Array of absorbent articles having ultrasonically bonded stretch laminates

Abstract

An array comprising at least two absorbent articles manufactured by the same manufacturer and / or sold under the same brand name, each having a side member made of ultrasonically bonded laminate. The ultrasonically bonded laminates in the absorbent articles differ and are distinguishable by two or more characteristics selected from ultrasonic bond geometry, ultrasonic bond pattern, presence of frangible bonds, elastic film basis weight, first nonwoven primary bond pattern, and first nonwoven basis weight. At least one dimension of the first absorbent article may also differ from at least one dimension of the second absorbent article.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to arrays of absorbent articles, and more particularly to arrays of absorbent articles that include ultrasonically bonded stretch laminates. [Background technology]

[0002] Despite the increasing complexity, manufacturers of disposable absorbent articles are investing in multiple brands, tiers, and size lineups. Manufacturers are investing to better meet the wide and ever-evolving range of consumer desires across an infant's life cycle, along with affordability points. Therefore, it becomes important to provide product features that allow differentiation across both sizes and tiers, for clear functional benefits and noticeable cues that signal underlying performance differences. However, consumers are known to be constantly on the go, and in today's world, consumers are finding themselves less attentive and less sensitive to differences, even in everyday household products that they constantly interact with. This makes it imperative for manufacturers to increase their investment in visibility.

[0003] Among the key product features of disposable absorbent articles, such as diapers and pants, is the fundamental need for comfort and fit. The latter, judged both at initial application and during wear, is typically achieved through a product feature that is extensible (i.e., stretchable). One way manufacturers attempt to balance the competing concerns of proper fit and variations in body type is through the use of expandable materials. Such a group of materials is known as stretch laminates. As the name suggests, these materials are actually composites of individual components laminated or bonded together.

[0004] In recent years, the commercialization of ultrasonically bonded laminates has been encouraged by the absorbent goods industry. These tension engines or members are simpler in construction, offering cost and complexity advantages, as they can eliminate the need for adhesives that require hardware, frequent cleaning, and contribute to ongoing costs and malodor in the product. Importantly, these simpler tension engines are subject to the same distinctiveness requirements as any other product feature or component.

[0005] Ultrasonically bonded laminates can be used, for example, as the front or back ears of tape-type diapers or as front or back side panels of pants. The front or back ears and side panels require different characteristics to accommodate brand, tier, and size lineups. Summary of the Invention [Problem to be solved by the invention]

[0006] Therefore, a need exists for improved design flexibility to support brand, tier, and size lineups without introducing complexity that offsets the bare-bones nature of ultrasonic lamination systems.

[0007] A discussion of deficiencies and needs existing in the art prior to the present disclosure is not intended to be an admission in any way that such deficiencies and needs were recognized by those skilled in the art prior to the present disclosure. [Means for solving the problem]

[0008] Various embodiments solve the above-mentioned problems and provide an array of absorbent articles that are useful for distinguishing absorbent articles made by the same manufacturer and / or sold under the same brand name. An array of products containing ultrasonically bonded laminates can be produced, with the laminates differing by at least two or more specific variables. Contrary to expectations, it has been unexpectedly discovered that varying only one variable may not result in meaningful differentiation for consumers. Sometimes, a single variable may result in a difference that is noticeable only in a direct side-by-side comparison, which is insufficient for strong brand and hierarchy positioning. While a wide range of variations are possible, the added complexity primarily offsets the benefits of having a simple ultrasonically treated laminate structure.

[0009] Thus, an array according to the present disclosure maximizes design flexibility for best-in-class fit and comfort for consumer characteristics while avoiding added complexity. Such an array may include a first absorbent article including a first elastic side member and a second absorbent article including a second elastic side member. Each of the first and second elastic side members may comprise a first nonwoven material, an elastic film in a face-to-face relationship with the first nonwoven material, and a plurality of ultrasonic bonds joining the first nonwoven material and the elastic film to form an ultrasonically bonded laminate. The ultrasonically bonded laminate in the first absorbent article may differ from and be distinguishable from the ultrasonically bonded laminate in the second absorbent article in two or more characteristics selected from ultrasonic bond geometry, ultrasonic bond pattern, presence of frangible bonds, elastic film basis weight, first nonwoven primary bond pattern, and first nonwoven basis weight. At least one dimension of the first absorbent article may also differ from at least one dimension of the second absorbent article.

[0010] These and other features, aspects, and advantages of various embodiments will become better understood with reference to the following description, drawings, and appended claims. [Brief explanation of the drawings]

[0011] Many aspects of the present disclosure can be better understood with reference to the following drawings. [Figure 1] 1 is a plan view of an exemplary absorbent article in the form of a tape diaper laid out flat with the garment-facing surface facing the viewer. FIG. [Figure 2] 2 is a plan view of the exemplary absorbent article of FIG. 1 laid out flat with the wearer-facing surface facing the viewer. [Figure 3] FIG. 3 is a front perspective view of the absorbent article of FIGS. 1 and 2 in a fastened position. [Figure 4] 1 is a front perspective view of an absorbent article in the form of pants. FIG. [Figure 5] FIG. 5 is a rear perspective view of the absorbent article of FIG. [Figure 6] 5 is a plan view of the absorbent article of FIG. 4 laid out flat with the garment-facing surface facing the viewer. [Figure 7] 7 is a cross-sectional view of the absorbent article taken near line 7-7 of FIG. 6. [Figure 8] 8 is a cross-sectional view of the absorbent article taken about line 8-8 of FIG. 6. [Figure 9] 1 is a plan view of an exemplary absorbent core or absorbent article. [Figure 10] 10 is a cross-sectional view of the absorbent core of FIG. 9 taken about line 10-10. [Figure 11] 11 is a cross-sectional view of the absorbent core of FIG. 9 taken about line 11-11. [Figure 12A] 1A-1C are cross-sectional views of various stretch laminates. [Figure 12B] 1A-1C are cross-sectional views of various stretch laminates. [Figure 12C] 1A-1C are cross-sectional views of various stretch laminates. [Figure 12D] 1A-1C are cross-sectional views of various stretch laminates. [Figure 12E] 1A-1C are cross-sectional views of various stretch laminates. [Figure 12F] 1A-1C are cross-sectional views of various stretch laminates. [Figure 13A]1 is an SEM micrograph showing a cross-section of a portion of an elastomeric film that has not been pre-activated. [Figure 13B] FIG. 13B is a magnified version of the SEM micrograph of FIG. 13A. [Figure 14A] 1 is an SEM micrograph showing a cross-section of a portion of a pre-activated elastomeric film. [Figure 14B] FIG. 14B is a magnified version of the SEM micrograph of FIG. 14A. [Figure 15] 1 is a transmission optical micrograph of a top view of a portion of an elastomeric film that has not been pre-activated. [Figure 16] 1 is a transmission optical micrograph of a top view of a portion of a pre-activated elastomeric film illustrating activation striations. [Figure 17] 1 is a schematic illustration of a continuous process for making a stretch laminate according to the present disclosure. [Figure 18] FIG. 1 is a schematic, illustrative view of a plurality of individual ultrasonic coupling geometries. [Figure 19] FIG. 1 is a schematic illustration of an open-cell bonding pattern. [Figure 20A] 1 is a schematic diagram of an exemplary closed-cell bonding pattern. [Figure 20B] 1 is a schematic diagram of an exemplary closed-cell bonding pattern. [Figure 21A] FIG. 1 is a plan view of an exemplary side member including laminates having two or more bonding patterns. [Figure 21B] FIG. 1 is a plan view of an exemplary side member including laminates having two or more bonding patterns. [Figure 22A] 1A-1C are schematic illustrations of laminates having different bond densities; [Figure 22B] 1A-1C are schematic illustrations of laminates having different bond densities; [Figure 23] 1 is a schematic illustration of a stretch laminate subjected to a lateral pulling force. [Figure 24A] 1A-1C are schematic illustrations of stretch laminates having various types of frangible bond sites after being subjected to a lateral pulling force. [Figure 24B]1A-1C are schematic illustrations of stretch laminates having various types of frangible bond sites after being subjected to a lateral pulling force. [Figure 24C] 1A-1C are schematic illustrations of stretch laminates having various types of frangible bond sites after being subjected to a lateral pulling force. [Figure 25A] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns of nonwoven materials that may be used in accordance with various embodiments. [Figure 25B] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns of nonwoven materials that may be used in accordance with various embodiments. [Figure 25C] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns of nonwoven materials that may be used in accordance with various embodiments. [Figure 25D] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns of nonwoven materials that may be used in accordance with various embodiments. [Figure 25E] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns of nonwoven materials that may be used in accordance with various embodiments. [Figure 25F] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns of nonwoven materials that may be used in accordance with various embodiments. [Figure 26A] FIG. 2 is an exploded perspective view of an exemplary side member, schematically illustrating an exemplary surface modification portion. [Figure 26B] FIG. 2 is a plan view of an exemplary side member illustrating an exemplary structural feature. [Figure 27A] 1 is a schematic, illustrative diagram showing several exemplary arrays of absorbent articles. [Figure 27B] 1 is a schematic, illustrative diagram showing several exemplary arrays of absorbent articles. [Figure 27C] 1 is a schematic, illustrative diagram showing several exemplary arrays of absorbent articles. [Figure 27D] 1 is a schematic, illustrative diagram showing several exemplary arrays of absorbent articles. [Figure 28] 1 is a schematic, illustrative diagram showing an exemplary back ear of an absorbent article, identifying features associated with the back ear that are subjected to laminate extension testing. [Figure 28A] 1 is a schematic, illustrative diagram of a side view of an exemplary back ear identification feature associated with a back ear subjected to a pull test method; [Figure 29A] 1 is a schematic, illustrative view of an exemplary side member of an absorbent article, identifying features associated with the side member subjected to laminate extension and tensile testing methods. [Figure 29B] 1 is a schematic, illustrative view of an exemplary side member of an absorbent article, identifying features associated with the side member subjected to laminate extension and tensile testing methods.

[0012] It should be understood that the various embodiments are not limited to the examples illustrated in the figures. DETAILED DESCRIPTION OF THE INVENTION

[0013] Introduction and Definitions This disclosure is written to describe the present invention to those skilled in the art, and those skilled in the art will understand that the disclosure is not limited to the specific examples or embodiments described. The examples and embodiments are single examples of the present invention and will make the broader scope apparent to those skilled in the art. Unless otherwise defined herein, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art. It should also be understood that the terminology used herein is for the purpose of describing examples and embodiments only, and is not intended to be limiting, as the scope of the present invention is limited only by the appended claims.

[0014] All features disclosed in this specification (including the accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The examples and embodiments described herein are for illustrative purposes only, and various modifications or changes will be suggested to those skilled in the art in light thereof and are intended to be included within the spirit and scope of the present application. Many variations and modifications can be made to the embodiments of the present disclosure without substantially departing from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure. For example, unless otherwise indicated, the present disclosure is not limited to particular materials, reagents, reaction materials, manufacturing processes, etc., and as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. It is also possible that steps can be executed in different order, where this is logically possible.

[0015] All numerical values ​​are assumed to be modified herein by the term "about," whether explicitly stated or not. The term "about" generally refers to a range of numbers that one of ordinary skill in the art would consider equivalent to the recited value (e.g., having the same function or result). In many instances, the term "about" may include numbers that are rounded to the nearest significant figure.

[0016] In everyday usage, an indefinite article (such as "a" or "an") precedes a countable noun, and uncountable nouns rarely take an indefinite article. It should therefore be noted that, as used in the following specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, a reference to "a support" includes a plurality of supports. In particular, where a single countable noun is recited as a claim element, the specification generally uses phrases such as "single." For example, "a single support."

[0017] Where a range of values ​​is provided, it is understood that each intermediate value between the upper and lower limits of that range, to the nearest tenth of the lower limit (unless the context clearly dictates otherwise), and any other stated value or intermediate value in that stated range, is encompassed within the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the scope of the disclosure, excluding any specific limit in that stated range. Where the stated range includes one or both limits, ranges excluding either or both of those included limits are also included in the disclosure.

[0018] In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings unless a contrary intention is apparent.

[0019] "Absorbent article" refers to a device that absorbs and contains liquids, and more specifically, a device that is placed against or near the body of a wearer to absorb and contain various body exudates.

[0020] "Activated" or "pre-activated" refers to a process of mechanically deforming a material to increase the extensibility of at least a portion of the material. A material can be activated or pre-activated, for example, by incrementally stretching the material in at least one direction.

[0021] "Adhesively bonded" or "adhesively laminated" refers to a laminate in which an adhesive is used to bond the elastomeric material to at least one cover layer.

[0022] "Attached" refers to elements being connected or united by fastening, adhering, bonding, or any other method suitable for connecting elements together and their constituent materials. Many methods suitable for attaching elements together are well known, including adhesive bonding, pressure bonding, thermal bonding, ultrasonic bonding, mechanical fastening, etc. Such attachment methods may be used to attach elements together either continuously or intermittently over a particular area.

[0023] "Diaper" generally refers to an absorbent article worn by infants and incontinent persons about the lower torso, having the general form of a sheet, different portions of which are fastened together to encircle the waist and legs of the wearer.

[0024] "Disposable" refers to absorbent articles that are generally not intended to be laundered or restored or reused as absorbent articles, i.e., absorbent articles that are intended to be discarded after a single use, preferably recycled, composted, or otherwise disposed of in an environmentally compatible manner.

[0025] "Disposed" is used to mean that an element is formed (joined and positioned) with other elements in a particular place or location as a unitary structure or as a separate element joined to another element.

[0026] "Extensible" refers to the property that, when a biasing force is applied to the material, the material can be stretched to an elongated length of at least 115% of its original relaxed length (i.e., 15% extensible) without rupturing or breaking in a way that would render the material unusable for its intended purpose. Materials that do not meet this definition are considered inextensible. In some embodiments, an extensible material may be capable of stretching to an elongated length of 125% or more of its original relaxed length without rupturing or breaking in a way that would render the material unusable for its intended purpose. An extensible material may or may not exhibit recovery after the application of a biasing force.

[0027] Throughout this disclosure, an extensible material is considered to be "elastically extensible" if, when a biasing force is applied to the material, the material can be stretched to an elongated length of at least 115% of its original relaxed length (i.e., can be stretched 15%) without rupturing or breaking such that the material is unusable for its intended purpose, and after the force is removed from the material, the material recovers at least 40% of its elongation. In various examples, when the force is removed from an elastically extensible material, the material may recover at least 60%, or at least 80% of its elongation.

[0028] "Elastic," "elastomer," or "elastomeric" refers to a material exhibiting elastic properties and includes any material that, when subjected to a force in its relaxed state, can be stretched or extended to an elongated length that is greater than 15% of its initial length, and will substantially recover to about its initial length when the applied force is released.

[0029] "Internal" and "external" refer to the location of elements intended to be placed against or toward the wearer's body when the absorbent article is worn, and the location of elements intended to be placed against or toward any clothing worn over the absorbent article, respectively. Synonyms for "internal" include, but are not limited to, "inner," "inside," "skin-facing," "skin-side," "wearer-facing," or "wearer-side." Synonyms for "external" include, but are not limited to, "outer," "outside," "garment-side," or "garment-facing." Additionally, in the context of tape diapers, when the interior of the absorbent article is oriented facing upward, for example, when placing the absorbent article in preparation for placing a wearer over it, synonyms include "upper" and "lower," and "top" and "bottom," respectively.

[0030] "Jointed" refers to a configuration in which an element is directly secured to another element by directly attaching the element to the other element, and also to a configuration in which an element is indirectly secured to another element by attaching the element to an intermediate member which is in turn attached to the other element.

[0031] "Lateral" or "transverse" refers to a direction at an angle of 90 degrees to the longitudinal direction, including directions within ±45 degrees of the lateral direction.

[0032] "Longitudinal" refers to a direction running horizontally parallel to the largest linear dimension of the article, and includes directions within ±45° of the longitudinal direction.

[0033] "Pant(s)" generally refers to absorbent articles worn by infants or incontinent persons about the lower torso, having the general form of shorts, which can be applied to or removed from the wearer without unfastening. Pants can be put into position on the wearer by inserting the wearer's legs into the leg openings and sliding the pant into position about the wearer's lower torso. Although the term "pant" is used herein, pant(s) are also commonly referred to as "closure diapers," "prefastened diapers," "pull-on diapers," "training pants," and "diaper pants."

[0034] "Recovery" refers to the ability of a material to return to its original size after being stretched.

[0035] "Refastenable" refers to the property that two elements can be releasably attached, separated, and then releasably reattached without substantial permanent deformation or rupture.

[0036] "Removably attached," "removably engaged," and variations thereof, refer to two elements that are connected or connectable such that they tend to remain connected in the absence of a separation force applied to one or both of the elements and are capable of separation without substantial permanent deformation or rupture. The required separation force typically exceeds the forces encountered while wearing the absorbent garment.

[0037] The "strain" or "percent strain" of a material is calculated by subtracting the original length from the stretched length, then dividing the result by the original length and multiplying by 100. Percent strain is described by the following formula: Percent strain = % strain = strain = 100 * [(Ls-L0) / L0] where L0 is the original length of the stretch laminate (or elastomeric film) at the start of the stretching step and Ls is the length of the stretched laminate (or elastomeric film) at the end of the stretching step. A sample stretched from an original length of 10 mm to a length of 30 mm will result in a strain of 200%. Strain can be calculated in the length direction, the width direction, or any direction in between.

[0038] The "set" or "percent set" of a material is calculated by subtracting the original length from the final length, then dividing the result by the original length and multiplying by 100. Percent set is described by the following formula: Percent permanent set = % permanent set = permanent set = 100 * [(L f -L0) / L0] where L is the original length of the stretch laminate (or elastomeric film) at the start of the stretching step, and L fis the length of the relaxed stretch laminate (or elastomeric film) after it has relaxed after the stretching step. The sample is stretched from its original length of 10 mm to a length of 30 mm. Upon relaxation (removal of stress), the sample returns to 15 mm. This results in a permanent set of 50%. The permanent set can be calculated in the length direction, the width direction, or any direction in between.

[0039] "Wrinkles" refer to small folds, ridges, or creases.

[0040] "Align," or "aligned," or "aligning" means to place or arrange in a straight line. Thus, aligning the edges of substrates means arranging the substrates so that the edges in question extend along approximately the same line. It is understood that aligning the edges of substrates can be accomplished in a variety of ways, including placing the substrates one on top of the other or side by side.

[0041] "Face-to-face relationship" refers to the relative positioning of materials, such as substrates, in which a surface of one material is oriented toward a surface of another material. For example, when two substrates are stacked on top of each other, they exist in a face-to-face relationship. This term does not require or exclude the presence of an intervening object, material, or layer.

[0042] "Machine direction" (MD) refers to the direction of material flow through a process. In addition, the relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.

[0043] "Cross direction" (CD) refers to the direction generally perpendicular to the machine direction.

[0044] As used herein, "nonwoven" refers to a material made from continuous (long) filaments (fibers) and / or discontinuous (short) filaments (fibers), for example, by processes such as spunbonding, meltblowing, carding, etc. In some configurations, the nonwoven may comprise a polyolefin-based nonwoven, including, but not limited to, polypropylene and / or polyethylene fibers, and / or nonwovens having bicomponent fibers comprising polyolefins. Non-limiting examples of suitable fibers include spunbond, spunlaid, meltblown, spunmelt, solvent-spun, electrospun, carded, film-fibrillated, melt-film-fibrillated, airlaid, dry-laid, wet-laid staple fibers, and other nonwoven web materials formed in part or entirely of polymeric fibers known in the art, as well as processable combinations thereof. Nonwovens do not have a woven or knitted filament pattern. It should be understood that nonwovens having a variety of basis weights may be used in accordance with the methods herein. For example, some nonwoven fabrics can have a basis weight of at least about 8 gsm, 12 gsm, 16 gsm, 20 gsm, 25 gsm, 30 gsm, 40 gsm, or 65 gsm. Some nonwoven fabrics can have a basis weight of about 8 gsm to about 65 gsm, or about 10 gsm to about 22 gsm, specifically reciting all 1 gsm increments within the above ranges and all ranges formed within or formed by the ranges. Nonwoven fabrics can include or be formed from natural fibers, such as cotton, and bio-based fibers, such as bio-PE or bio-PP.

[0045] As used herein, "pattern" means a decorative or distinctive design, not necessarily repetitive or mimetic, including, but not limited to, clusters, geometric shapes, speckles, swirls, spirals, arrays, textures, spirals, cycles, contours, lace, tessellations, stars, leaves, blocks, pleats, concaves, convexs, nets, tapered shapes, and combinations thereof. In some embodiments, a pattern may include one or more repeating design elements.

[0046] Overview of absorbent articles An exemplary absorbent article 10 according to the present disclosure, shown in the form of a tape-type diaper, is shown in Figures 1-3. Figure 1 is a plan view of the exemplary absorbent article 10 in a flat, laid-out state (i.e., without elastic contraction) with the garment-facing surface 2 facing the viewer. Figure 2 is a plan view of the exemplary absorbent article 10 of Figure 1 in a flat, laid-out state with the wearer-facing surface 4 facing the viewer. Figure 3 is a front perspective view of the absorbent article 10 of Figures 1 and 2 in a fastened configuration. The absorbent article 10 of Figures 1-3 is shown for illustrative purposes only, as the present disclosure can be used to make a wide variety of diapers, such as, for example, adult incontinence products, pants, or other absorbent articles such as sanitary napkins and absorbent pads.

[0047] The absorbent article 10 may include a front waist region 12, a crotch region 14, and a back waist region 16. The crotch region 14 may extend intermediate the front waist region 12 and the back waist region 16. The front wait region 12, the crotch region 14, and the back waist region 16 may each be one-third of the length of the absorbent article 10. The absorbent article 10 may include a front edge 18, a back edge 20 opposite the front edge 18, and transversely opposed side edges 22 and 24 extending longitudinally and defined by a chassis 52.

[0048] The absorbent article 10 may include a liquid-permeable topsheet 26, a liquid-impermeable backsheet 28, and an absorbent core 30 positioned at least partially intermediate the topsheet 26 and the backsheet 28. The absorbent article 10 may also include one or more barrier leg cuffs 32, with or without elastics 33, one or more leg elastics 34, one or more elastic waistbands 36, and / or one or more acquisition materials 38. The acquisition materials 38 may be positioned intermediate the topsheet 26 and the absorbent core 30. A masking layer may be intermediate the absorbent core and the backsheet film. An outer cover material 40, such as a nonwoven material, may cover the garment-facing surface of the backsheet 28. The absorbent article 10 may include back ears 42 in the rear waist region 16. The back ears 42 may include fasteners 46 and may extend from the back waist region 16 of the absorbent article 10 and be attached (using the fasteners 46) to landing zone areas or landing zone material 44 in the garment-facing portion of the front waist region 12 of the absorbent article 10. The absorbent article 10 may also have front ears 47 in the front waist region 12. The absorbent article 10 may have a central lateral (or transverse) axis 48 and a central longitudinal axis 50. The central lateral axis 48 extends perpendicular to the central longitudinal axis 50. The absorbent article, in the context of a shaped diaper, may include a secondary fastening system in addition to the primary fastening system.

[0049] In another example, the absorbent article may be in the form of pants with permanent or refastenable side seams. Suitable refastenable seams are disclosed in U.S. Patent Application Publication No. 2014 / 0005020 and U.S. Patent No. 9,421,137. Referring to FIGS. 4-8, an exemplary absorbent article 10 in the form of pants is illustrated. FIG. 4 is a front perspective view of the absorbent article 10. FIG. 5 is a rear perspective view of the absorbent article 10. FIG. 6 is a plan view of the absorbent article 10 laid flat with the garment-facing surface facing the viewer. Elements in FIGS. 4-8 having the same reference numbers as those described above in connection with FIGS. 1-3 may be the same elements (e.g., absorbent core 30). FIG. 7 is an exemplary cross-sectional view of the absorbent article taken approximately along line 7-7 in FIG. 6. FIG. 8 is an exemplary cross-sectional view of the absorbent article taken approximately along line 8-8 in FIG. 6. FIGS. 7 and 8 illustrate exemplary configurations of the front belt 54 and the back belt 56. The absorbent article 10 may have a front waist region 12, a crotch region 14, and a back waist region 16. Each of the regions 12, 14, and 16 may be one-third of the length of the absorbent article 10. The absorbent article 10 may have a chassis 52 (sometimes referred to as a central chassis or center panel) similar to that described above with reference to Figures 1-3, including a topsheet 26, a backsheet 28, an absorbent core 30 disposed at least partially intermediate the topsheet 26 and the backsheet 28, and optional acquisition material 38. The absorbent article 10 may include a front belt 54 in the front waist region 12 and a back belt 56 in the back waist region 16. The chassis 52 may be joined to the wearer-facing surfaces 4 of the front belt 54 and the back belt 56 or to the garment-facing surfaces 2 of the belts 54, 56. The side edges 23 and 25 of the front belt 54 may be joined to the side edges 27 and 29 of the back belt 56, respectively, to form two side seams 58. The side seams 58 may be any suitable seam known to those skilled in the art, such as, for example, a butt seam or an overlap seam. Once the side seams 58 are permanently formed or refastenably closed, the pant-form absorbent article 10 has two leg openings 60 and a waist opening perimeter 62.The side seams 58 may be permanently joined, for example, using an adhesive or bonding agent, or may be refastenably closed, for example, using hook and loop fasteners.

[0050] belt 7 and 8 , the front belt 54 and the back belt 56 may include a front inner belt layer 66 and a back inner belt layer 67, and a front outer belt layer 64 and a back outer belt layer 65 having an elastomeric material (e.g., strands 68 or a film (which may be apertured)) at least partially disposed therebetween. The elastic elements 68 or film may be relaxed (including cut) to reduce elastic strain on the absorbent core 30, or alternatively, may pass continuously across the absorbent core 30. The elastic elements 68 may have uniform or variable spacing between them in any portion of the belt. The elastic elements 68 may also be subjected to the same or different amounts of pre-strain. The front belt 54 and / or the back belt 56 may have one or more elastic-element-free zones 70 where the chassis 52 overlaps the belts 54, 56. In other examples, at least some of the elastic elements 68 may extend continuously across the chassis 52.

[0051] The front inner and back inner belt layers 66, 67 and the front outer belt layers 64, 65 may be joined using adhesive, heat bonding, pressure bonding, thermoplastic bonding, or ultrasonic bonding. Various suitable belt layer configurations can be found in U.S. Patent Application Publication No. 2013 / 0211363. Either of the belts 54 and 56 may include a stretch laminate, as described below.

[0052] The front belt edge 55 and the rear belt edge 57 may extend longitudinally beyond the front chassis edge 19 and the rear chassis edge 21 (shown in FIG. 6 ), or they may be coterminous. The front and rear belt side edges 23, 25, 27, and 29 may extend laterally beyond the chassis side edges 22 and 24. The front belt 54 and the rear belt 56 may be continuous (i.e., have at least one layer that is continuous) from belt side edge to belt side edge (e.g., transverse distances from 23 to 25 and 27 to 29). Alternatively, the front belt 54 and the rear belt 56 may be discontinuous from belt side edge to belt side edge (e.g., transverse distances from 23 to 25 and 27 to 29) so that they are distinct.

[0053] As disclosed in U.S. Pat. No. 7,901,393, the longitudinal length (along the central longitudinal axis 50) of the rear belt 56 may be longer than the longitudinal length of the front belt 54, which may be particularly useful for increased buttock coverage when the rear belt 56 has a greater longitudinal length compared to the front belt 54 adjacent or immediately adjacent the side seam 58.

[0054] The front outer belt layer 64 and the back outer belt layer 65 may be separated from one another so that each layer is distinct, or alternatively, these layers may be continuous so that the layers run continuously from the front belt edge 55 to the back belt edge 57. This may also be true for the front inner belt layer 66 and the back inner belt layer 67, i.e., they may be distinct or continuous in the longitudinal direction. Furthermore, while the front inner belt layer 66 and the back inner belt layer 67 are distinct in the longitudinal direction, the front outer belt layer 64 and the back outer belt layer 65 may be continuous in the longitudinal direction, so that gaps are formed therebetween (the gaps between the front outer belt layer 64 and the back outer belt layer 65 and the gaps between the front inner belt layer 66 and the back inner belt layer 67 are shown in FIG. 7 , and the gaps between the front inner belt layer 66 and the back inner belt layer 67 are shown in FIG. 8 ).

[0055] The front and back belts 54, 56 may include slits, holes, and / or perforations that provide increased breathability, flexibility, and a garment-like texture. The underwear-like appearance can be enhanced by substantially aligning the waist and leg edges at the location of the side seams 58 (see FIGS. 4 and 5).

[0056] The front belt 54 and the back belt 56 may include graphics (see, for example, 78 in FIG. 1 ). The graphics may extend substantially around the entire circumference of the absorbent article 10 and may be located across the side seams 58 and / or across the proximal front belt seam 15 and back belt seam 17, or alternatively, may be located adjacent seams 58, 15, and 17 in the manner described in U.S. Patent No. 9,498,389 to create a more underwear-like article. The graphics may also be discontinuous.

[0057] Alternatively, instead of attaching belts 54 and 56 to chassis 52 to form pants, separate side panels may be attached to the side edges of chassis 22 and 24. Suitable forms of pants including separate side panels are described in U.S. Patent Nos. 6,645,190; 8,747,379; 8,372,052; 8,361,048; 6,761,711; 6,817,994; 8,007,485; 7,862,550; and 6,911,161. Nos. 6,953,452, 6,840,928, 8,579,876, 7,682,349, 7,156,833, and 7,201,744.

[0058] Top sheet The topsheet 26 is the portion of the absorbent article 10 that contacts the wearer's skin. The topsheet 26 may be joined to portions of the backsheet 28, the absorbent core 30, the barrier leg cuffs 32, and / or any other layers, as known to those skilled in the art. The topsheet 26 may be conformable, soft-feeling, and non-irritating to the wearer's skin. Further, at least a portion of, or all of, the topsheet may be liquid pervious, allowing liquid body exudates to readily penetrate through its thickness. The topsheet may be formed from one or more layers of equal or unequal size or area. Suitable topsheets can be made from a wide range of materials, including woven or nonwoven materials such as porous foams, reticulated foams, apertured plastic films, woven materials, nonwoven materials, natural fibers (e.g., wood fibers or cotton fibers), synthetic fibers or filaments (e.g., polyester fibers, or polypropylene fibers, or bicomponent PE / PP fibers, or bio-based fibers, biopolymers, PIR polymers, or mixtures thereof), or combinations of natural and synthetic fibers. The topsheet can have one or more layers. The topsheet can be apertured (element 31 in Figure 2), have any suitable three-dimensional features, and / or have multiple embossments (e.g., bonded patterns). The topsheet can be apertured by strongly bonding the material and then rupturing the strong bonds through a ring roll, as disclosed in U.S. Patent No. 5,628,097 (Benson et al., issued May 13, 1997) and U.S. Patent Application Publication No. 2016 / 0136014 (Arora et al.). Any portion of the topsheet can be coated with a skin care composition, an antimicrobial agent, a surfactant, and / or other benefit agent. The topsheet can be hydrophilic or hydrophobic, or can have hydrophilic and / or hydrophobic portions or layers. If the topsheet is hydrophobic, openings will typically be present to allow bodily exudates to pass through the topsheet.

[0059] back seat The backsheet 28 is generally that portion of the absorbent article 10 positioned adjacent the garment-facing surface of the absorbent core 30. The backsheet 28 may be joined to the topsheet 26, the outer cover material 40, the absorbent core 30, and / or any other layer of the absorbent article by any attachment method known to those skilled in the art. The backsheet 28 prevents or at least inhibits body exudates absorbed and contained within the absorbent core 10 from soiling articles such as bedsheets, undergarments, and / or clothing. The backsheet is typically liquid-impermeable, or at least substantially liquid-impermeable. The backsheet may be or include a thin plastic film, such as a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm. Other suitable backsheet materials may include breathable materials that allow vapors to escape from the absorbent article while still preventing or at least inhibiting body exudates from passing through the backsheet. The backsheet may be printed with graphic inks. The backsheet may also be printed with a wetness indicator, such as through the use of one or more hydrochromic inks.

[0060] Outer Cover Material The outer cover material (sometimes referred to as the backsheet nonwoven) 40 may comprise one or more nonwoven materials that are joined to and cover the backsheet 28. The outer cover material 40 forms at least a portion of the garment-facing surface 2 of the absorbent article 10 and effectively "covers" the backsheet 28 such that no film is present on the garment-facing surface 2. The outer cover material 40 may include bond patterns, apertures, and / or three-dimensional features. The outer cover material 40 may be a hydroentangled nonwoven material.

[0061] absorbent core As used herein, the term "absorbent core" 30 refers to a component of an absorbent article 10 that is positioned within the article to absorb and contain liquids, such as urine, received by the absorbent article. As such, the absorbent core typically has a high absorbent capacity. An exemplary absorbent core 30 is shown schematically in Figures 9-11. The absorbent core typically includes an absorbent material 72 enclosed within or sandwiched between a core bag 74.

[0062] The core wrap may be a single material folded and attached to itself, or may include separate top and bottom layers that may be bonded or otherwise joined together. The absorbent material typically includes superabsorbent particles, optionally mixed with cellulosic fibers. As used herein, "absorbent core" does not include any acquisition distribution system, topsheet, or backsheet of the absorbent article.

[0063] The exemplary absorbent core 30 shown alone in Figures 9-11 is in a dry state (prior to use). The absorbent core may typically have a generally rectangular shape as defined by its longitudinal edges and transverse front and rear edges, or may have other shapes.

[0064] The absorbent material 72 may be deposited as an absorbent layer having a generally rectangular profile, as shown in FIG. 9 . A wide variety of absorbent cores may also be used. The layer of absorbent material 72 may also have a non-rectangular perimeter (a "shaped" core); in particular, the absorbent material 72 may define a taper (or "dogbone" shape) along its width toward a central region of the core. In this manner, the absorbent material deposition area may have a relatively narrow width in areas of the core intended to be placed in the crotch region or toward the front region of the absorbent article. This may, for example, provide better wearing comfort. Other shapes for the absorbent material area may also be used, such as a "T," "Y," or "hourglass" shape.

[0065] The absorbent material 72 can be any conventional absorbent material known in the art. For example, the absorbent material can include a blend of cellulose fibers and superabsorbent particles ("superabsorbent particles" (SAP)), with the percentage of SAP typically ranging from about 50% to about 75% by weight of the absorbent material. According to various embodiments, the absorbent material can include at least 80% superabsorbent polymer by weight of the absorbent material. The absorbent material can also be free of cellulose fibers, as known in so-called airfelt-free cores, where the absorbent material consists or essentially of SAP. The absorbent material can also be a high internal phase emulsion foam.

[0066] As used herein, "superabsorbent polymer" or "SAP" refers to absorbent materials, typically crosslinked polymer materials, capable of absorbing at least 10 times their weight in 0.9% saline, as measured using the Centrifuge Retention Capacity (CRC) test (EDANA Method WSP241.2.R3(12)). SAPs may specifically have a CRC value of at least 20 g / g, specifically 20 g / g to 40 g / g. As used herein, "superabsorbent polymer particles" refers to superabsorbent polymer material in a particulate form such that it is flowable in the dry state.

[0067] Various absorbent core designs containing large amounts of SAP have been proposed in the past, see, for example, U.S. Pat. No. 5,599,335 (Goldman), European Patent No. 1,447,066 (Busam), International Publication No. WO 95 / 11652 (Tanzer), U.S. Patent Application Publication No. 2008 / 0312622 (A1) (Hundorf), and WO 2012 / 052172 (Van Malderen). In particular, SAP printing techniques disclosed in U.S. Patent Application Publication No. 2006 / 024433 (Blessing), U.S. Patent Application Publication No. 2008 / 0312617, and U.S. Patent Application Publication No. 2010 / 0051166 (A1) (both to Hundorf et al.) may be used. However, the present disclosure is not limited to any particular type of absorbent core. The absorbent core may also include one or more adhesives, such as a supplemental adhesive, applied between the inner surface of one (or both) of the core wrap layers and the absorbent material to reduce leakage of SAP outside the core wrap. Also, as described in the Hundorf reference above, microfibrous adhesive nets may be used in airfelt-free cores. These glues are not shown in the figures for simplicity. Other core structures, including a high-loft nonwoven substrate, such as a carded nonwoven layer, having a porous structure with SAP particles deposited therein, may also be used in the present disclosure.

[0068] The absorbent material can be deposited as a continuous layer within the core wrap. The absorbent material can also be present discontinuously, for example, as individual pockets or stripes of absorbent material enclosed within the core wrap and separated from one another by material-free bond areas. A continuous layer of absorbent material, particularly SAP, can also be obtained by combining two absorbent layers having matching discontinuous absorbent material application patterns, with the resulting layer being substantially continuously distributed across the absorbent particulate polymer material area, as illustrated in Figures 10-11. For example, as taught in U.S. Patent Application Publication No. 2008 / 312,622 (A1) (Hundorf), each absorbent material layer thus includes a pattern having absorbent material land areas and absorbent material-free bond areas, with the absorbent material land areas of the first layer substantially corresponding to the absorbent material-free bond areas of the second layer, and vice versa.

[0069] The basis weight (amount of material deposited per surface unit) of the absorbent material can be varied to create a contoured distribution of absorbent material, particularly longitudinally to provide more absorbency toward the center and middle of the core, but also transversely across the core, or in both directions. The absorbent core can also include one or more longitudinally (or otherwise) extending channels 76, which are areas of the absorbent layer that are substantially free of absorbent material within the absorbent layer. The upper side of the core wrap can advantageously be bonded to the underside of the core through these material-free areas by adhesive, mechanical, or ultrasonic bonding. Exemplary disclosures of such channels in airfelt-free cores can be found in WO 2012 / 170778 (Rosati et al.) and U.S. Patent No. 2012 / 0312491 (Jackels). Channels, of course, can also be formed in absorbent cores comprising a mixture of cellulose fibers and SAP particles. These channels can embody any suitable shape, and any suitable number of channels can be provided. In other examples, the absorbent core may be embossed to provide channel depressions. The absorbent cores of Figures 9-11 are merely exemplary absorbent cores. Many other absorbent cores, with or without channels, are within the scope of this disclosure.

[0070] Barrier leg cuff / leg elastic For example, referring to Figures 1 and 2, the absorbent article 10 may include one or more pairs of barrier leg cuffs 32 and one or more pairs of leg elastics 34. The barrier leg cuffs 32 may be positioned laterally inward of the leg elastics 34. Each barrier leg cuff 32 may be formed by a single piece of material that extends upward from the wearer-facing surface 4 of the absorbent article 10 and is bonded to the absorbent article 10 to provide improved containment of body exudates near the junction between the wearer's torso and legs. The barrier leg cuffs 32 are bounded by proximal edges that are bonded directly or indirectly to the topsheet and / or backsheet, and free distal edges that are intended to contact and form a seal with the wearer's skin. The barrier leg cuffs 32 may extend at least partially between the front edge 18 and the rear edge 20 of the absorbent article 10 on either side of the central longitudinal axis 50 and may be present in at least the crotch region 14. Each barrier leg cuff 32 may include one or more elastics 33 (e.g., elastic strands or strips) near or at its free distal edge. These elastics 33 enable the barrier leg cuffs 32 to help form a seal around the legs and torso of the wearer. The leg elastics 34 extend at least partially between the front edge 18 and the back edge 20. The leg elastics 34 essentially enable the portions of the absorbent article 10 adjacent the chassis side edges 22, 24 to help form a seal around the legs of the wearer. The leg elastics 34 may extend at least into the crotch region 14.

[0071] Elastic waistband 1 and 2, the absorbent article 10 may include one or more elastic waistbands 36. The elastic waistbands 36 may be positioned on the garment-facing surface 2 or the wearer-facing surface 4. As an example, a first elastic waistband 36 may be present near the front belt edge 18 in the front waist region 12, and a second elastic waistband 36 may be present near the rear edge 20 in the back waist region 16. The elastic waistbands 36 may seal the absorbent article 10 around the waist of the wearer and help to at least inhibit leakage of body exudates from the absorbent article 10 through the periphery of the waist opening. In some examples, the elastic waistband may completely surround the periphery of the waist opening of the absorbent article. The waistband may include elastic strands, an elastic film, or a combination thereof. The waistband may be a stretch laminate within the scope of the present disclosure and may be ultrasonically bonded.

[0072] Captured material 1, 2, 7, and 8, an acquisition layer comprising one or more acquisition materials 38 may be at least partially intermediate the topsheet 26 and the absorbent core 30. The acquisition material 38 is typically a hydrophilic material that provides significant wicking of bodily exudates. These materials can dehydrate the topsheet 26 and rapidly transfer bodily exudates into the absorbent core 30. The acquisition material 38 may comprise, for example, one or more nonwoven materials, foams, formed films, aperture-formed formed films, cellulosic materials, crosslinked cellulosic materials, airlaid cellulosic nonwoven materials, spunlace materials, or combinations thereof. In some examples, a portion of the acquisition material 38 may extend through a portion of the topsheet 26, a portion of the topsheet 26 may extend through a portion of the acquisition material 38, and / or the topsheet 26 may be nested with the acquisition material 38. Typically, the acquisition material 38 may have a width and length that are smaller than the width and length of the topsheet 26. In the context of a feminine pad, the acquisition material may be a secondary topsheet. The acquisition material may have one or more channels (including embossed versions) as described above with respect to absorbent core 30. The channels of the acquisition material may or may not be aligned with the channels of absorbent core 30. In one example, the first acquisition material may include a nonwoven material and the second acquisition material may include a cross-linked cellulosic material.

[0073] Landing Zone 1 and 2, the absorbent article 10 may have a landing zone area 44 formed in a portion of the garment-facing surface 2 of the outer cover material 40. The landing zone area 44 may be in the rear waist region 16 if the absorbent article 10 is fastened front-to-back, or in the front waist region 12 if the absorbent article 10 is fastened back-to-front. In some examples, the landing zone 44 may be or may include one or more separate nonwoven materials attached to a portion of the outer cover material 40 in the front waist region 12 or the back waist region 16, depending on whether the absorbent article is front-fastened or back-fastened. Essentially, the landing zone 44 is configured to receive the fastener 46 and may include, for example, a plurality of loops configured to engage with a plurality of hooks of the fastener 46, or vice versa. The landing zone may include a nonwoven having sufficient fiber loops to allow for proper fastening.

[0074] Wetness Indicator / Graphic Referring to FIG. 1 , the absorbent article 10 of the present disclosure may include a graphic 78 and / or wetness indicator 80 visible from the garment-facing surface 2. The graphic 78 may be printed on the landing zone 40, the backsheet 28, and / or other locations. The wetness indicator 80 is typically applied to the side of the backsheet 28 facing the absorbent core, and thus may come into contact with bodily exudates within the absorbent core 30. In some examples, the wetness indicator 80 may form part of the graphic 78. For example, the wetness indicator may appear or disappear, forming / removing text within some graphics. In other examples, the wetness indicator 80 may blend in with the graphic 78 (e.g., same design, same pattern, same color) or may not. The wetness indicator may be slot coated, gravure printed, or digitally printed onto a carrier substrate. The indicator, which is usually a color change, can be pH sensitive (blue to green to yellow, blue to yellow, etc.) or can be thermochromic (temperature sensitive).

[0075] Front and back ears 1 and 2, as referenced above, the absorbent article 10, in the context of a tape diaper, may have front ears 47 and / or back ears 42. In most tape diapers, only one set of ears may be required. One set of ears may include fasteners 46 configured to engage with the landing zone or landing zone area 44. If two sets of ears are provided, in most instances, only one set of ears will have fasteners 46, while the other set does not. The ears or portions thereof may be elastic or may include elastic panels. In one embodiment, an elastic film or elastic strands may be positioned intermediate the first nonwoven material and the second nonwoven material. The elastic film may or may not be perforated. The ears may be molded. The ears may be integral (e.g., extensions of the outer cover material 40, backsheet 28, and / or topsheet 26) or may be separate components attached to the wearer-facing surface 4, the garment-facing surface 2, or intermediate the two surfaces 4, 2 of the absorbent article chassis 52. Additionally or alternatively, any of the ears 42, 47 may comprise a stretch laminate, as described below. The front and / or back ears may have a length ratio, as determined by the tensile test method herein, of about 3 or less, or about 2.95 or less, or from about 1 to about 3, or from about 1.75 to about 3, or from about 1 to about 2.5, with each range recited in 0.05 intervals within the range. Forming the ears with such length ratios reduces the likelihood of roping within the ears. Furthermore, the specified length ratios result in increased strength of the ears.

[0076] Masking Layer One or more masking layers or materials may be provided within the absorbent article 10. The masking layer may be a layer that provides cushioning when the absorbent article is touched from the garment-facing side 2 or the wearer-facing side 4. The masking layer may "mask" any roughness that may be caused by the absorbent material 72, such as a superabsorbent polymer. The masking layer may "hide" the visibility of bodily exudates when viewing the wearer-facing side 4 or the garment-facing side 2 of the absorbent article 10. The masking layer may have a basis weight ranging from about 15 gsm to about 50 gsm or from about 15 gsm to about 40 gsm. The masking layer may include one or more nonwoven materials (e.g., hydroentangled nonwoven materials), foams, pulp layers, and / or other suitable materials. The masking layer may be the outer cover material 40. The masking layer may be a layer that forms the garment-facing or wearer-facing side of the core bag 74. The masking layer may be a separate material positioned intermediate the garment-facing side of the core bag 74 and the liquid-impermeable backsheet 28 .

[0077] Sensor Referring again to FIG. 1 , the absorbent article of the present disclosure may include a sensor system 82 for monitoring changes within the absorbent article 10. The sensor system 82 may be separate from or integral to the absorbent article 10. The absorbent article 10 may include sensors capable of sensing various aspects of the absorbent article 10 associated with the generation of bodily wastes such as urine and / or feces (e.g., the sensor system 82 may sense temperature, humidity, the presence of ammonia or urea, various vapor components of bodily wastes (urine and feces), changes in the breathability of the garment-facing layer of the absorbent article, changes in the translucency of the garment-facing layer, and / or variations in color change of the garment-facing layer). Additionally, the sensor system 82 may sense components of urine, such as ammonia or urea, and / or by-products resulting from the reaction of these components with the absorbent article 10. The sensor system 82 may sense by-products resulting from the mixing of urine with other components of the absorbent article 10 (e.g., adhesive, AGM). These components or by-products to be sensed may exist as vapors that may pass through the garment-facing layer. It may also be desirable to include a reactive substance in the absorbent article that, when mixed with urine or feces, changes state (e.g., color, temperature) or produces a measurable by-product. The sensor system 82 may also sense changes in pH, pressure, odor, the presence of gas, blood, chemical or biological markers, or combinations thereof. The sensor system 82 may have components on or proximate to the absorbent article that transmit a signal to a receiver more distal to the absorbent article, such as an iPhone. The receiver may output a result to communicate the status of the absorbent article 10 to a caregiver. In other examples, a receiver may not be provided, but instead the status of the absorbent article 10 may be visually or audibly apparent from a sensor on the absorbent article.

[0078] Bio-based ingredients for building blocks Components of the absorbent articles described herein can be at least partially composed of bio-based components, such as those described in U.S. Patent Application Publication No. 2007 / 0219521 A1. For example, superabsorbent polymer components can be bio-based via their derivation from bio-based acrylic acid. Bio-based acrylic acid and methods of manufacture are further described in U.S. Patent Application Publication No. 2007 / 0219521, as well as U.S. Patent Nos. 8,703,450, 9,630,901, and 9,822,197. Other components, such as nonwoven and film components, can include bio-based polyolefin materials. Bio-based polyolefins are further discussed in U.S. Patent Application Publication Nos. 2011 / 0139657, 2011 / 0139658, 2011 / 0152812, and 2016 / 0206774, and U.S. Patent No. 9,169,366. Exemplary bio-based polyolefins for use in the present disclosure include polymers available under the designations SHA7260™, SHE150™, or SGM9450F™ (all available from Braskem SA).

[0079] The absorbent article components may comprise a biobased content value of, for example, about 10% to about 100%, about 25% to about 100%, about 40% to about 100%, about 50% to about 100%, about 75% to about 100%, or about 90% to about 100% using ASTM D6866-10, Method B.

[0080] Bio-based absorbent articles suitable for recycling Components of the absorbent articles described herein, whether or not they are at least partially made from recyclable materials, can be recycled for other uses. Examples of absorbent article materials that can be recycled include nonwoven fabrics, films, fluff pulp, and superabsorbent polymers. The recycling process can use an autoclave to sterilize the absorbent articles, after which the absorbent articles can be shredded and separated into different by-product streams. Exemplary by-product streams can include plastics, superabsorbent polymers, and cellulose fibers such as pulp. These by-product streams can be used in the manufacture of fertilizers, plastic manufacturing articles, paper products, viscose, building materials, absorbent pads for pets or hospital beds, and / or for other uses. Further details regarding absorbent articles that aid recycling, diaper designs suitable for recycling, and diaper designs with bio-based components suitable for recycling are disclosed in U.S. Patent Application Publication No. 2019 / 0192723, published June 27, 2019.

[0081] stretch laminate Various elements of the absorbent article 10 described herein, particularly the elastic side members, may comprise a stretch laminate. For example, any of the belts 54 and 56 and / or any of the ears 42, 47 may comprise a stretch laminate, as described below. The waistband may also comprise a stretch laminate. Such a laminate may include an elastomeric layer that provides extensibility to the laminate, and one or more outer layers that are less extensible but are suitable for providing durability and desirable tactile properties. In this way, the laminate allows the absorbent article components to closely and comfortably contact the wearer while providing desirable aesthetic qualities.

[0082] 12A-12F are cross-sectional views of various stretch laminates 90. As shown in FIG. 12A, the stretch laminate 90 can include a first cover layer 100 and an elastomeric film layer 300 joined via one or more ultrasonic bonds 400. The elastomeric film layer 300 can have one or more coatings, such as a first coating 301 providing a first surface and a second coating 302 providing a second surface. As shown in FIG. 12B, the stretch laminate 90 can include a first cover layer 100 and a second cover layer 200, as well as an elastomeric film layer 300 sandwiched between and facing both the first cover layer 100 and the second cover layer 200. All three layers can be joined via one or more ultrasonic bonds 400. 12C and 12D, all or a portion of first cover layer 100 may include one or more layers, such as first layer 101 and second layer 102, which may have the same or different compositions. Similarly, all or a portion of second cover layer 200 may include one or more layers, such as first layer 201 and second layer 202, which may have the same or different compositions. As shown in Figures 12E and 12F, a portion of first cover layer 100 or second cover layer 200 may be folded over to provide a multi-layer structure over all or a portion of the opposite side of stretch laminate 90.

[0083] The elastomeric film layer 300 of the stretch laminate 90 may comprise a single layer or multiple layers of one or more elastically extensible materials. The elastically extensible material may be about 10 μm to about 100 μm, or about 20 μm to about 60 μm, or about 30 μm to about 50 μm thick, or in some embodiments, about 40 μm thick. The elastically extensible material may comprise an elastomeric polyolefin, and in some embodiments, a polyolefin (POE) blown film.

[0084] The elastically extensible material may include a modified resin.

[0085] The elastically extensible material may contain a variety of additives. Suitable additives, including but not limited to stabilizers, antioxidants, and bacteriostats, may be used to prevent thermal, oxidative, and biochemical degradation of the elastically extensible material. The additives may comprise from about 0.01% to about 60% of the total weight of the elastically extensible material. In other embodiments, the composition comprises from about 0.01% to about 25%. In other preferred embodiments, the elastically extensible material comprises from about 0.01% to about 10% by weight of the additives.

[0086] The elastically extensible material may include various stabilizers and antioxidants known in the art, including high molecular weight hindered phenols (i.e., phenolic compounds having sterically bulky radicals in close proximity to the hydroxyl group), polyfunctional phenols (i.e., phenolic compounds having sulfur- and phosphorus-containing groups), phosphates such as tris-(p-nonylphenyl)-phosphite, hindered amines, and combinations thereof. Proprietary stabilizers and / or antioxidants are available under several trade names, including various Wingstay®, Tinuvin®, and Irganox® products.

[0087] The elastically extensible material may contain various antimicrobial agents known in the art. Examples of suitable antimicrobial agents include benzoates, phenols, aldehydes, halogen-containing compounds, nitrogen compounds, metal-containing compounds such as mercury, zinc compounds, and tin compounds. Representative examples are available under the trade name Irgasan Pa. (Ciba Specialty Chemical Corporation, Tarrytown, NY).

[0088] The elastically extensible material may contain viscosity modifiers, processing aids, slip agents, or antiblocking agents. Processing aids include processing oils, which are well known in the art and include synthetic and natural oils, naphthenic oils, paraffinic oils, olefin oligomers and low molecular weight polymers, vegetable oils, animal oils, and their derivatives, including hydrogenated versions. Processing oils may also incorporate combinations of such oils. Mineral oils may be used as processing oils. Viscosity modifiers are also well known in the art. For example, petroleum-derived waxes can be used to reduce the viscosity of slow-recovery elastomers during thermal processing. Suitable waxes include low-number-average molecular weight (e.g., 0.6 to 6.0 kilodaltons) polyethylene; petroleum waxes and microcrystalline waxes, such as paraffin wax; atactic polypropylene; synthetic waxes made by polymerizing carbon monoxide and hydrogen, such as Fischer-Tropsch wax; and polyolefin waxes.

[0089] The desirability and conspicuousness of many stretch laminate features have been tested by consumers. The choice of nonwoven can affect the appearance of the bond pattern and can change the tactile softness of the laminate. Ultrasound and variations in the nonwoven bond pattern can change the texture of the stretch laminate, both tactilely and visually. Simply put, by varying these parameters in the laminate, clear distinctions can be created that consumers notice and understand. Some additional variations are detailed below.

[0090] coating Exemplary elastomeric film layers 300 useful in the stretch laminates 90 (i.e., elastically extensible materials having at least one coating disposed on a surface thereof) detailed herein include M18-1117 and M18-1361 elastomeric films commercially available from Clopay Corporation of Cincinnati, Ohio; K11-815 and CEX-826 elastomeric films commercially available from Tredegar Film Products of Richmond, Virginia; and elastomeric films commercially available from Mondi Gronau GmbH of Gronau, Germany. These exemplary elastomeric films may include a single layer of elastically extensible material having coatings 301, 302 disposed on both surfaces of the material. Other elastomeric film layers applicable to the stretch laminates detailed herein need not have coatings 301, 302 on both surfaces of the material, but instead may have no coatings or may have a coating on only one surface.

[0091] nonwoven material The first cover layer 100 and cover layer material 200, as well as any layers 101, 102, 201, 202 comprising either material, can comprise any suitable nonwoven material or combination of nonwoven materials, including, but not limited to, spun-only or spun-meltblown combinations, such as SM (spunbond meltblown), SMS (spunbond meltblown spunbond), SMMS (spunbond meltblown meltblown spunbond) nonwovens, SSMMS (spunbond meltblown meltblown spunbond), hydroentangled nonwovens, and softbond nonwovens. Nonwoven materials can also include carded nonwoven materials, such as those specifically designed and manufactured to be compatible with activation (e.g., ring rolling) processes. One exemplary nonwoven material is a carded nonwoven material made from polypropylene homopolymer. Spunbonds can also be specifically designed and / or manufactured to be compatible with activation processes. However, it is believed that through the use of elastomeric films according to the present disclosure, greater flexibility in design options may be achieved. For example, spunbond may be selected for applications where only carded nonwoven materials have been used in the past, or thinner elastomeric films may be used in conjunction with carded nonwoven materials. Other improvements in design flexibility will be apparent to those skilled in the art. For example, in some embodiments, the cover layer may be a stretchable nonwoven material, which may or may not need to undergo an activation process to impart stretchability to the stretch laminate.

[0092] The nonwoven material may have a basis weight of less than about 30 gsm. Indeed, according to certain embodiments, the basis weight may be less than about 27 gsm. In other embodiments, the basis weight may be less than about 25 gsm. In yet other embodiments, the nonwoven material may have a basis weight of less than about 24 gsm. The nonwoven material may further include additives such as, for example, CaCO3. Woven or knitted fabrics may also be used as the cover layers 100, 200 in the stretch laminate 90 embodiments described herein.

[0093] Although the ultrasonic bond 400 preferably eliminates the need for adhesive, adhesives may be used to bond the layers 100, 200, and 300 of the stretch laminate 90. The adhesive may be selected from any known adhesive to provide a suitable attachment between the elastomeric film layer 300 and the cover layers 100 and 200. In some embodiments, the adhesive may be a hot melt adhesive having a basis weight of less than about 15 gsm. According to one embodiment, the adhesive may be H2031, available from Bostik Inc. (Middleton, Massachusetts). One attribute of this adhesive is that it has significant pressure-sensitive characteristics at 23°C, making it useful for manually manufacturing stretch laminates. However, the adhesive is also suitable for use in fabricating stretch laminates from the above-described elastomeric film and cover layers using conventional stretch laminate manufacturing equipment (such equipment being well known in the art).

[0094] Pre-activation The elastomeric film layer 300 may be mechanically preactivated prior to attachment to at least one cover layer 100, 200. For example, the elastomeric film layer 300 may be preactivated by stretching it more than 50% in a direction transverse to its web direction (i.e., greater than 50% strain). In some embodiments, an expansion of about 100% to about 500% occurs relative to the initial width of the elastomeric film layer 300. In alternative embodiments, the elastomeric film layer 300 may be stretched in the web direction, in a direction other than the web direction or transverse to the web direction, or in a combination of these directions. The term "stretching" refers to the fact that the expansion of the elastomeric film layer 300 is not completely reversible; the inelastic portions result in a film with a larger width after preactivation (i.e., the elastomeric film does not have 100% recovery and therefore a percent permanent set value). After expansion, the elastomeric film layer 300 contracts to a width that may be about 10% to about 30% greater than the initial width of the film. In other words, after the pre-activated expansion and contraction detailed below, the elastomeric film layer 300 may exhibit a permanent set of about 10% to about 30%.

[0095] According to various embodiments in which the elastomeric film layer 300 includes both an elastically extensible material and at least one coating disposed on the elastically extensible material, the pre-activation process can physically change these materials differently, for example, because the materials have different elasticity and recovery properties. During pre-activation, the coatings 301 and / or 302 and the elastically extensible material are stretched similarly (i.e., placed under similar strain). However, after stretching, the coating and the elastically extensible material exhibit different contraction and recovery (i.e., different permanent set). Compared to the elastically extensible material, the coating is less elastic and therefore recovers less after stretching, i.e., has a higher permanent set value. Also, because the coating is much thinner than the elastically extensible material, the contraction and recovery of the thicker elastically extensible material after pre-activation stretching forces the attached coating to contract as well. However, because the skin cannot recover as well as an elastically extensible material, the skin will bend and wrinkle. Thus, the cross-sectional shape and top surface appearance of the elastomeric film layer 300 are altered after the pre-activation process.

[0096] Figures 13A, 13B, 14A, and 14B are SEM micrographs of enlarged cross-sections of elastomeric films. These SEM micrographs, as well as others included herein, were taken with a scanning electron microscope (Hitachi Model 3500). Information for calculating specific magnifications and distances is included with each SEM micrograph along the underside of the frame. Figure 13A is an SEM micrograph taken at approximately 900x magnification showing a cross-section of a portion of an elastomeric film that has not been preactivated. The skins are thin strips of material with contrast above and below the cross-section, with a thicker, elastically extensible material between them. The skin on the top side of the cross-section is more easily identified by the cross-section view, which cuts through that area more cleanly. Without preactivation, the skin, and therefore the outer surface of the elastomeric film, is substantially smooth in the cross-section. FIG. 13B is a higher magnification image (approximately 3500x magnification) of the coating on top of the cross section shown in the SEM micrograph of FIG. 13A.

[0097] Figure 14A is an SEM micrograph taken at approximately 900x magnification showing a cross-section of a portion of a pre-activated elastomeric film. Again, the skin is a thin strip of material with contrast above and below the cross-section, with a thicker, elastically extensible material between them. With pre-activation, the skin, and thus the outer surface of the elastomeric film, is wrinkled in cross-section. Figure 14B is a higher magnification image (approximately 3500x magnification) of the upper skin away from the cross-section shown in the SEM micrograph of Figure 14A.

[0098] 14A and 14B show that after preactivation, the skin 301 of the elastomeric film layer 300 contains multiple wrinkles with ridges and grooves. For example, as shown in the non-limiting sample photograph in FIG. 14B, there are approximately six ridges and six grooves of varying sizes within a length of approximately 35 μm taken along the cross-section of the preactivated elastomeric film. This is in comparison to FIG. 13B, which shows no ridges or grooves within a length of approximately 35 μm taken along the cross-section of the non-preactivated elastomeric film. However, as can be seen on the top surface of the elastomeric film shown in FIG. 14B, one or more irregular ridges and / or grooves may be present within a particular length of the cross-section of the non-preactivated elastomeric film. These irregular ridges and / or grooves are due to irregularities in the surface of the elastomeric film. Such irregular ridges and / or grooves should not be confused with the ridges and grooves of multiple wrinkles intentionally formed in the elastomeric film by the mechanical preactivation process.

[0099] Figures 15 and 16 are transmission optical micrographs of enlarged top views of elastomeric films. The transmission optical micrographs were taken in color using a Nikon SMZ1500 binocular optical microscope equipped with an Evolution Mp5C digital camera, with white light shining from below the elastomeric film sample. The blue scale at the bottom of Figures 15 and 16 is in millimeters. This scale can be used to calculate specific magnifications and distances for the transmission optical micrographs. Figure 15 is a transmission optical micrograph showing a top view of a portion of an elastomeric film that has not been preactivated. Without preactivation, the observable outer surface of the elastomeric film (i.e., the top view of the film) has a uniform appearance with no discernible striations. Figure 16 is a transmission optical micrograph showing a top view of a portion of an elastomeric film that has been preactivated. With preactivation, the top view of the film contains multiple striations of varying thickness related to the size and pitch of the interlocking discs of the mechanical preactivation means. The stripes, referred to herein as activation stripes, indicate zones of the pre-activated elastomeric film that are at a particular range of stretch during the pre-activation process. For example, as shown in the non-limiting sample in the photograph of Figure 16, there are medium-thickness dark blue stripes indicating higher film wrinkles, thicker thickness light blue stripes indicating medium film wrinkles, and thin white stripes indicating lower film wrinkles.

[0100] Additionally, after preactivation but before utilizing the elastomeric film layer 300 in fabricating the stretch laminate 90, the film layer 300 can optionally be printed with an image or motif that is visible through the cover layers 100, 200 of the stretch laminate 90. The ink or other pigment utilized in printing is deposited in the ridges and grooves of the wrinkles of the preactivated elastomeric film. By depositing the ink on the uneven surface of the preactivated elastomeric film, a greater surface area of ​​contact between the elastomeric film and the ink is achieved. Therefore, when printing on a preactivated elastomeric film, the image adheres more strongly to the film compared to an image printed on the smoother surface of an elastomeric film that has not been preactivated.

[0101] Furthermore, if the stretch laminate 90 includes a mechanically pre-activated (and then printed) elastomeric film, the undeformed printed image on the film will be uniformly and reversibly stretched along the film. This is because a significant portion or all of the inelastic portions of the elastomeric film 90 have already been removed in the pre-activation process before the image is printed onto the pre-activated elastomeric film. In other words, permanent strain is removed from the elastomeric film 300 layer prior to printing. Therefore, the printed image will not be substantially deformed further upon subsequent activation of the stretch laminate 90 or upon further stretching of the laminate by the user. In contrast, if an image or motif is printed on an elastomeric film that has not been pre-activated, and the printed film is used to fabricate a stretch laminate that is then mechanically activated, the desired image will be deformed in the final activated stretch laminate. This is because the permanent set in the elastomeric film is not removed prior to the printing process, and such permanent set is removed from the elastomeric film during mechanical activation of the fabricated stretch laminate, distorting the original printed image. Similarly, if the elastomeric film is printed and then pre-activated, the permanent set in the elastomeric film is not removed prior to the printing process, and such permanent set is removed from the elastomeric film during the pre-activation process, distorting the original printed image.

[0102] In another embodiment, the pre-activated elastomeric film can be re-stretched while printing the film. The printed film is then relaxed and used to fabricate and activate a stretch laminate. The resulting activated stretch laminate has an aesthetically pleasing image or motif when the stretch laminate is in a stretched state during use (e.g., when a user stretches the stretch laminate during application or removal of an absorbent article).

[0103] In embodiments of stretch laminates that include a pre-activated and then printed elastomeric film, the ink or other pigment utilized in printing is deposited on the ridges and into the grooves of the film's wrinkles. As detailed above, ink deposited on the uneven surface of a pre-activated elastomeric film will adhere more strongly to the film (compared to ink placed on an elastomeric film that has not been pre-activated) due to the additional surface area of ​​contact between the elastomeric film and the ink.

[0104] Additionally, preactivating the elastomeric film also reduces the force required to subsequently stretch the film (compared to a non-activated film), which aids in the subsequent mechanical activation of the stretch laminate, as a lower load is required to activate a stretch laminate made with the pre-activated film (relative to an unactivated film).

[0105] Stretch laminate manufacturing method The schematic illustration of FIG. 17 details one exemplary embodiment of a method 500 for fabricating the stretch laminate 90 detailed herein. The method 500 includes providing and preactivating an elastomeric film 300. The elastomeric film 300 is mechanically preactivated by stretching the film by more than 50% in the transverse direction relative to the web direction. In some embodiments, an expansion of about 100% to about 500% occurs relative to the initial width of the elastomeric film 300. The term "stretching" refers to the fact that the expansion of the elastomeric film 300 is not fully reversible; inelastic portions result in the film having a larger width after contraction (i.e., reverse expansion). After expansion, the elastomeric film 300 contracts and has a width B2 that is about 10% to about 30% larger than the film's initial width B1. Thus, the elastomeric film 300 has a permanent set of about 10% to about 30% resulting from the preactivation process.

[0106] For the preactivation process, the elastomeric film 300 may be guided through a system of interlocking rollers, each roller including a disk packet with multiple interlocking disks arranged on an axis (i.e., a ring-roll process). The elastomeric film 300 is stretched in the transverse direction by the interlocking disk packet. The stretching may be uniform or may vary across the width of the film. The preactivation process may be performed with a varying pitch and / or varying depth of engagement. The preactivation process may be performed in the machine direction or any other direction. Preactivation of the elastomeric film 1 has a positive effect on the stretch force profile, thereby helping to facilitate the stretch behavior of stretch laminates fabricated over large expansion areas. Furthermore, the recovery of stretch laminates may also be improved by preactivating the elastomeric film 300. Recovery is the ability of a stretch laminate to return to its original size after being stretched to its expansion limit. The increased recovery of the elastomeric film 300 after the preactivation process is due to the removal of the amount of permanent set in the film.

[0107] After preactivation, but before cutting the elastomeric film 300 into film strips 502, an image or motif may optionally be printed onto the film at printing station 511, with the image or motif being visible through the cover layer of the stretch laminate. Any known continuous printing method may be used to print the elastomeric film 300. Non-limiting exemplary printing methods include digital printing, inkjet printing, and rotary printing, particularly flexographic printing. As a non-limiting example, the printed image or motif may be a stripe motif made of parallel colored stripes extending longitudinally across the web of the elastomeric film 300.

[0108] The pre-activated and optionally printed film may then be optionally cut into film strips 502. The film strips 502 are guided across a redirecting means 503 and fed as parallel strips to a laminating means 504. The film strips 502 are then laminated in the laminating means 504 between cover layers 100, 200 fed above and below the film strip. The film strips 502 and cover layers 100, 200 may be bonded together or connected to each other by thermal means, such as ultrasonic bonding, to form a composite material 507 (i.e., one embodiment of the stretch laminate material detailed herein). As illustrated in FIG. 17 , the film strips 502 are laminated between the cover layers 100, 200 at a distance from each other. The cover layers 100, 200 may thus be directly connected to each other in the areas between the film strips 502. Elastic regions 508 as well as inelastic regions 509 may therefore optionally be created in the composite material 507. The distance between the filmstrips 502 can be adjusted by positioning the redirecting means, and it is also contemplated that reinforcing strips can be laminated between the filmstrips 502 to reinforce the inelastic regions 509 between the filmstrips.

[0109] The composite material 507 is then fed to an activation means 510, where the composite material is stretched in the elastic region 508 in a direction transverse to the web direction. To stretch, the composite material 507 can be guided through a nip between two shape rollers, each roller including at least two disk packets having a plurality of interlocking disks arranged on an axis. The composite material 507 is stretched in the transverse direction at that location by the interlocking disk packets. The region of the composite material 507 stretched by the interlocking disk packets is referred to as the stretch zone. Between the disk packets and / or in the outer roller section, the shape rollers form gaps through which the composite material 507 is guided essentially without stretching in the transverse direction. The region of the composite material 507 not stretched by the interlocking disk packets is referred to as the anchor zone. In the stretch zone, the fibers of the cover layer 100, 200 are modified and irreversibly stretched due to fiber breakage and rearrangement. Thus, the expansion properties of the composite material 507 are improved in the transverse direction (i.e., transverse to the longitudinal web direction) in the tension zones. After activation, with minimal applied force, the composite material 507 can readily expand in the transverse direction up to its expansion limit, which is preset by the stretching of the activation means 510.

[0110] When utilizing a conventional nonwoven material as the cover layer, preactivation of the elastomeric film 300 cannot replace, but can only supplement, the mechanical activation of the composite 507. Thus, even when the elastomeric film 300 is preactivated, it is still necessary to stretch the composite 507 transverse to the web direction in areas that are provided with elasticity via the laminated elastomeric film strips (i.e., stretch zones). However, there may be some composite 507 embodiments that use extensible nonwoven materials as the cover layer, and therefore, activation of the composite may not be necessary.

[0111] In fabricating embodiments of the printed stretch laminate disclosed herein, the elastomeric film 300 is optionally printed with an image or motif that is visible through at least one of the cover layers 100, 200 of the composite material 507. Because the elastomeric film 300 is provided with an imprint, proper alignment of the printed motif with respect to the elastic regions of the composite material 507 is always ensured. Additionally, stretching the composite material 507 causes the printed image to stretch uniformly and reversibly along the composite material. Furthermore, the printed motif is visible through both the front and back sides of the composite material 507, such that the composite is equally visually appealing on both sides.

[0112] Ultrasonic bonding shape As shown in FIG. 18 , individual ultrasonic bonds can be formed in a variety of shapes, including, but not limited to, curved shapes, straight-sided shapes, and combinations thereof. Examples of curved shapes include, but are not limited to, circles, ellipses, and wavy lines. Examples of straight-sided shapes include, but are not limited to, triangles, squares, rectangles, diamonds, pentagons, hexagons, octagons, or any multi-sided shape. With respect to multi-sided shapes, the shape can have any number of sides, for example, the shape can have 3 to 12 sides. An example of a shape that is a combination of curved and straight-sided shapes is a heart. Providing a variety of ultrasonic bond shapes can add visual appeal and help distinguish various absorbent articles without compromising bond strength.

[0113] Ultrasonic Bonding Pattern The ultrasonic bond groups can be arranged unit by unit, and the units can be arranged to form a pattern. The pattern can be a closed-cell pattern, an open-cell pattern, or a combination thereof. A closed-cell pattern includes closed-cell units but not open-cell patterns. A pattern can include a combination of areas with closed-cell patterns and other areas with open-cell patterns. Figure 19 is a schematic illustration of an open-cell bond pattern 600. The pattern 600 shown in Figure 19 also includes multiple ultrasonic bond shapes, including elliptical bond shapes 602a, circular bond shapes 602b, and diamond bond shapes 602c.

[0114] 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 in space of which is necessary to reconstruct the pattern. A pattern may be formed from one or more units. A "repeating unit" is a unit that is substantially the same (i.e., slight variations in dimension, shape, and / or size) or is the same and occurs multiple times within the pattern, and the unit may be rotated, mirrored, or otherwise reoriented. A repeating unit is considered to be substantially the same if its size and / or shape is within 10% of another repeating unit.

[0115] "Closed-cell unit" means a unit that is discernible as a shape having a perimeter to the human eye with 20 / 20 vision at a distance of 12 inches, where the perimeter is formed by at least five bonds that substantially enclose an area free of permanent bonds with a bond separation distance of less than about 3.5 mm according to the Bond Measurement Test Method. The perimeter may be formed by discontinuous bonds. For example, separate bonds that are sufficiently small and / or close together that an observer sees a shape substantially surrounded by the perimeter. Adjacent bonds along the perimeter of the closed-cell unit have a bond separation distance of about 3.5 mm or less. Closed-cell units may share bond sites with each other to form closed cells.

[0116] FIG. 20A is a schematic diagram of an exemplary closed-cell bonding pattern 601 including a plurality of individual ultrasonic bonds 602. The perimeter 604 is shown as a dashed line for illustrative purposes and to better understand the present disclosure; however, the dashed line does not form part of the bonding pattern. The perimeter 604 is formed by connecting adjacent individual bonds 602 to surround a closed-cell unit 606. The closed-cell 606 unit includes an encapsulated portion 608 that is substantially surrounded by the perimeter 604. It is understood that the perimeter 604 of a first closed-cell unit 606 can form a portion of the perimeter of a second closed-cell unit. It is also understood that multiple closed-cell unit shapes can be used in a single bonding pattern. For example, FIG. 20A is a schematic diagram of an exemplary closed-cell bonding pattern 601 including a plurality of closed-cell unit shapes, including an octagonal closed-cell unit 606a and a square closed-cell unit 606b.

[0117] 21A and 21B are plan views of an exemplary side member including a stretch laminate 90 having two or more bonding patterns. The exemplary side member can be a first elastic side member 914 or a second elastic side member, as illustrated in FIGS. 27A-27D. For example, the laminate can include an open-cell bonding pattern 600 and a closed-cell bonding pattern 601. Additionally or alternatively, the second bonding pattern can differ from the first bonding pattern in at least one of bond shape, number of bonds, number of closed-cell units (or absence of closed-cell units), repeating unit shape, enclosed area of ​​closed-cell units, bond density, percent bond area, and combinations thereof. The second bonding pattern can be positioned outside the first bonding pattern, such that the two patterns are in a non-overlapping relationship. As illustrated in FIGS. 21A and 21B, the second bonding pattern, shown as an open-cell bonding pattern 600, can be disposed along one or more edges of the laminate. In this manner, the second bond pattern may at least partially surround or frame at least a portion of the first bond pattern, shown as closed-cell bond pattern 601, or the entire first bond pattern. The first and second bond patterns may also overlap in a transition zone. In embodiments having multiple bond patterns, such as a first and second bond pattern, the first and second bond patterns may also have different bond densities.

[0118] Joint density "Bond density" refers to the number of bonds per unit area. Figures 22A and 22B are schematic, illustrative views of stretch laminates 90 having different bond densities, with the stretch laminate 90 of Figure 22A having a lower bond density than the laminate shown in Figure 22B.

[0119] Breakable Joints Breakable bonds refer to ultrasonic bonds that can be broken when stretched. FIG. 23 is a schematic illustration of a stretch laminate 90 including an elastomeric film layer 300 sandwiched between a first cover layer 100 and a second cover layer 200. The layers may be held together by multiple ultrasonic bonds 400. The stretch laminate 90 may be subjected to a lateral pulling force. FIGS. 24A-24C are schematic illustrations of the stretch laminate 90 of FIG. 23 having various types of breakable bond regions 700 after being subjected to a lateral pulling force. In FIG. 24A, the breakable bond region 700 is separated from both the first cover layer 100 and the second cover layer 200 at the area of ​​separation 702. In FIG. 24B, the breakable bond region 700 is separated from either the first cover layer 100 or the second cover layer 200 at the area of ​​separation 702. In FIG. 24C, the breakable bond site 700 is only partially separated from either the first cover layer 100 or the second cover layer 200 at the area of ​​separation 702.

[0120] Cover layer linear bond pattern 25A-25F are schematic, illustrative diagrams showing various primary bond patterns for cover layers that may be used in accordance with various embodiments. The bond patterns may be imprinted or embossed onto a cover layer, such as the first cover layer 100 or second cover layer 200 described herein. As described herein, the cover layer may comprise a nonwoven material, in which case the primary bond pattern may be referred to as a nonwoven bond pattern. Such patterns may provide an attractive and / or distinctive texture and appearance to the stretch laminate.

[0121] Laminate with slits and cuts In some configurations, it may be desirable to provide a stretch laminate or side member comprising a stretch laminate with different zonal performance characteristics. Such enhanced properties may include breathability, softness, strength, thickness, wrinkle uniformity, modulus, aesthetic enhancements, tear resistance, combinations of any of the foregoing, and / or zones having different values ​​of any of the foregoing characteristics. According to various embodiments, stretch laminates and / or side members comprising stretch laminates may include embossments, apertures, perforations, slits, melted materials or coatings, compressible materials, secondary bonds spaced apart from the chassis attachment bonds, plastic deformations, and creases.

[0122] FIG. 26A is an exploded perspective view of an exemplary side member, schematically illustrating an exemplary surface modification. The exemplary side member can be a first resilient side member 914 or a second resilient side member, as illustrated in FIGS. 27A-27D. The surface modification can be created on the precursor material prior to lamination. One or more surface modifications 800 (also referred to as morphological features) are illustrated on one or more layers of the laminate. The surface modifications 800 can include embossments 802, cuts 804 (e.g., apertures, perforations, slits), melted material or coating 806, compressed material 808, plastic deformations 810 (e.g., activation stripes 812), folds 814, post-formation bonds 816 (e.g., adhesive bonds, pressure bonds, thermal bonds, and / or ultrasonic bonds applied after the substrate is formed), and combinations thereof. The surface modification can be formed after the initial formation of the substrate itself, thereby forming a modified substrate. In other words, thermally bonding fibers to produce a nonwoven fabric is not considered a surface modification. Forming bonds in a nonwoven fabric after it is formed is considered a surface modification. Additionally or alternatively, surface modifications 800 on different layers may work together to provide enhanced properties.

[0123] FIG. 26B is a plan view of an example side member illustrating example structural features. The example side member can be a first resilient side member 914 or a second resilient side member, as illustrated in FIGS. 27A-27D. One or more structural features 801 can be formed on the laminate after initial bonding of the layers. The structural features 801 can include embossments 802, cuts 804 (e.g., openings, perforations, slits), melted material or coating 806, compressed material 808, plastic deformations 810 (e.g., activation stripes 812), folds 814, secondary bonds 816 (e.g., adhesive bonds, pressure bonds, thermal bonds, and / or ultrasonic bonds applied after initial bonding of the laminate), and combinations thereof. The structural features or surface modifications can be in the form of design elements 820.

[0124] It is understood that a combination of one or more surface modifications 800 and one or more structural features 801 may be used. It is also understood that certain cover layer substrates may be selected for their affinity for the surface modifications and / or structural features. As a non-limiting example, if the substrate and / or laminate is to be mechanically activated, a carded nonwoven may be selected. Low modulus materials, such as polyethylene-based materials, may be more suitable for modification by laser energy.

[0125] size Various measurements can be useful in defining and distinguishing absorbent articles 10. All measurements are taken with the absorbent article lying flat and the waistband undone; measurements may require the use of clamps to prevent contraction of the various elastic members. "Chassis width" is the width of the chassis 52 of the absorbent article 10 at the product width, or central transverse axis 48, as shown in FIG. 1. Chassis pitch (length) is the length of the chassis 52 of the absorbent article 10 at the product length, or central longitudinal axis 50, as shown in FIG. 1. "Wingspan" is the width 13 between the innermost edge of one fully extended fastener 46 and the innermost edge of the opposing fully extended fastener 46 when the absorbent article 10 and back ears 42 are lying flat, as shown in FIG. 1. Tables 1 and 2 provide example measurements for various brands of diapers designed for infants of specific weights.

[0126] [Table 1]

[0127] [Table 2]

[0128] According to various embodiments, the chassis width may be in the range of 200-400 mm, or 247-346 mm, or 247-295 mm, or 247-346 mm, or 295-325 mm, or 295-346 mm, or 325-346 mm, and specifically all enumerations therebetween in 1 mm increments.

[0129] According to various embodiments, the wingspan of the absorbent article is 200 to 400 mm, or 247 mm to 359 mm, or 247 mm to 259 mm, or 247 mm to 295 mm, or 247 mm to 325 mm, or 247 mm to 346 mm, or 247 mm to 347 mm, or 247 mm to 359 mm, or 259 mm to 295 mm, or 259 mm to 325 mm, or 259 mm to 346 mm, or 259 mm to 347 mm. m, or 259 mm to 359 mm, or 295 mm to 325 mm, or 295 mm to 346 mm, or 295 mm to 347 mm, or 295 mm to 359 mm, or 325 mm to 346 mm, or 325 mm to 347 mm, or 325 mm to 359 mm, or 346 mm to 347 mm, or 346 mm to 359 mm, or 347 mm to 359 mm, and specifically all enumerations in 1 mm increments therebetween.

[0130] According to various embodiments, the chassis width of the absorbent article may be 100 to 300 mm, or 143 mm to 225 mm, or 143 mm to 150 mm, or 143 mm to 195 mm, or 143 mm to 210 mm, or 143 mm to 225 mm, or 150 mm to 195 mm, or 150 mm to 210 mm, or 150 mm to 225 mm, or 195 mm to 210 mm, or 195 mm to 225 mm, or 210 mm to 225 mm, and specifically all enumerations therebetween in 1 mm increments.

[0131] According to various embodiments, the chassis width of the absorbent article is 250 to 650 mm, or 303 mm to 557 mm, or 303 mm to 330 mm, or 303 mm to 356 mm, or 303 mm to 387 mm, or 303 mm to 390 mm, or 303 mm to 410 mm, or 303 mm to 431 mm, or 303 mm to 432 mm, or 303 mm to 471 mm, or 303 mm to 478 mm, or 303 mm to 500 mm, or 303 mm to 505 mm, or 303 mm to 525 mm, or 303 mm to 526 mm, or 303 mm to 557 mm, or 330 mm to 550 mm. mm~356mm, or 330mm~387mm, or 330mm~390mm, or 330mm~410mm, or 330mm~431mm, or 330mm~432mm, or 330mm~471mm, or 330mm~478mm, or 330mm~500mm, or 330mm~505mm, or 330mm~525mm, or 330mm~526mm, or 330mm~557mm, or 356mm~387mm, or 356mm~390mm, or 356mm~410mm, or 356mm~431mm, or 356mm~432mm, or 3 56mm~471mm, or 356mm~478mm, or 356mm~500mm, or 356mm~505mm, or 356mm~525mm, or 356mm~526mm, or 356mm~557mm, or 387mm~390mm, or 387mm~410mm, or 387mm~431mm, or 387mm~432mm, or 387mm~471mm, or 387mm~478mm, or 387mm~500mm, or 387mm~505mm, or 387mm~525mm, or 387mm~526mm, or 387mm~557mm, or is 390mm~410mm, or 390mm~431mm, or 390mm~432mm, or 390mm~471mm, or 390mm~478mm, or 390mm~500mm, or 390mm~505mm, or 390mm~525mm, or 390mm~526mm, or 390mm~557mm, or 410mm~431mm, or 410mm~432mm, or 410mm~471mm, or 410mm~478mm, or 410mm~500mm, or 410mm~505mm, or 410mm~525mm, or 410mm~526mm,or 410mm~557mm, or 431mm~432mm, or 431mm~471mm, or 431mm~478mm, or 431mm~500mm, or 431mm~505mm, or 431mm~525mm, or 431mm~526mm, or 431mm~557mm, or 432mm~471mm, or 432mm~478mm, or 432mm~500mm, or 432mm~505mm, or 432mm~525mm, or 432mm~526mm, or 432mm~557mm, or 471mm~478mm, or 471mm~500mm, or 471mm~505mm, or 471mm~ It can be 525mm, or 471mm to 526mm, or 471mm to 557mm, or 478mm to 500mm, or 478mm to 505mm, or 478mm to 525mm, or 478mm to 526mm, or 478mm to 557mm, or 500mm to 505mm, or 500mm to 525mm, or 500mm to 526mm, or 500mm to 557mm, or 505mm to 525mm, or 505mm to 526mm, or 505mm to 557mm, or 525mm to 526mm, or 525mm to 557mm, or 526mm to 557mm, or 526mm to 557mm, and specifically, all enumerations in 1mm increments therebetween.

[0132] package The absorbent articles of the present disclosure may be placed in a package. The package may include a polymer film and / or other materials. Graphics and / or indicia relating to the characteristics of the absorbent article may be formed, printed, positioned, and / or placed on the exterior portion of the package. Each package may include multiple absorbent articles. The absorbent articles are packed under compression to reduce the possible size of the package while still providing a sufficient amount of absorbent articles per package. Packaging the absorbent articles under compression allows caregivers to easily handle and store the package and also provides manufacturers with reduced distribution costs due to the size of the package.

[0133] array An "array" refers to a display of packages containing disposable absorbent articles of different article configurations (e.g., different elastomeric materials (compositionally and / or structurally) in the side panels, side flaps, and / or belt flaps, different graphic elements, different product structures, fasteners, or the absence thereof). The packages may have the same brand and / or sub-brand and / or the same trademark registration and / or be manufactured by or for a common manufacturer, and the packages may be available at a common point of sale (e.g., oriented close to each other in a given area of ​​a retail store). Arrays are typically marketed to customers as a lineup of products with similar packaging elements (e.g., type of packaging material, film, paper, primary color, design theme, etc.) that communicate to consumers that the different individual packages are part of a larger lineup. Arrays often have the same brand, e.g., "Huggies," and the same sub-brand, e.g., "Pull-Ups." Different products within an array may have the same brand, "Huggies," and the sub-brand, "Little Movers." Differences between the "Pull-Ups" products in the array and the "Little Movers" products in the array may include product form, application style, different fastening designs, or other structural elements intended to accommodate differences in physiological or psychological development. Additionally, the packaging is noticeably different in that "Pull-Ups" are packaged primarily in blue or pink film bags and "Little Movers" are packaged primarily in red film bags.

[0134] Further, with respect to an "array," as another example, an array may be formed by different products having different product forms that are manufactured by the same manufacturer, e.g., Kimberly-Clark, and have common trademark registrations; for example, one product may have the brand name "Huggies" and the sub-brand "Pull-Ups." Different products within the array may have the brand / sub-brand "Good Nites," both of which are registered trademarks of The Kimberly-Clark Corporation and / or manufactured by Kimberly-Clark. Arrays also often have the same trademarks, such as trademarks of brands, sub-brands, and / or features and / or benefits across the lineup. An "online array" refers to an array that is manufactured and / or distributed by a common online source.

[0135] As shown in Figures 27A, 27B, 27C, and 27D, an array 900 of absorbent articles 10 may comprise a plurality of absorbent articles 10, such as a first absorbent article 912 comprising a first elastic side member 914 and a second absorbent article 922 comprising a second elastic side member 924. The first absorbent article 912 and the second absorbent article 922 may be manufactured by the same manufacturer and / or sold under the same brand name. The absorbent articles 10 are shown in a fastened position or in pant form merely for ease of illustration, with it being understood that the articles 10 may be in any configuration, such as folded, unfastened, and / or laid flat. The array may also be positioned within a package.

[0136] Each of the first elastic side member 914 and the second elastic side member 924 may include any version of the stretch laminate 90 described herein. For example, as shown in Figures 12A-12F, each of the first elastic side member 914 and the second elastic side member 924 may include at least a first cover layer 100 including a nonwoven material, an elastomeric film layer 300 in a face-to-face relationship with the first cover layer 100, and a plurality of ultrasonic bonds 400 joining the first cover layer 100 and the elastomeric film layer 300 to form the ultrasonically bonded stretch laminate 90.

[0137] Various elements of the absorbent article 10 described herein may comprise a stretch laminate. For example, the belts 54 and 56 and / or the elastic side members, including but not limited to the ears 42, 47, may comprise the stretch laminate 90. It is understood that the specific elements identified in FIGS. 27A-27C are merely exemplary. As illustrated in FIG. 27A, the first absorbent article 912 may be a tape diaper, and the elastic side members 916 may be front or back ears. The second absorbent article 922 may be a tape diaper, and the elastic side members 926 may be front or back ears. As illustrated in FIG. 27B, the first absorbent article 912 may be a pant diaper, and the elastic side members 916 may be side panels. The second absorbent article 922 may be a pant diaper, and the elastic side members 926 are side panels. 27A, the first absorbent article 912 may be a tape diaper and the elastic side members 916 may be front or back ears. The second absorbent article 922 may be a pant diaper and the elastic side members 926 are side panels. It is understood that the array 900 may comprise any number of absorbent articles having the same or different configurations and characteristics.

[0138] 27A-27C, the ultrasonically bonded stretch laminate 90 in the first absorbent article 912 may differ from the ultrasonically bonded stretch laminate 90 in the second absorbent article 914 in two or more characteristics selected from ultrasonic bond geometry, ultrasonic bond pattern, presence of frangible bonds, elastic film basis weight, first nonwoven primary bond pattern, and first nonwoven basis weight. In other words, the first absorbent article 912 may have a first plurality of features 916, and the second absorbent article 922 may have a second plurality of features 926. The first plurality of features 916 may include two or more features that the second plurality of features 926 does not include. Additionally or alternatively, the first plurality of features 916 may include two or more features that have different properties from the same or similar features of the second plurality of features 926.

[0139] Figure 27D is identical to Figure 27B except that the first elastic side member 914 and the second elastic side member 924 are separate. By "separate," we mean that the side members 914, 924 are separate components that are attached to the respective absorbent articles 912, 922 at attachment points 915, 925. The side member 914 can be attached by any suitable means, including via adhesive or ultrasonic bonding.

[0140] Various other differences and similarities exist between the first absorbent article 912 and the second absorbent article 914 in the array 900. For example, at least one dimension 918 of the first absorbent article 912 may differ from at least one dimension 928 of the second absorbent article 922. The first absorbent article 912 and the second absorbent article 914 in the array 900 may be similar or different based on any of the properties or characteristics described herein. For example, the first absorbent article or the second absorbent article may include an elastic waist feature in its front waist region or back waist region. The first absorbent article or the second absorbent article may include an acquisition layer between the topsheet and the absorbent core. A portion of the acquisition layer may overlap a portion of the elastic waist feature. The first absorbent article or the second absorbent article may include a core bag between the topsheet and the backsheet. A portion of the core bag may overlap a portion of the elastic waist feature. The elastic waist feature may include elastic strands. The first absorbent article or the second absorbent article may include an absorbent core including an absorbent material, and the absorbent material may include at least 80% superabsorbent polymer by weight of the absorbent material. The absorbent material may define channels therein.

[0141] Similarly, the first absorbent article 912 and the second absorbent article 914 in the array 900 can be similar or different based on the characteristics of the stretch laminate and the components made therefrom. For example, the elastic film in the first or second elastic side member can have activation stripes. The elastic film in the first or second elastic side member can have a coating on its surface. A portion of the coating can have multiple wrinkles, and the wrinkles can have grooves. The ultrasonically bonded laminate can include openings, slits, three-dimensional protrusions, or coloring. The first nonwoven material or elastic film can include bio-based resin or recycled resin. The ultrasonic bonding pattern can form one or more closed cells. The ultrasonic bonding pattern may not include one of the more closed cells. At least some of the ultrasonic bonds can be breakable in the elastic regions of the elastic side members. One or more of the ultrasonic bonds of the ultrasonic bonding pattern can be visible when viewing the garment-facing surface of the ultrasonically bonded laminate.

[0142] The elastic side members of the first absorbent article may have a different elongation, as measured by a tensile test, than the elastic side members of the second absorbent article. The elongation of the elastic side members of the first absorbent article may differ from the elongation of the elastic side members of the second absorbent article by 1% to 25%, or 5% to 20%, or 10% to 15%, as measured by a tensile test. For example, the elastic side members of the first absorbent article may have a 5% different elongation, as measured by a tensile test, than the elastic side members of the second absorbent article.

[0143] Any or all of the elastic side members of either the first absorbent article or the second absorbent article may have an engineering strain of 5% to 25%, or greater than about 8%, or about 10% to 20%, at a force of about 2 N or less, when measured according to the Laminate Stretch Test. For example, any or all of the elastic side members of either the first absorbent article or the second absorbent article may have an engineering strain of greater than about 8% at a force of about 2 N or less, when measured according to the Laminate Stretch Test.

[0144] Test Method Bond measurement test method The bond measurement test method is performed on reflected light microscopy images generated using a stereoscopic optical microscope (such as a Zeiss V20 Stereoscope) and a mounted camera (such as a Carl Zeiss AxioCam MRc5). Images containing at least one single repeat unit of the bond impression pattern are acquired while the sample is fully stretched and backed with a black background. If the area of ​​the single repeat pattern is too large for stereoscopic imaging, a DSLR camera (such as a Pentax R20D) or scanner (such as an Epson Perfection V750 Pro Flatbed Scanner) capable of at least 50 microns / pixel resolution can be used to collect the image. Measurements are performed using image analysis software (such as Image Pro Plus software version 7.0.0.591, Media Cybernetics, USA) calibrated to allow distances within the image to be accurately measured to the nearest 50 microns. For purposes of this method, a bond impression is the intentional joining of two or more layers and the deformed area caused during the bonding process (e.g., reduced caliper at the bond site). Prior to testing, samples are preconditioned under the same environmental conditions for 2 hours at approximately 23°C ± 2°C and approximately 50% ± 2% relative humidity.

[0145] Before and during image acquisition, the sample is fully stretched and held in a planar stretched state. For corrugated laminates, the specimen is fully stretched when the corrugations are substantially flattened by stretching the laminate, ensuring that the inelastic substrate of the laminate is not plastically deformed. For laminates without corrugations, the specimen is considered fully stretched without such stretching.

[0146] Percent Bond Area Open the image in image analysis software and identify single repeat units within the pattern of bond impressions and non-bonded areas. Draw a region of interest (ROI) encompassing the single repeat unit. Calculate and record the area of ​​the single repeat unit ROI. Next, use the irregular area tool to trace around each individual, separate bond impression or portion thereof enclosed within the single repeat unit ROI and record their individual areas. Calculate the sum of all individual, separate bond impression areas or portions thereof within the single repeat unit. Calculate the percent bonded area as follows:

[0147]

number

[0148] This procedure is repeated for a total of three replicate repeat units. The arithmetic mean of the three values ​​is calculated and reported as percent bound area rounded to the nearest 0.1%.

[0149] The arithmetic mean of all recorded areas was calculated, excluding any partial individual separate bonded impression areas, to within 0.01 mm 2 Report as discrete bond area rounded to the nearest unit.

[0150] bond separation distance The bond separation distance is defined as the shortest (minimum) linear distance between the perimeters of any two individual bond sites within a single closed-cell unit. Using image analysis software, measure and record the bond separation distance for all distinct bond sites that make up the perimeter of the identified single closed-cell unit. This procedure is repeated for a total of three replicate closed-cell units. Calculate and report the arithmetic mean of the recorded values, rounded to the nearest 0.1 mm, as the bond separation distance.

[0151] Laminate stretching test 1. Posterior ear Structures associated with the posterior ear 28 is a schematic, illustrative diagram showing an exemplary back ear 42 of an absorbent article and identifies features relevant to the analysis of the back ear according to the Laminate Stretch Test. The back ear 42 can have an overall width W extending from an inner edge 96 to an outer edge 97. The outer edge 97 is the free distal longitudinal edge of the ear when the ear is joined to the chassis. The inner edge 96 is substantially opposite the outer edge and is joined to or overlaps the chassis when the ear is joined to the chassis.

[0152] The back ear 42 may include a stretch laminate 90. The stretch laminate 90 comprises all or a portion of the overall width W of the back ear 42. The back ear 42 may include an elastic region 92. The elastic region 92 may coincide with all or a portion of the stretch laminate 90. The elastic region 92 may have a width WE extending from an inner edge 93 to an outer edge 94 of the elastic region 92. The width WE of the elastic region 92 may be less than or equal to the overall width W of the back ear 42. The inner edge 93 of the elastic region 92 may have a length LEP. The back ear 42 may further include a fastener 46 having a length LFP. In some embodiments, the area of ​​the elastic region comprises at least about 20% of the total area of ​​the ear, or from about 30% to about 100%, with 5% increments therebetween.

[0153] The back ear 42 may further include one or more inelastic regions. In certain embodiments, the back ear 42 includes a first inelastic region 98 that extends laterally outward from the inner edge 96 and is adjacent to the elastic region 92 at the inner edge 93 of the elastic region 92. The ear may further include a second inelastic region 99 that may extend laterally outward from the outer edge 97 and be adjacent to the outer edge 94 of the elastic region 92. The first and second inelastic regions may be made of the same or different materials.

[0154] Still referring to Figure 28, the nominal width WS may be identified as the width from the join line (defined in the following paragraph) to the inner edge 45 of the fastener 46. In some examples, the fastener 46 may have an irregular shape or orientation or may consist of multiple engaging portions, and in such examples, the point at which such shape, orientation, or extensible portion is closest to the longitudinal axis of the absorbent article is considered the inner edge 45 of the fastener 46.

[0155] As used herein, with respect to a back ear comprising a component separate from other components of the absorbent article to which it is welded, bonded, glued, or otherwise attached, the term "bond line" means a longitudinal line 95 parallel to the longitudinal axis of the absorbent article that passes through the outermost points of the chassis attachment bonds where the back ear is joined to the chassis. Note: In some instances of back ears, the back ear is joined to the chassis so as to have an irregular shape or orientation; in such instances, the point at which such shape or orientation is closest to the outer edge of the back ear will indicate the location of the bond line. With respect to a back ear comprising one or more components that are not separate from, but rather integral with, one or more components of a diaper chassis positioned in an open, stretched position and laid flat and horizontal, as viewed from above, "bond line" means a line parallel to the longitudinal axis that passes through the edge of the chassis at its narrowest point.

[0156] Preparation of back ear specimens To prepare back ear specimens for laminate extension testing, the following procedure may be used. 1. Open the diaper. 2. If the back ear 42 is attached to the article, separate the back ear from the article at a location sufficiently inboard of the bond line 95 so that the grips of the tensile tester can reach beyond the bond line 95 to grip a specimen for testing. If the back ear 42 is an integral part of the chassis, identify the bond line 95, mark a line on the back ear 42 that coincides with the bond line 95, and separate the back ear from the article at a location sufficiently inboard of the bond line 95 so that the grips of the tensile tester can reach beyond the bond line to grip a specimen for testing. 3. Place the back ear 42 on a substantially flat, horizontal surface and measure the width WS as described herein without applying any lateral tension to the back ear 42. 4. Using a steel ruler aligned to NIST or equivalent, measure the length LFP as described herein to the nearest 1 mm. 5. Mark the midpoint of the LFP. The midpoint is located at 1 / 2 of the LFP.

[0157] Testing of back ear specimens Engineering strain and extension of the back ear specimens are measured using a constant rate of extension tensile tester with a computer interface, such as MTS Alliance under Test Works 4 software (MTS Systems Corp., USA), fitted with a suitable load cell. The load cell should be selected to operate within 10% to 90% of its stated maximum load. All tests are conducted in a climate-controlled room maintained at approximately 23°C ± 2°C and approximately 50% ± 2% relative humidity. As used herein, specimen width and length are the transverse width and longitudinal length as defined herein. Precondition specimens to approximately 23°C ± 2°C and approximately 50% ± 2% relative humidity for two hours prior to testing. 1. Insert the outer edge 97 of the back ear 42, including the fastener 46, into the upper clamp of the tensile tester so that the clamp is centered in the fixture, and engage the clamp to grip the specimen. The clamp width is at least as wide as the length of the inner edge of the fastener 46, and preferably no wider than 1 inch beyond the length of the inner edge of the fastener 46. Align the face of the clamp (after gripping the specimen) with the inner edge of the fastener 46 to within 1 mm, align the longitudinal midpoint of the LFP with the center of the clamp, and hang the unclamped portion of the back ear from the upper clamp. 2. Insert the inside edge 96 of the back ear 42 into the lower clamp of the tensile tester. The width of the lower clamp is selected so that no portion of the back ear 42 extends beyond the width of the clamp, and preferably the width of the lower clamp is no more than 1 inch longer than the length of the portion of the back ear 42 that is inserted into the clamp. The face of the clamp (after gripping the specimen) is aligned to within 1 mm with the bond line 95, and the specimen is oriented so that a transverse line perpendicular to the longitudinal axis of the diaper with the back ear 42, when drawn from the midpoint of the LFP, extends vertically and is aligned with the center of the fixture holding the lower clamp. 3. Extend the jaws of the tensile tester so that the distance between the face of the upper clamp and the face of the lower clamp is equal to WS. Set the gauge length equal to WS. 4. Zero the crosshead position, load, and engage the lower clamp to grip the specimen. 5. Set the tensile tester to extend the specimen at a rate of 254 mm / min and collect data at a frequency of at least 100 hz. 6. Start the test so that the clamps of the tensile tester extend the specimen at the defined rate, and collect data including extension and load in a data file. 7. Determine the engineering strain under a 2N load by measuring the extension, which is the distance extended from the zero point under a 2N load, and calculating as follows: 100% × [extension at 2N load / WS (no lateral tensile load)]. 8. Similarly, for each test product being evaluated, test a total of three (3) replicate samples. Report extension as the average of the replicates to the nearest 0.1 cm, and report engineering strain as the average of the replicates to the nearest 0.1 cm.

[0158] 2. Side members Preparation of side member test specimens To prepare belt side member specimens for laminate extension: 1. Open the pants 10 by separating the belt side members where they are attached to one another, such as at the side seams 58 illustrated in FIG. 4. This is accomplished by cutting the fused or permanently bonded side seam regions 58 with an exacto knife, scissors, or the like, as illustrated in FIGS. 29A and 29B. Cut the side seam so that enough side seam remains available to grip the sample onto the clamps of the tensile tester. In the case of refastenable pants, the side members are not permanently fused or bonded to one another along the lateral sides of the article, but instead are attached to one another by releasable fasteners (typically a mechanical fastening system). In these cases, open the pants by carefully disengaging or separating the fasteners that releasably connect the side members to one another along the lateral sides of the article. 2. Separate the belt side member from the article at a location transverse to the bond line X so that the grips of the tensile tester can adequately grasp the specimen for testing at bond line X. Bond line X is a line parallel to the longitudinal axis of the article located at the outer edge of the absorbent structure. If the absorbent structure is irregularly shaped, the outer edge is considered to be the furthest laterally outer point of the irregularly shaped absorbent structure. Also, cut the belt side member along bond line Y. Bond line Y is a line parallel to the transverse axis of the article located at the inner longitudinal edge of the side seam as illustrated in Figures 29A and 29B. If the belt is rectangular in shape and is no longer than the side seam, it may not be necessary to cut bond line Y. 2a. If the pant article 10 contains separate side members attached to the chassis instead of a belt, cut the side member specimen at bond line 95 (consistent with the tape-on diaper back ear sampling procedure). Also, cut the separate side member along bond line Y as described herein and continue with step 3. 3. With the side member resting on a substantially flat horizontal surface and with no lateral tension applied, measure its width WS, which is the distance between the join line X and the laterally inner edge of the previously separated side seam region 58, as illustrated in Figures 29A and 29B. 4. Using a steel ruler aligned with a NIST or equivalent, measure the length LFP to the nearest 1 mm. LFP is the longitudinal length of the side member specimen at the outer cut edge. 5. Mark the midpoint of the LFP. The midpoint is half of the LFP.

[0159] Testing of side member specimens Side member testing The engineering strain and extension of the side member specimens are measured using a constant-rate-of-extension tensile tester with a computer interface, such as MTS Alliance under Test Works 4 software (MTS Systems Corp., USA), fitted with a suitable load cell. The load cell should be selected to operate within 10% to 90% of its stated maximum load. All tests are conducted in an air-conditioned room maintained at approximately 23°C ± 2°C and approximately 50% ± 2% relative humidity. Specimen width and length are defined herein as transverse width and longitudinal length. Precondition specimens to approximately 23°C ± 2°C and approximately 50% ± 2% relative humidity for two hours prior to testing. 1. Insert the outer edge of the side member into the upper clamp in the tensile tester so that the clamp is centered in the fixture, and engage the clamp to grip the specimen. For refastenable pants, grip the specimen by the side seam region 58, which includes a previously separated permanent side seam attachment bond or removable fastener. The clamp width is at least as wide as the length of the outer edge, and preferably does not exceed the length of the outer edge of the specimen by more than 1 inch. The clamp is set to grip the outer edge of the side member in a position aligned to within 1 mm, with the longitudinal midpoint of the outer edge of the side member aligned with the center of the clamp, and the unclamped portion of the side member hanging from the upper clamp. 2. Insert the inside edge of the side member into the lower clamp of the tensile tester. The lower clamp width is selected so that no portion of the side member extends beyond the width of the clamp, and preferably the lower clamp width does not exceed the length of the portion of the side member inserted into the clamp by more than 1 inch. Set the clamps to grip the specimen in a position aligned to within 1 mm of bond line X, and orient the specimen so that a transverse line perpendicular to the longitudinal axis of the pants with side members, when drawn from the midpoint of the LFP, extends perpendicular and is aligned with the center of the fixture holding the lower clamp. 3. Extend the jaws of the tensile tester so that the clamped distance between the upper and lower grip position clamps is equal to WS. Set the gauge length equal to WS. 4. Zero the crosshead position, load, and engage the lower clamp to grip the specimen. 5. Set the tensile tester to extend the specimen at a rate of 254 mm / min and collect data at a frequency of at least 100 hz. 6. Start the test so that the clamps of the tensile tester extend the specimen at the defined rate, and collect data including extension and load in a data file. 7. Determine the engineering strain under a 2N load by measuring the extension, which is the distance extended from the zero point under a 2N load, and calculating as follows: extension at 100% strain = 2 N load / WS (no transverse tensile load)]. 8. Similarly, test a total of three (3) replicate samples for each test product being evaluated. Report extension as the average of the replicates to the nearest 0.1 cm, report engineering strain as the average of the replicates to the nearest 0.1 cm, and report percent strain to the nearest 0.1%.

[0160] Tensile Test Method Tensile testing is described and illustrated in U.S. Patent Application Publication No. 2018 / 0042786, entitled "Array of Absorbent Articles with Ear Portions," by Mueller et al., which is incorporated by reference in its entirety. Tensile testing is used to measure the strength of test specimens at relatively high strain rates representative of product applications. This method uses a suitable tensile tester with a servohydraulic actuator, such as the MTS810 available from MTS Systems Corp. (Eden Prairie, Minn.), or equivalent, capable of speeds exceeding 5 m / s after 28 mm of travel and a closeout of 6 m / s after 40 mm of travel. The tensile tester is fitted with a 50 lb force transducer (available, for example, from Kistler North America (Amherst, NY) as product code 9712 B50 (50 lb)) and a signal conditioner with a dual-mode amplifier (available, for example, from Kistler North America as product code 5010). Grips should be used to secure the specimen during tensile testing. The opposing grips may have the same or different widths as specified. All testing is performed in a conditioned room maintained at about 23°C ± 2°C and about 50% ± 2% relative humidity. As used herein, the width and length of the test specimen are the transverse width and longitudinal length as defined herein. Precondition the specimen to about 23°C ± 2°C and about 50% ± 2% relative humidity for two hours prior to testing.

[0161] (a) Grip Line grips are selected to provide clear definition of standard dimensions and to avoid excessive slippage. The specimen is positioned with minimal slack between the grips. One or both portions of the grips may be constructed to contain a material that reduces the tendency of the specimen to slip (e.g., urethane or neoprene rubber strips with a Shore A hardness of 50-70). Unless otherwise specified, 6-inch wide top and bottom grips are used to clamp the specimen.

[0162] (b) Tensile test of specimen from absorbent article - rear ear The ears are generally bonded to the chassis via heat, adhesive, or similar bonding. The ears should be separated from the chassis so that the ears are not damaged and their performance is not altered. If the chassis bond is too strong (i.e., the ears are damaged upon removal), the portion of the chassis bonded to the ear should be cut within the chassis material without damaging the ear. Folded fastening systems (e.g., release tape covering the fastening elements) should be unfolded.

[0163] As illustrated in Figure 28A, the specimen is clamped in the upper grip at a first grip position inside the fastener attachment joint. The grip line is kept parallel to the longitudinal centerline of the product. If the fastener attachment joint is angled, the specimen is gripped in the center of the bond area, with the grip line kept parallel to the longitudinal centerline of the product at the center. The width of the upper grip should be equal to the maximum length of the fastener attachment joint measured parallel to the longitudinal centerline of the article. If the length of the specimen in the first grip position is the same as the maximum length of the fastener attachment joint, any grip width greater than the length of the specimen in the first grip position can be used. The specimen is attached and suspended from the upper grip. In a relaxed state, opposing edges of the specimen are attached to the bottom grip. The bottom grip position is adjusted so that the specimen is gripped at the outer edges of the chassis joint. If the chassis joints are curved, the specimen is gripped at the outer edge of the outermost joint, shown as joint line 95 in Figure 28. The bottom grip is greater than the length of the ears at the second gripping position. The top and bottom grips are parallel to each other.

[0164] The specimen is tested as follows: The perpendicular distance (perpendicular to the grip line) from the first grip position to the second grip position is measured to the nearest 0.1 mm using a ruler and used as the gauge length for the test. 9.1 seconds using the gauge length selected for the specimen. -1 The specimen is tested at a test speed that provides a strain rate of 9.1 s. -1Calculate by multiplying by the gauge length in mm. Before testing, allow 5 mm of slack between the grips.

[0165] Each specimen is pulled to break. During the test, one of the grips is held stationary while the opposing grip moves. Force and actuator displacement data generated during the test are recorded using a MOOG SmarTEST ONE STO03014-205 independent controller, with the data acquisition frequency set at 1 kHz. The resulting load data can be expressed as load at break in Newtons. The extension (mm) at 5N and 10N is also recorded. For example, a total of five specimens are tested. The mean load and standard deviation at break, the mean extension and standard deviation at 5N, and the mean extension and standard deviation at 10N are recorded. If the recorded standard deviation is higher than 5%, a new set of five specimens is tested.

[0166] (c) Length ratio - rear ear As in the previous step, the grips are positioned at the first and second grip positions. The ratio of the length of the specimen at the second grip position (L2) to the length of the specimen at the first grip position (L1) is the length ratio. Each length is measured to an accuracy of 0.1 mm using a ruler.

[0167] (d) Tensile test of specimens from absorbent articles - side members To prepare belt side member specimens for tensile testing: 1. Open the pants 10 by separating the belt side members where they are attached to one another, such as at the side seams 58 illustrated in FIG. 4. This is accomplished by cutting the fused or permanently bonded side seam regions 58 with an exacto knife, scissors, or the like, as illustrated in FIGS. 29A and 29B. Cut the side seam so that enough side seam remains available to grip the sample onto the clamps of the tensile tester. In the case of refastenable pants, the side members are not permanently fused or bonded to one another along the lateral sides of the article, but instead are attached to one another by releasable fasteners (typically a mechanical fastening system). In these cases, open the pants by carefully disengaging or separating the fasteners that releasably connect the side members to one another along the lateral sides of the article. 2. Separate the belt side member from the article at a location transverse to the bond line X so that the grips of the tensile tester can adequately grasp the specimen for testing at bond line X. Bond line X is a line parallel to the longitudinal axis of the article located at the outer edge of the absorbent structure. If the absorbent structure is irregularly shaped, the outer edge is considered to be the furthest laterally outer point of the irregularly shaped absorbent structure. Also, cut the belt side member along bond line Y. Bond line Y is a line parallel to the transverse axis of the article located at the inner longitudinal edge of the side seam as illustrated in Figures 29A and 29B. If the belt is rectangular in shape and is no longer than the side seam, it may not be necessary to cut bond line Y. 2a. If the pant article 10 contains separate side members attached to the chassis instead of a belt, cut the side member specimen at bond line 95 (consistent with the tape-on diaper back ear sampling procedure). Also, cut the separate side member along bond line Y as described herein and continue with step 3. 3. With the side member resting on a substantially flat horizontal surface and with no lateral tension applied, measure its width WS, which is the distance between the join line X and the laterally inner edge of the previously separated side seam region 58, as illustrated in Figures 29A and 29B. 4. Using a steel ruler aligned with a NIST or equivalent, measure the length LFP to the nearest 1 mm. LFP is the longitudinal length of the side member specimen at the outer cut edge. 5. Mark the midpoint of the LFP. The midpoint is half of the LFP.

[0168] To test the side members for tension testing, 1. Insert the outer edge of the side member into the upper clamp in the tensile tester so that the clamp is centered in the fixture, and engage the clamp to grip the specimen. For refastenable pants, grip the specimen by the side seam region 58, which includes a previously separated permanent side seam attachment bond or removable fastener. The clamp width is at least as wide as the length of the outer edge, and preferably does not exceed the length of the outer edge of the specimen by more than 1 inch. The clamp is set to grip the outer edge of the side member in a position aligned to within 1 mm, with the longitudinal midpoint of the outer edge of the side member aligned with the center of the clamp, and the unclamped portion of the side member hanging from the upper clamp. 2. In a relaxed state, insert the inside edge of the side member into the lower clamp of the tensile tester. The lower clamp width is selected so that no portion of the side member extends beyond the width of the clamp, and preferably the lower clamp width does not exceed the length of the portion of the side member inserted into the clamp by more than 1 inch. Set the clamps to grip the specimen in a position aligned to within 1 mm of the bond line X, and orient the specimen so that a transverse line perpendicular to the longitudinal axis of the pants with side members, when drawn from the midpoint of the LFP, extends perpendicular and is aligned with the center of the fixture holding the lower clamp.

[0169] The specimen is tested as follows: The perpendicular distance (perpendicular to the grip line) from the first grip position to the second grip position is measured to the nearest 0.1 mm using a ruler and used as the gauge length for the test. 9.1 seconds using the gauge length selected for the specimen. -1 The specimen is tested at a test speed that provides a strain rate of 9.1 s. -1 Calculate by multiplying by the gauge length in mm. Before testing, allow 5 mm of slack between the grips.

[0170] Each specimen is pulled to break. During the test, one of the grips is held stationary while the opposing grip moves. Force and actuator displacement data generated during the test are recorded using a MOOG SmarTEST ONE STO03014-205 independent controller, with the data acquisition frequency set at 1 kHz. The resulting load data can be expressed as load at break in Newtons. The extension (mm) at 5N and 10N is also recorded. For example, a total of five specimens are tested. The mean load and standard deviation at break, the mean extension and standard deviation at 5N, and the mean extension and standard deviation at 10N are recorded. If the recorded standard deviation is higher than 5%, a new set of five specimens is tested.

[0171] Examples / Combinations: 1. An array of absorbent articles, the array comprising: a first absorbent article including a first elastic side member; a second absorbent article including a second elastic side member; Each of the first and second elastic side members is a first nonwoven material; and an elastic film in face-to-face relationship with the first nonwoven material; a plurality of ultrasonic bonds joining the first nonwoven material and the elastic film to form an ultrasonically bonded laminate; the ultrasonically bonded laminate in the first absorbent article differs from the ultrasonically bonded laminate in the second absorbent article in two or more characteristics selected from ultrasonic bond geometry, ultrasonic bond pattern, presence of frangible bonds, elastic film basis weight, first nonwoven primary bond pattern, and first nonwoven basis weight; at least one dimension of the first absorbent article is different from at least one dimension of the second absorbent article; An array of absorbent articles, wherein the first and second absorbent articles are manufactured by the same manufacturer and / or sold under the same brand name. 2. The first and second elastic side members each include a second nonwoven material in facing relationship with the elastic film; an elastic film positioned intermediate the first nonwoven material and the second nonwoven material; 10. The absorbent article of paragraph 1, wherein a plurality of ultrasonic bonds join the first nonwoven material, the elastic film, and the second nonwoven material to form an ultrasonically bonded laminate. 3. The absorbent article of paragraph 1 or 2, wherein the ultrasonically bonded laminate in the first absorbent article has a different ultrasonic bond density per unit area than the ultrasonically bonded laminate in the second absorbent article. 4. An absorbent article described in paragraph 2 or 3, wherein the first nonwoven material and the second nonwoven material of the first elastic side member each have only a single layer, and the first nonwoven material or the second nonwoven material of the second elastic side member has two layers in a portion thereof. 5. An absorbent article described in any one of paragraphs 1 to 4, wherein the elastic films in the first and second elastic side members are pre-activated before being ultrasonically bonded to the first nonwoven material, such that when the elastic films are in a stretched state, the elastic films are bonded to the first nonwoven material. 6. The absorbent article of any one of paragraphs 1-5, wherein the elastic film in the first and second elastic side members has activation stripes. 7. The absorbent article of any one of paragraphs 1 to 6, wherein the elastic film in the first and second elastic side members has a coating on its surface, a portion of the coating having a plurality of wrinkles, and the wrinkles having grooves. 8. The absorbent article of any one of paragraphs 1 to 7, wherein the first absorbent article or the second absorbent article comprises an elastic waist feature in its front waist region or its back waist region. 9. The absorbent article of paragraph 8, wherein the first absorbent article or the second absorbent article includes an acquisition layer between the topsheet and the absorbent core, and a portion of the acquisition layer overlaps a portion of the elastic waist feature. 10. The absorbent article of paragraph 8, wherein the first absorbent article or the second absorbent article includes a core bag between the topsheet and the backsheet, and a portion of the core bag overlaps a portion of the elastic waist feature. 11. The absorbent article of paragraph 8, wherein the elastic waist feature comprises elastic strands. 12. The absorbent article of any one of paragraphs 1-11, wherein the ultrasonically bonded laminate comprises openings, slits, three-dimensional protrusions, or coloring. 13. The absorbent article of any one of paragraphs 1 to 12, wherein the first nonwoven material or elastic film comprises a bio-based resin or a recycled resin. 14. The absorbent article of any one of paragraphs 1-13, wherein the ultrasonic bonding pattern forms one or more closed cells. 15. The absorbent article of any one of paragraphs 1-13, wherein the ultrasonically bonded pattern does not include one of the more closed cells. 16. The absorbent article of any one of paragraphs 1-15, wherein at least some of the ultrasonic bonds are breakable in the elastic region of the elastic side member. 17. The absorbent article of any one of paragraphs 1-16, wherein one or more of the ultrasonic bonds of the ultrasonic bonding pattern are visible when viewing the garment-facing surface of the ultrasonically bonded laminate. 18. The absorbent article according to any one of paragraphs 1 to 17, wherein the first absorbent article is a tape-type diaper and the elastic side members are front ears or back ears. 19. The absorbent article of any one of paragraphs 1 to 18, wherein the second absorbent article is a tape-type diaper and the elastic side members are front ears or back ears. 20. The absorbent article of any one of paragraphs 1 to 18, wherein the second absorbent article is a pair of pants and the elastic side members are side panels. 21. The absorbent article of paragraph 20, wherein the pant is refastenable. 22. The absorbent article of any one of paragraphs 1 to 21, wherein the first absorbent article or the second absorbent article comprises an absorbent core comprising an absorbent material, and the absorbent material comprises at least 80% superabsorbent polymer by weight of the absorbent material. 23. The absorbent article according to paragraph 22, wherein the absorbent material defines channels therein. 24. The absorbent article of any one of paragraphs 1-23, wherein the elastic side members of the first absorbent article have an elongation that differs from that of the elastic side members of the second absorbent article by 5% according to a tensile test. 25. An absorbent article described in any one of paragraphs 1 to 23, wherein the elastic side members of the first absorbent article have an engineering strain of greater than about 8% at a force of about 2 N or less, when measured according to the Laminate Extension Test.

[0172] Further definitions and cross-references Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0173] All documents cited herein, including any cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest, or disclose any such invention, either alone or in combination with any other reference or references. Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall control.

[0174] While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. An array of absorbent articles, said array comprising: a first absorbent article including a first elastic side member; a second absorbent article including a second elastic side member; Each of the first and second elastic side members is a first nonwoven material; and an elastic film in face-to-face relationship with the first nonwoven material; a plurality of ultrasonic bonds joining the first nonwoven material and the elastic film to form an ultrasonically bonded laminate; the ultrasonically bonded laminate in the first absorbent article differs from the ultrasonically bonded laminate in the second absorbent article in two or more characteristics selected from ultrasonic bond geometry, ultrasonic bond pattern, presence of frangible bonds, elastic film basis weight, first nonwoven primary bond pattern, and first nonwoven basis weight; at least one dimension of the first absorbent article is different from at least one dimension of the second absorbent article; An array of absorbent articles, wherein said first and second absorbent articles are manufactured by the same manufacturer and / or sold under the same brand name.

2. each of the first and second elastic side members includes a second nonwoven material in facing relationship with the elastic film, the elastic film being positioned intermediate the first nonwoven material and the second nonwoven material; 10. The absorbent article of claim 1, wherein the plurality of ultrasonic bonds join the first nonwoven material, the elastic film, and the second nonwoven material to form the ultrasonically bonded laminate.

3. 3. The absorbent article of claim 1, wherein the ultrasonically bonded laminate in the first absorbent article has a different ultrasonic bond density per unit area than the ultrasonically bonded laminate in the second absorbent article.

4. 4. The absorbent article of claim 1, wherein the elastic films on the first and second elastic side members are pre-activated before being ultrasonically bonded to the first nonwoven material, such that when the elastic films are in a stretched state, the elastic films are bonded to the first nonwoven material.

5. The absorbent article of any one of claims 1 to 4, wherein the elastic films in the first and second elastic side members have activation stripes.

6. The absorbent article according to any one of claims 1 to 5, wherein the elastic film in the first and second elastic side members has a coating on its surface, a portion of the coating has a plurality of wrinkles, and the wrinkles have grooves.

7. The absorbent article of any one of claims 1 to 6, wherein the first absorbent article or the second absorbent article comprises an elastic waist feature in its front waist region or its back waist region.

8. The absorbent article according to any one of claims 1 to 7, wherein the first nonwoven material or the elastic film comprises a bio-based resin or a recycled resin.

9. The absorbent article of any one of claims 1 to 8, wherein said ultrasonic bonding pattern forms one or more closed cells.

10. The absorbent article of any one of claims 1 to 9, wherein said ultrasonic bonding pattern does not include one of a plurality of closed cells.

11. The absorbent article of any one of claims 1 to 10, wherein at least some of the ultrasonic bonds are breakable in the elastic regions of the elastic side members.

12. The absorbent article according to any one of claims 1 to 11, wherein the first absorbent article is a tape-type diaper, and the elastic side members are front ears or rear ears.

13. The absorbent article according to any one of claims 1 to 12, wherein the second absorbent article is a pair of pants and the elastic side members are side panels.

14. 14. The absorbent article of any one of claims 1 to 13, wherein the elastic side members of the first absorbent article have an extension that differs from the elastic side members of the second absorbent article by 5% according to a tensile test.

15. 15. The absorbent article of any one of claims 1 to 14, wherein the elastic side members of the first absorbent article have an engineering strain of greater than about 8% at a force of about 2N or less when measured according to the Laminate Extension Test.

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