some non - limiting examples, the non - woven fabric used for the belt portion may include a material that provides good recovery when external pressure is applied and removed.

[0101] The elastomeric layer of the lumbar features such as the belt portion may include one or more elastic members 155. The elastic member 155 may be an elastomeric fiber such as LYCRA® fiber available from INVISTA (Wichita, KS) at various denier levels. The elastic member 155 may also include any thermally shrinkable elastic material well known in the art. Other suitable elastomers include, but are not limited to, rubber, styrene-ethylbutylene-styrene, styrene-ethylene-propylene-styrene, styrene-ethylene-propylene-styrene, styrene-butadiene-styrene, styrene-isoprene-styrene, polyolefin elastomer, elastomeric polyurethane, and other elastomeric materials known in the art, and combinations thereof. In some non-limiting examples, the elastic member may be an extruded strand elastomer having any number of strands (or filaments). In some embodiments, the elastic member may have a denier in the range of 50 to 2000, or any integer value for any denier value within this range. One skilled in the art may select an appropriate denier based on the desired amount of shrinkage and other principles discussed herein. In a further embodiment, the elastic member may be in the form of a film. Examples of the film are described in prior patent applications (see, for example, U.S. Patent Application Publication No. 2010 / 0040826). This film can be made using various resins combined in at least one of several sub-layers, thereby providing different benefits to the film.

[0102] In addition, the elastic member 155 may take a plurality of configurations. For example, the width may vary, a single strand or a plurality of parallel or non-parallel strands of the elastic material may be used, or various shapes including straight and curved lines may be used, or various cross-sectional shapes may be used (circular, rectangular, square, etc.).

[0103] The waist features (e.g., the belt portion) and / or the layers of the chassis 120 may be joined together around the elastic strands 155 by an adhesive deposited between the layers, by thermal bonding, by compression bonding, or by a combination thereof. In other examples, one or more elastic members may be strips or pieces of film formed from an elastomeric material. When the elastic member is elongated, it may be desirable for the strand 155 to have its longer dimension oriented transversely, or to be substantially aligned transversely, as depicted, for example, in FIG. 11B.

[0104] The belt portion or other form of the 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.

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

[0106] During manufacture of the waist feature, the elastic member 155 may be pre-strained by a desired amount when incorporated into the waist feature. Upon subsequent relaxation of the waist feature, the elastic members will contract laterally towards their unstrained lengths. This may cause gathers in the layers of the waist feature, generally forming wrinkles or pleats having raised and valley portions extending in the z-direction across the length of the elastic member 155.

[0107] In a further embodiment, the elastic members may be individually coated with an adhesive (a "strand coating") prior to incorporation into the waist laminate in order to adhere the components of the waist feature laminate. A variety of coating methods and techniques, including strand coating methods and techniques, are shown, for example, in U.S. Pat. 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 an elastic and flexible hot melt type adhesive (such as OMNIMELT BLOCKS22H2401F available from Bostik, Inc. (Wauwatosa, Wisconsin), or ZEROCREEP (trademark) such as AVANCE) that is suitable for attaching a pre-strained elastic material to a substrate.

[0108] In certain embodiments, as suggested in FIG. 11B, the corners of the front belt portion and / or the rear belt portion may be cut off. The corners may be cut along a straight line or along a cut-off path that is curved concave or convex with respect to the remaining area of the belt portion, so as to desirably result in the contour of a particular curved leg edge. Such cutting as described above, in combination with the configuration of the elastic strands, may desirably provide an interlayer bond along the edges of each belt portion 322, 323. Such a bond can be used to prevent any separation of the layers along the edges, which can contribute to a non-uniform appearance, and can also help to efficiently pull the rear belt portion laterally inwardly towards the central chassis 120 under the contraction force of the elastic strands below the seam 324. The bond can act, for example, by mechanical bonding / compression bonding as described in U.S. Pat. Nos. 4,854,984 and 4,919,738, by thermal bonding or welding, or by deposition of an adhesive between the layers. In non-limiting examples, such a bond may form a pattern along the edge. Such a bond may generally supplement any bond between the layers that holds the respective belt portions 322, 23 together as a laminate structure.

[0109] The side seam 324 can be permanent or reattachable. A permanent seam can be formed between the front belt portion and the rear belt portion by any joining mechanism, and the front and rear belt portions cannot be forcibly separated without causing significant damage to one or both of the front and rear belt portions, or without including a mechanism that would allow substantial reattachment or refixing. The joining that forms a permanent seam can include compression joining, thermal joining / welding, ultrasonic joining, or adhesive joining. A reattachable seam can be formed between the front belt portion and the rear belt portion by any mechanism configured to allow substantial non-destructive forced separation of the front and rear belt portions and subsequent substantial reattachment or refixing at the same location. An example of such a mechanism is a hook-and-loop fastening system, such as the VELCRO fastening system. Hook components of suitable size and shape may be joined to one of the front or rear belt portions along its longitudinal edge at a location where they can engage together to form the seam 224, and may also be joined to the other of the front or rear belt portions along its longitudinal edge. Examples are depicted in U.S. Patent Application Nos. 61 / 787,416, 61 / 787,332, and 61 / 666,065.

[0110] Exemplary belt and absorbent pant structures are disclosed in U.S. Patent Application 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 a polymer film, paper, and / or other materials. Graphics and / or markings regarding the characteristics of the absorbent article may be formed, printed, positioned, and / or arranged on the outer portion of the package. Each package may include a plurality of absorbent articles. The absorbent articles may be packaged under compression to reduce the size of the package while still providing a sufficient amount of absorbent articles per package. By packaging the absorbent articles under compression, caregivers can easily handle and store the packages, and manufacturers can also reduce distribution costs due to the size of the packages.

[0112] The package may include a polymer film containing recycled materials, such as about 20% to about 100%, about 30% to about 90%, about 30% to about 80%, about 40% to about 60%, or about 50% recycled materials. The recycled materials may include post-industrial recycled materials (PIR) and / or post-consumer recycled materials (PCR). In some cases, the polymer film used for the package may include two outer layers and one or more inner layers. The one or more inner layers may include recycled materials or may include more recycled materials than the outer layers. The recycled materials may include recycled polyethylene. The recycled materials may include recycled polyethylene PIR from cuttings from the packaging operation.

[0113] The packaging material may include paper, paper-based materials, paper having one or more barrier layers, or a paper / film laminate. The packaging material may be in the range of about 50 gsm to about 100 gsm or about 70 gsm to about 90 gsm, and one or more barrier layers may be in the range of about 3 gsm to about 15 gsm. With or without one or more barrier layers, the paper-based packaging material may exhibit a machine direction tensile strength of at least 5.0 kN / m, a machine direction elongation of at least 3 percent, a machine cross direction tensile strength of at least 3 kN / m, and a cross direction elongation at break of at least 4 percent, each as determined by ISO 1924-3.

[0114] Paper-based packaging materials or paper-based packaging materials containing a barrier layer or film may be recyclable or recyclable in normal paper recycling operations. The degree of recyclability of paper-based packages can be determined by the recyclable percentage. The paper-based packages of the present disclosure may exhibit a recyclable percentage of 70% or more, 80% or more, or 90% or more. The paper-based packages of the present disclosure may have a recyclable percentage of from about 70% to about 99.9%, from about 80% to about 99.9%, or from about 90% to about 99.9%. In one example, the packaging materials of the present disclosure may exhibit a recyclable percentage of from about 95% to about 99.9%, from about 97% to about 99.9%, or from about 98% to about 99.9%. The recyclable percentage of paper-based packages can be determined by the Category II test PTS-RH:021 / 97 (Draft October 2019) conducted by the Papiertechnische Stiftung located at Pirnaer Strasse 37, 01809 Heidenau, Germany. In another example, the paper-based packages of the present disclosure may exhibit an overall "pass" test result when determined by PTS-RH:021 / 97 (Draft October 2019) of the Category II method. Any of the paper-based packages may have an opening feature such as a perforation and may also have a handle.

[0115] Accordingly, the package of the absorbent article of the present disclosure may have a stacking height within the bag 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, in accordance with the in-bag stacking height test described herein. Alternatively, the package of the absorbent article of the present disclosure may have an in-bag stacking height of from about 70 mm to about 110 mm, from about 70 mm to about 105 mm, from about 70 mm to about 100 mm, from about 70 mm to about 95 mm, from about 70 mm to about 90 mm, from about 70 mm to about 85 mm, from about 72 mm to about 80 mm, or from about 74 mm to about 78 mm, in accordance with the in-bag stacking height test described herein.

[0116] FIG. 12 illustrates an exemplary package 1000 that includes a plurality of absorbent articles 1004. The package 1000 defines an internal space 1002 in which the plurality of absorbent articles 1004 are placed. The plurality of absorbent articles 1004 are arranged as one or more stacks 1006.

[0117] Test method Bond dimension test method Using the joint dimension test method, various dimensions of permanent joints and releasable joints in the laminate are measured. This test measures the size of the joint (joint size) and the distance between adjacent joints (joint separation distance), as illustrated in FIG. 13. For the purposes of this method, a joint is an intentional joining of two or more layers and is the deformed region that occurs during the joining process (e.g., the joint site or the reduced caliper in the fused fibers or fused thermoplastic material). The dimensional measurements are determined from an image of the joined laminate and are obtained using an image capture tool (microscope, camera, or similar image capture tool) and image analysis software. An image of the joined laminate is captured while the laminate is fully stretched. In the case of a corrugated laminate, 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. In the case of a non-corrugated laminate, the specimen is considered to be fully stretched without such stretching while lying flat. Prior to the test, the sample / test specimen is pre-conditioned for 2 hours under the same environmental conditions at approximately 23°C ± 2°C and approximately 50% ± 2% relative humidity.

[0118] In this method, a "unit cell" is the smallest pattern that includes both permanent joints and releasable joints and, when repeated through a combination of translation, reflection, and rotation, creates the entire joint pattern being investigated. Within the captured image, the unit cell is identified and both the permanent joints and releasable joints are distinguished and identified within the unit cell pattern. If the permanent joints and releasable joints cannot be distinguished by inspection, the joint ratio test method is used to investigate similar unit cells to distinguish the permanent joints from the releasable joints.

[0119] The joint dimensions in the stretch and longitudinal directions are measured for a selected unit area. The joint size in the stretch or transverse direction and in the longitudinal direction perpendicular to the transverse direction is defined as the shortest (minimum) straight-line distance of the joint region (i.e., the deformed region) in the transverse and longitudinal directions, respectively.

[0120] For permanent bonding sites, using the captured images of unit bubbles, measure and record the bond size measurements in the expansion / contraction direction and measure and record the bond size measurements in the longitudinal direction. Similarly, for releasable bonding sites, using the captured images of unit bubbles, measure and record the bond size measurements in the expansion / contraction direction and measure and record the bond size measurements in the longitudinal direction. Repeat this procedure for a total of three unit bubbles. Calculate and report the arithmetic mean of the recorded values and report them as the bond sizes of the permanent and releasable bonding sites. Report the values rounded to the nearest 0.1 mm.

[0121] The bond separation distance is defined as the shortest (minimum) straight-line distance between any two individual bonding sites (either permanent or releasable bonding sites). As illustrated in Figure 13, determine the positions around the first bonding site and around the second different bonding site and measure the shortest straight-line distance between the perimeters. Record the value and repeat for a total of three unit bubbles. Calculate and report the arithmetic mean of the recorded values and report them as the bond separation distance rounded to the nearest 0.1 mm.

[0122] Peeling force test method The peel force test method is used to determine the force associated with separating and peeling the top and bottom layers of a laminate sample. A suitable tensile testing machine such as an MTS model Alliance RT / 1 equipped with TestWorks4 (registered trademark) software or equivalent is used. The tensile testing machine is placed in a temperature-controlled chamber at 23°C ± 2°C and a relative humidity of 50 ± 10%. Calibrate the instrument according to the manufacturer's instructions. The data acquisition speed is set to at least 50 Hertz. The gripping part used in the test is wider than the test piece. For example, a gripping part with a width of 50.8 mm may be used. The gripping part is a pneumatic gripping part with one flat surface and an opposing surface designed to concentrate the total gripping force along a single line perpendicular to the direction of the test stress. From the opposing surface, a semi-circular shape (radius = 6 mm, for example, part number: 56-163-827 from MTS Systems Corp.) that minimizes the slippage of the test piece protrudes, or an equivalent gripping part. The load cell is selected such that the measured force is between 5% and 95% of the capacity of the load cell used. The initial distance (gage length) between the lines of the gripping force is adjusted according to the sample permanent strain. Zero the load reading on the instrument to correct for the mass of the fixture and the gripping part.

[0123] Identify the corrugated or stretchable portion on an absorbent article product having a bonding pattern that includes releasable joints or secondary joints. Collect at least four test pieces that include the releasable joints and cut them from the same portion of the same absorbent article product so that the test pieces are not damaged during the separation process. The stretch direction of the test piece is the direction in which the test piece is intended to stretch and contract in the product. Cut test pieces that are 25 mm in the stretch direction and at least 40 mm in a direction perpendicular to the stretch direction, or as close to 40 mm as possible if at least 40 mm cannot be obtained. The test pieces are carefully cut from the absorbent article from the corrugated or stretchable portion of the laminate. Prior to testing, condition the test pieces for 2 hours under the same environmental conditions at approximately 23 °C ± 2 °C and approximately 50% ± 2% relative humidity. Starting from one of the ends of the test piece, separate the first substrate layer from the remaining layers of the laminate at the bonding joint without damaging the layers until enough of the test piece is separated so that the test piece can be attached to the gripping portion. The first substrate can be the upper or bottom substrate layer of the laminate. The first substrate is attached to one of the gripping portions and the remaining layers are attached to the other gripping portion.

[0124] Attach the test piece to the gripping part so that there is no sag and the measured load is between 0.00 N and 0.02 N. Attach the test piece to the center of the gripping part so that it is parallel to the tensile stress applied in the test piece peeling direction perpendicular to the expansion and contraction direction. Place the test piece between the gripping parts so that the first gripping part holds the first substrate and the second gripping part holds the second substrate, thereby peeling the first substrate from the second substrate in the 180° peeling direction. If the test piece size is smaller or larger, other dimension bonded test pieces may be used for the peel force test method; however, those skilled in the art should recognize that the effective bonding area should continue to be at the center of the test piece. Start the peel test and stretch the test piece at 127 mm / min at a data acquisition rate of at least 50 Hz until the test piece is completely separated. The peel force (N) is averaged from 5 mm after the start of crosshead movement to at least 5 mm before the end of crosshead movement, which is reported as the test piece peel force (N). The peel force (N) is typically averaged over a movement of at least 30 mm. The test piece peel force (N / cm) is calculated using the following formula.

[0125]

Number

[0126] For test pieces tested according to the specified dimension method, the width of the test piece is equal to 1 inch or 2.54 cm.

[0127] Record the arithmetic mean of the test piece peel forces (N / cm) for the four test pieces as the average peel force (N / cm) for either the topmost or bottommost layer.

[0128] The peeling procedure is performed for both the topmost and bottommost layers of the laminate. Report the larger value between the average peel force of the topmost layer and the average peel force of the bottommost layer, rounded to the nearest 0.01 N / cm, as the peel force of the laminate.

[0129] To calculate the releasable joint peel force, a test piece is cut that is wider than the width of the releasable joint, contains only the releasable joint, and is long enough to allow the 40 mm travel distance required by the above-described peel test method. The peel procedure is also performed for both the top and bottom layers of the laminate. The smaller of the average peel force of the top layer and the average peel force of the bottom layer is rounded to the nearest 0.01 N and reported as the peel force of the releasable joint. For the releasable joint peel force, the peel force is normalized and recorded as N per average number of joints. The number of joints per width in the test piece is calculated as follows. Starting from a joint site on the test piece, draw a straight line in the primary stretch direction (the test piece width direction and within 5 degrees of the angle). Count the number of joint sites that the line intersects. Repeat three times, drawing the line from a different joint site each time. Record the number of joints that each line intersects and round the arithmetic mean to the nearest 0.1 joint unit as the average number of joints per width. The releasable joint peel force is calculated using the following formula.

[0130] [Number]

[0131] The arithmetic mean of the releasable joint peel forces (N / joint) from four test pieces is rounded to the nearest 0.01 N / joint and recorded as the average releasable joint peel force (N / joint).

[0132] Hysteresis Test Method The hysteresis test method is used to characterize a specific strain or load value after being subjected to a cycle of stretching. The hysteresis test is performed using a commercially available tensile testing machine (e.g., manufactured by Instron Engineering Corp. (Canton, MA), SINTECH - MTS Systems Corporation (Eden Prairie, MN), or equivalent). The test is conducted under laboratory conditions of 23°C ± 2°C and relative humidity 50% ± 2%. The test pieces are conditioned 24 hours before the test.

[0133] Identify the corrugated or stretchable portion on an absorbent article product having a bonding pattern including releasable joints and permanent joints. Cut test specimens from the region of the absorbent article product to the dimensions listed in the following table for the test being conducted.

[0134] Test Protocol 1. Select a suitable gripping part and load cell. The gripping part must have one flat surface and must be wide enough to grip the test specimen along its entire width. Also, the gripping part must provide sufficient force and a suitable surface area to ensure that the test specimen does not slip during the test. The gripping part is a pneumatic gripping part having one flat surface and an opposing surface designed to concentrate the total gripping force along a single line perpendicular to the direction of the test stress. From the opposing surface, a semi-circular shape (radius = 6 mm, for example, part number: 56 - 163 - 827 from MTS Systems Corp.) that minimizes slippage of the test specimen protrudes, or an equivalent gripping part. The load cell is selected such that the tensile response from the test specimen being tested is between 5% and 95% of the load cell capacity used. Calibrate the testing machine according to the manufacturer's instructions. 2. Set the distance (gage length) between the gripping parts for each test conducted (see the following table). 3. Place the test specimen on the flat surface of the gripping part so that its uniform width is positioned along a direction perpendicular to the gage length direction. Attach the test specimen such that the stretching direction of the test specimen becomes the test direction. Fix the test specimen with the upper gripping part, allow the test specimen to hang slack, and then close the lower gripping part. 4. Preload: Set the preload at 0.05 N / in of sag and set the preload crosshead speed at 13 mm / min. This means that data collection starts when the sag is removed with a force of 0.05 N / in (at a constant crosshead speed of 13 mm / min). The strain is the adjusted gage length (l), which is the length of the test specimen between the gripping parts of the tensile testing machine at a force of 0.05 N / in. ini) is calculated based on this. This adjusted gauge 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 gauge length, multiplied by 100 and divided by the adjusted gauge length. 5(a). First cycle loading: Pull the specimen to a given end point (load or strain) at a constant crosshead speed defined in the following table for the test. Report the length l of the elongated specimen between the grips max as such. 5(b). First cycle unloading: Hold the specimen at the end point of step 5(a) for 30 seconds, then return the crosshead to its starting position (0% strain or initial specimen length, l ini ) at the constant crosshead speed defined in step 5(a) above. 5(c). Hold the specimen in a relaxed state for 1 minute. 5(d). Second cycle: Repeat steps 5(a) and 5(b).

[0135]

Table 1

[0136] Record the force applied to the specimen during the test as a function of the applied strain. From the generated data, collect and report the following quantities. i. The specimen length l between the grips at a preload sag of 0.05 N / in, rounded to the nearest 0.01 mm ini ). ii. The specimen length l between the grips on the first cycle at a given strain or a given force, rounded to the nearest 0.01 mm max ). iii. The specimen length l between the grips at a second cycle loading force of 0.05 N / in, rounded to the nearest 0.001 mm ext ). iv. For the laminate performance test setup, the force at 50% strain during the first load cycle, rounded to the nearest 0.01 N / in (reported as the load force at 50%). v. Regarding the laminate performance test settings, the force at 50% strain during the second unloading cycle, rounded to the nearest 0.01 N / in (reported as the unloading force at 50%).

[0137] The percentage of permanent strain is rounded to the nearest 0.01% and is defined as ((l ext -l ini ) / (l max -l ini ) * × 100%.

[0138] Repeat the test for three separate samples and report the arithmetic mean.

[0139] Laminate stretching test method The stretching of the laminate (such as the ear, waist, cuff, etc.) is measured using a constant-speed stretching tensile testing machine such as the MTS Alliance. Set up the equipment and pre-condition the test piece according to the above hysteresis test method. The test is conducted under laboratory conditions of 23°C ± 2°C and relative humidity 50% ± 2%. Condition the test piece 24 hours before the test.

[0140] Identify the corrugated or stretchable part on the absorbent article product having a bonding pattern including releasable joints and permanent joints. Cut the test piece from this area of the absorbent article product to the dimensions listed in the following table. Measure the stretching of the laminate using the dimensions, gauge length, and test speed of the test piece listed in the following table.

[0141]

Table 2

[0142] Test protocol: 1) Select a suitable gripping part and load cell. The gripping part must have one plane and be wide enough to grip the test piece along its entire width. Also, the gripping part should provide sufficient force and a suitable surface area to ensure that the test piece does not slip during the test. The gripping part is a pneumatic gripping part with one flat surface and an opposing surface designed to concentrate the total gripping force along a single line perpendicular to the direction of the test stress. From the opposing surface, a semi-circular shape (radius = 6 mm, for example, part number: 56-163-827 from MTS Systems Corp.) that minimizes the slippage of the test piece protrudes, or an equivalent gripping part. The load cell is selected such that the tensile response from the test piece being tested is between 5% and 95% of the load cell capacity used. Calibrate the testing machine according to the manufacturer's instructions. 2) Set the distance (gage length) between the gripping parts as described in the table. 3) Place the test piece on the flat surface of the gripping part such that the uniform width is positioned along a direction perpendicular to the gage length direction. Attach the sample so that the expansion and contraction direction of the sample becomes the test direction. Fix the test piece with the upper gripping part, let the test piece hang in a slack state, and then close the lower gripping part. 4) Preload: Set the preload with a sag of 0.05 N per inch and set a preload crosshead speed of 13 mm / min. This means that data collection starts when the sag is removed with a force of 0.05 N per inch (at a constant crosshead speed of 13 mm / min). Strain is calculated based on the adjusted gage length (l ini ) which is the length of the test piece between the gripping parts of a tensile testing machine with a force of 0.05 N per inch. Take this adjusted gage length as the initial test piece 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 and multiplied by 100. 5) If specified, pull the test piece to the end point at the test speed or, otherwise, pull the test piece to break at the test speed. Breakage is defined as a sudden drop in force of at least 50%.

[0143] From the data, determine the elongation at a force of 0.5 N / in, the elongation at a force of 1.5 N / in, the elongation at a force of 4 N / in, the elongation at the break point, and the break point load. The elongation is defined as (the length of the test piece between the gripping parts at a given force - l ini ) and is recorded rounded to the nearest 0.1 mm.

[0144] Record the break point load rounded to the nearest 0.01 Newton.

[0145] For each product example, test five replicate test pieces. For each of the four test pieces, report the average elongation at a force of 0.5 N / in, the average elongation at a force of 1.5 N / in, the average elongation at a force of 4 N / in, the average elongation at the break point, and the average break point load.

[0146] Bond ratio test method Prepare the test piece according to the laminate elongation test method. Identify the regions containing the permanent joints and the releasable joints.

[0147] Test the test piece according to the above laminate elongation test method, and the end point of step 5 of the method is defined in the following table.

[0148] [Table 3]

[0149] After pulling the test piece to the desired elongation or the desired force, hold the test piece in that state. Visually examine the joints in the stretched test piece. Record the number of released joints as the releasable joints and the number of joints that were not released as the permanent joints.

[0150] Test four test pieces. For each test piece, record the number of releasable joints and the number of permanent joints. The bond ratio for each test piece is calculated by dividing the number of permanent joints by the number of releasable joints. The average bond ratio is determined by calculating the average (arithmetic mean) of the individual bond ratios for each of the four test pieces. Record the bond ratio and the average bond ratio rounded to the nearest 0.1 unit.

[0151] Air Permeability Test Method Determine the air permeability of a laminate or substrate (e.g., film, nonwoven fabric, or component of an article) by measuring the flow rate of air at standard conditions through a test specimen, driven by a specific pressure drop. This test is particularly suitable for materials with relatively high gas permeability such as nonwoven fabrics and perforated ear laminates. Modify as follows and use ASTM D737.

[0152] Use a Textest FX 3300 instrument or equivalent available from Textest AG, Switzerland, or Advanced Testing Instruments ATI, Spartanburg SC, USA). Perform the procedures described in the airtightness test and in the function and calibration checks in the operating instructions of the Textest FX 3300 air permeability tester manual. When using different instruments, follow the same regulations regarding airtightness and calibration according to the manufacturer's instructions.

[0153] Cut the test specimen from an absorbent article portion that includes releasable and permanent joints. The test specimen is tested while in a relaxed state, and the area to be tested should include the releasable and permanent joints.

[0154] The test is performed using a test head with an area of 5 cm 2 The pressure drop is adjusted to obtain a stable reading. Record the results to three significant figures. Calculate the average (arithmetic mean) of five test specimens and report the air permeability value in m 3 / m 2 / min).

[0155] In - Bag Stacked Height Test Method Measure the in - bag laminate height of a package of absorbent articles as follows.

[0156] Equipment A thickness tester with a flat and rigid horizontal sliding plate is used. The thickness tester is configured such that the horizontal sliding plate is always maintained in a horizontal orientation immediately above a flat and rigid horizontal base plate and is free to move in the vertical direction. The thickness tester includes a device suitable for measuring the gap between the horizontal sliding plate and the horizontal base plate 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 gram (8.34 N) to the absorbent article package, which can be achieved by placing a suitable weight at the center of the upper surface of the horizontal sliding plate that does not contact the package so that the total mass of the sliding plate plus the additional weight is 850 ± 1 gram.

[0157] Test Procedure The absorbent article package is equilibrated at 23 ± 2 °C and 50 ± 5% relative humidity before measurement.

[0158] Raise the horizontal sliding plate and place the absorbent article package at the center under the horizontal sliding plate so that the absorbent article within the package is in a horizontal orientation (see Figure 12). Fold any handles or other packaging mechanisms on the surface of the package that would contact either plate flat against the surface of the package to minimize the effect on the measurement. Slowly lower the horizontal sliding plate until it contacts the upper surface of the package and then release it. Measure the gap between the horizontal plates within ±0.5 mm 10 seconds after releasing the horizontal sliding plate. Measure five identical packages (packages of the same size and the same number of absorbent articles) and report the arithmetic mean as the package width. Calculate "stacked height in bag" = (package width / number of absorbent articles per stack) × 10 and report it within ±0.5 mm.

[0159] The dimensions and values disclosed in this specification 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 the functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm". Further, for all numerical ranges specified in this application, it is to be understood that the range includes all numerical increments within the recited range and all ranges formed therein or thereby. For example, the numerical increment can be 0.1 mm, 1 gsm, and / or 0.1 mm 2 can be.

[0160] All documents cited in this specification, including any patents or patent applications that are cross-referenced or related, and any patent applications or patents for which this application claims priority or the benefit thereof, are hereby incorporated by reference in their entirety to the extent not expressly excluded or otherwise limited. The citation of any document is not to be construed as an admission that it is prior art to any invention disclosed or claimed in this specification, or that it alone or in combination with any other reference(s) teaches, suggests, or discloses any such invention. Further, 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 given to the term in this document shall prevail.

[0161] Although specific embodiments of the present disclosure have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is intended that all such changes and modifications within the scope of the invention be covered by the appended claims.

Claims

1. An absorbent article comprising: a topsheet; a backsheet; an absorbent core disposed between the topsheet and the backsheet; at least one elastic ear portion comprising a laminate having an elastomer layer and a nonwoven layer; wherein the laminate has a plurality of discrete primary ultrasonic bonding portions and a plurality of secondary ultrasonic bonding portions, the elastomer layer and the nonwoven layer are permanently attached by the primary ultrasonic bonding portions, and remain releasably attached by the secondary ultrasonic bonding portions, and the secondary ultrasonic bonding portions release when the laminate is stretched more than about 5 mm in the stretch direction.

2. The absorbent article of claim 1, wherein the bonding ratio is greater than about 1.

3. The absorbent article of claim 1, wherein the plurality of primary discrete ultrasonic bonding portions are greater in number than the plurality of secondary ultrasonic bonding portions.

4. The absorbent article according to any one of claims 1 to 3, wherein the laminate peel force is 0.3 N / cm or more.

5. The absorbent article according to any one of claims 1, wherein the at least one elastic ear portion includes a first portion and a second portion opposite the first portion, and the first portion of the at least one elastic ear portion is joined to at least one of the topsheet and the backsheet at a chassis attachment joint.

6. The absorbent article of claim 5, wherein the plurality of secondary ultrasonic bonding portions do not overlap the chassis attachment joint.

7. The absorbent article according to any one of claims 1 to 6, wherein at least a portion of the plurality of secondary ultrasonic bonding portions are released when the absorbent article is first applied to a wearer.

8. The absorbent article according to any one of claims 1 to 7, wherein the plurality of secondary ultrasonic bonding portions are uniformly distributed across the laminate.

9. The absorbent article according to any one of claims 1 to 8, wherein the plurality of primary ultrasonic bonding portions form one or more independent bubble units, and at least a portion of the secondary ultrasonic bonding portions are disposed within the one or more independent bubble units.

10. The absorbent article according to any one of claims 1 to 9, wherein the primary ultrasonic bonding portions form a bonding pattern upon release of the plurality of secondary ultrasonic bonding portions.

11. The absorbent article according to any one of claims 1 to 10, wherein the elastomer layer is pre-activated.

12. The absorbent article according to any one of claims 1 to 11, wherein the laminate includes one or more holes.

13. The absorbent article according to any one of claims 1 to 12, wherein the nonwoven layer of the laminate includes at least one of a spunbond nonwoven fabric, a carded nonwoven fabric, a hydroentangled nonwoven fabric, an air-through bonded nonwoven fabric, and a spunlace nonwoven fabric.

14. The absorbent article according to any one of claims 1 to 13, wherein the laminate has a plurality of waveforms.

15. An absorbent article, comprising: a topsheet; a backsheet; an absorbent core disposed between the topsheet and the backsheet; and at least one elastic ear portion including a laminate having an elastomer layer and a nonwoven layer, wherein the laminate has a plurality of separate primary ultrasonic bonding portions and a plurality of secondary ultrasonic bonding portions, the elastomer layer and the nonwoven layer are permanently attached by the primary ultrasonic bonding portions, and remain releasably attached by the secondary ultrasonic bonding portions, and the secondary ultrasonic bonding portions are released when the laminate is stretched with a force of at least 0.5 N / in in the stretching direction.

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