Absorbent article having bonded stretch laminate

Abstract

A stretch laminate for an absorbent article includes a nonwoven substrate and an elastomeric film joined to the nonwoven substrate by a plurality of bonds. These bonds can be ultrasonic bonds or any combination of mechanical bonds including ultrasonic bonds. The plurality of bonds form a bond pattern having a relative standard deviation percent of greater than about 30% according to a bond-to-bond measurement test.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to absorbent articles, and more particularly to absorbent articles that include mechanically bonded stretch laminates having a bonding pattern. [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 a 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 easily 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 they interact with constantly. This makes it imperative for manufacturers to increase their investment in noticeable features.

[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 that are laminated or bonded together to provide different degrees of stretchability.

[0004] In recent years, the commercialization of ultrasonically bonded laminates has been encouraged by the absorbent article industry. These ultrasonically bonded laminates are simpler in construction and offer cost and complexity advantages, as they can eliminate the need for adhesives that require relatively more hardware, frequent cleaning, and contribute to ongoing costs and malodor in the product. Importantly, these simpler stretch laminates are subject to the same distinctiveness requirements as any other product feature or component. Summary of the Invention [Problem to be solved by the invention]

[0005] Ultrasonically bonded laminates may be used, for example, as the front or back ears of tape-type diapers or as the front or back side panels of pants. The front or back ears and side panels require different features to accommodate brands, tiers, and size lineups. Furthermore, these bonded laminates need to be distinctive to the consumer, so that functionality and / or aesthetics are conveyed therethrough without sacrificing performance. Thus, a need exists for improved design flexibility to support brands, tiers, and size lineups without introducing complexity and sacrificing performance.

[0006] 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]

[0007] In some embodiments, a stretch laminate for an absorbent article can include a nonwoven substrate and an elastomeric film joined to the nonwoven substrate by a plurality of ultrasonic bonds, the plurality of ultrasonic bonds forming a bond pattern having a relative standard deviation percent of greater than about 30% according to a bond-to-bond measurement test.

[0008] In some embodiments, the absorbent article comprises a stretch laminate. The stretch laminate comprises a nonwoven material and an elastomeric film joined to the nonwoven material by a plurality of ultrasonic bonds. The plurality of ultrasonic bonds form a bond pattern. The bond pattern has a relative standard deviation percent of greater than about 30% according to a bond-to-bond measurement test.

[0009] In some embodiments, an absorbent article includes a stretch laminate. The stretch laminate includes a first nonwoven material, a second nonwoven material, and an elastomeric film. The elastomeric film is joined to the first and second nonwoven materials by a plurality of ultrasonic bonds. The plurality of ultrasonic bonds form a bond pattern. The bond pattern has a relative standard deviation percent of greater than about 30% according to a bond-to-bond measurement test.

[0010] These and other features, aspects, and advantages of various embodiments will become better understood with reference to the following specification, figures, and 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, illustrative views of laminates having bond patterns with different bond densities; [Figure 22B] 1 is a schematic illustration of a laminate having bond patterns with different bond densities; [Figure 23A] FIG. 1 is a schematic illustration of an exemplary bonding pattern. [Figure 23B] 23B is a photograph of a portion of a back ear having the bonding pattern illustrated in FIG. 23A and attached to an absorbent article, the back ear including a tear. [Figure 24] 1 is a schematic illustration of a bond and two adjacent bonds, and the bond separation angle between the identified bond and the adjacent bond; [Figure 25] 1 is a schematic illustration of a bond and the bond separation angle and bond separation distance for the bond; [Figure 26A] 1 is a schematic, illustrative view of a bond pattern, as well as bond separation angles and bond separation distances, for one or more identified bonds; [Figure 26B] 1 is a schematic, illustrative view of a bond pattern, as well as bond separation angles and bond separation distances, for one or more identified bonds; [Figure 26C] 1 is a schematic, illustrative view of a bond pattern, as well as bond separation angles and bond separation distances, for one or more identified bonds; [Figure 27A] 1 is a schematic illustration of various joint shapes and the longest dimension for each of these joint shapes. [Figure 27B]1 is a schematic illustration of various joint shapes and the longest dimension for each of these joint shapes. [Figure 27C] 1 is a schematic illustration of various joint shapes and the longest dimension for each of these joint shapes. [Figure 28A] FIG. 1 is a schematic, illustrative diagram of determining bond separation angle and bond separation distance for a bond; [Figure 28B] 1A-1C are schematic illustrations of bond separation angles and bond separation distances for various non-circular bond shapes. [Figure 28C] 1A-1C are schematic illustrations of bond separation angles and bond separation distances for various non-circular bond shapes. [Figure 28D] 1A-1C are schematic illustrations of bond separation angles and bond separation distances for various non-circular bond shapes. [Figure 29A] FIG. 1 is a schematic illustration of a Voronoi diagram and the relative standard deviation percentage obtained for each bonding pattern. [Figure 29B] FIG. 1 is a schematic illustration of a Voronoi diagram and the relative standard deviation percentage obtained for each bonding pattern. [Figure 30A] 1A-1C are schematic illustrations of various bonding patterns. [Figure 30B] 1A-1C are schematic illustrations of various bonding patterns. [Figure 30C] 1A-1C are schematic illustrations of various bonding patterns. [Figure 30D] 1A-1C are schematic illustrations of various bonding patterns. [Figure 31] 30A-30D are charts containing the standard deviation and percent relative standard deviation for each of the various binding patterns illustrated in FIGS. 30A-30D. [Figure 32] 1 is a schematic illustration of a stretch laminate subjected to a lateral pulling force; [Figure 33A] 1A-1C are schematic illustrations of stretch laminates having various types of frangible bond sites after being subjected to a lateral tension force. [Figure 33B] 1A-1C are schematic illustrations of stretch laminates having various types of frangible bond sites after being subjected to a lateral tension force. [Figure 33C]1A-1C are schematic illustrations of stretch laminates having various types of frangible bond sites after being subjected to a lateral tension force. [Figure 34A] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns for nonwoven materials that may be used in accordance with various embodiments. [Figure 34B] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns for nonwoven materials that may be used in accordance with various embodiments. [Figure 34C] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns for nonwoven materials that may be used in accordance with various embodiments. [Figure 34D] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns for nonwoven materials that may be used in accordance with various embodiments. [Figure 34E] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns for nonwoven materials that may be used in accordance with various embodiments. [Figure 34F] 1A-1C are schematic, illustrative diagrams showing various primary bond patterns for nonwoven materials that may be used in accordance with various embodiments. [Figure 35A] FIG. 2 is an exploded perspective view of an exemplary side member, schematically illustrating an exemplary surface modification portion. [Figure 35B] FIG. 2 is a plan view of an exemplary side member illustrating exemplary structural features. [Figure 36] FIG. 1 is a schematic, illustrative view of adjacent bonds and features involved for determining bond separation distance. [Figure 37] FIG. 1 is a schematic illustration of adjacent bonds and features involved for determining a bond separation angle; [Figure 38A] 1 is a schematic, illustrative diagram showing an exemplary back ear of an absorbent article, identifying features relevant to the Back Ear Extension Test. [Figure 38B] 1 is a schematic, illustrative diagram showing a side view of an exemplary back ear of an absorbent article, identifying features relevant to the Back Ear Extension Test. [Figure 39A] FIG. 1 is a schematic illustration of a partial absorbent article with attached ears and associated cutting lines for the Back Ear Hang Time Test. [Figure 39B] FIG. 10 is a schematic illustration of the clamp attachment associated with the Back Ear Hang Time Test. [Figure 39C] 10 is a photograph of an exemplary back ear including a burst associated with a back ear hang time test. [Figure 40A] 10A-10C are schematic illustrations of various additional bonding patterns. [Figure 40B] 10A-10C are schematic illustrations of various additional bonding patterns. [Figure 40C] 10A-10C are schematic illustrations of various additional bonding patterns. [Figure 40D] 10A-10C are schematic illustrations of various additional bonding patterns. [Figure 40E] 10A-10C are schematic illustrations of various additional bonding patterns. [Figure 40F] 10A-10C are schematic illustrations of various additional bonding patterns.

[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 provided to explain the present invention to those skilled in the art, and those skilled in the art will understand that the present 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 the 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), unless expressly stated otherwise, may be replaced by alternative features serving the same, equivalent, or similar purpose. 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 be noted, therefore, 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 listed as an element of a claim, 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 otherwise restored or reused as absorbent articles, i.e., they 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 of a material whereby, 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 would be 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 the material's original relaxed length without rupturing or breaking such that the material would be 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 would be 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] "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."

[0032] "Refastenable" refers to the property that two elements can be releasably attached, separated, and then releasably reattached without substantial permanent deformation or rupture.

[0033] "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.

[0034] 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.

[0035] 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 f is 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.

[0036] "Wrinkles" refer to small folds, ridges, or creases.

[0037] "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.

[0038] "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.

[0039] "Machine direction" (MD) refers to the direction of material flow through a process. Additionally, 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.

[0040] "Cross direction" (CD) refers to the direction generally perpendicular to the machine direction.

[0041] 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, nonwovens may include polyolefin-based nonwovens, including, but not limited to, nonwovens having polypropylene and / or polyethylene fibers and / or 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.

[0042] "Pattern," as used herein, 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.

[0043] The lateral or transverse axis of an absorbent article refers to a direction that extends at an angle of 90 degrees to the longitudinal direction, including directions within ±45 degrees of the lateral direction.

[0044] The longitudinal axis of an absorbent article refers to a direction extending parallel to the largest linear dimension of the article, including directions within ±45° of the longitudinal direction.

[0045] 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.

[0046] 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.

[0047] 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 material(s) 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.

[0048] 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 at line 7-7 in FIG. 6. FIG. 8 is an exemplary cross-sectional view of the absorbent article taken approximately at line 8-8 in FIG. 6. 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 FIGS. 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 and back belts 54 and 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.

[0049] 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.

[0050] The front and back inner belt layers 66, 67 and the front and back 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.

[0051] The front belt edge 55 and the rear belt edge 57 can extend longitudinally beyond the front chassis edge 19 and the rear chassis edge 21 (shown in FIG. 6 ), or they can be coterminous. The front and rear belt side edges 23, 25, 27, and 29 can extend laterally beyond the chassis side edges 22 and 24. The front belt 54 and the rear belt 56 can be continuous (i.e., have at least one layer that is continuous) from belt side edge to belt side edge (e.g., the transverse distances from 23 to 25 and 27 to 29). Alternatively, the front belt 54 and the rear belt 56 can be discontinuous from belt side edge to belt side edge (e.g., the transverse distances from 23 to 25 and 27 to 29) so that they are distinct.

[0052] 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.

[0053] 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 ).

[0054] 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).

[0055] 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.

[0056] 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.

[0057] 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, permitting 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 porous foams, reticulated foams, apertured plastic films, woven or 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, apertures will typically be present to allow body exudates to pass through the topsheet.

[0058] 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, underwear, 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.

[0059] 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 a bond pattern, apertures, and / or three-dimensional features. The outer cover material 40 may be a hydroentangled nonwoven material.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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 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.

[0064] 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 consists essentially of SAP. The absorbent material can also be a high internal phase emulsion foam.

[0065] 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. "Superabsorbent polymer particles," as used herein, refer to superabsorbent polymer materials that are in particulate form such that they are flowable in the dry state.

[0066] 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, a microfibrous adhesive net may be used in airfelt-free cores. These adhesives 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.

[0067] 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.

[0068] The basis weight (volume 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 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 Application Publication 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 be embodied in 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.

[0069] 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.

[0070] 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, the wearer-facing surface 4, or between the garment-facing surface and the wearer-facing surface. 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 wearer's waist 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.

[0071] 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 may 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, apertured 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, a first acquisition material may include a nonwoven material and a second acquisition material may include a cross-linked cellulosic material.

[0072] 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.

[0073] 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).

[0074] 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 may 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, the backsheet 28, and / or the 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 chassis 52 of the absorbent article. Additionally or alternatively, any of the ears 42, 47 may comprise a stretch laminate, as described below.

[0075] 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 .

[0076] 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.

[0077] 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 by deriving them 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).

[0078] The absorbent article components may comprise a biobased content value of 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, for example, ASTM D6866-10, Method B.

[0079] Bio-based absorbent articles suitable for recycling The 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.

[0080] 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.

[0081] 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. It should also be understood that the layers of the stretch laminate can be joined using a combination of mechanical bonds, such as thermal bonds, pressure bonds, and ultrasonic bonds. 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.

[0082] 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.

[0083] The elastically extensible material includes one or more elastomeric materials that provide elasticity to at least a portion of the layer. Non-limiting examples of elastomeric materials include films (e.g., polyurethane films, films derived from rubber and / or other polymeric materials), elastomeric coatings applied to another substrate (e.g., hot melt elastomers, elastomeric adhesives, printed elastomers, or elastomers coextruded onto another substrate), elastomeric nonwovens, scrims, etc. The elastomeric material may be formed from any suitable elastomeric polymer, including polymers with known elastomers, including, but not limited to, styrene derivatives (e.g., styrenic block copolymer materials), polyesters, polyurethanes, polyetheramides, polyolefins, combinations thereof, or coextruded VISTAMAXX®. Exemplary elastomers and / or elastomeric materials are disclosed in U.S. Patent Nos. 8,618,350, 6,410,129, 7,819,853, 8,795,809, 7,806,883, 6,677,258, and U.S. Patent Publication No. 2009 / 0258210.Commercially available elastomeric materials include KRATON (a styrenic block copolymer available from Kraton Chemical Company, Houston, TX), SEPTON (a styrenic block copolymer available from Kuraray America, Inc., New York, NY), VECTOR (a styrenic block copolymer available from TSRC Dexco Chemical Company, Houston, TX), ESTANE (a polyurethane available from Lubrizol, Inc., Ohio), PEBAX (a polyether-based block amide available from Arkema Chemicals, Philadelphia, PA), HYTREL (a polyester available from DuPont, Wilmington, DE), VISTAMAXX (a homopolyolefin and random copolymer, and blends of random copolymers available from EXXON Mobile, Spring, TX), VERSIFY (a homopolyolefin and random copolymer, and blends of random copolymers available from Dow Chemical Company, Midland, Michigan), and INFUSE (a Dow Chemical The elastically extensible material may include a modified resin.

[0084] The elastically extensible material may contain a variety of additives. Suitable additives may be used to prevent thermal, oxidative, and biochemical degradation of the elastically extensible material, including, but not limited to, stabilizers, antioxidants, and bacteriostats. 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 additive.

[0085] 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.

[0086] 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).

[0087] 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.

[0088] The desirability and perceptibility of many stretch laminate features have been tested by consumers. The choice of nonwoven can affect the appearance of the bond pattern and 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. In short, by varying these parameters in the laminate, clear distinctions can be made that are easily noticed and understood by consumers. Some further variations are detailed below.

[0089] The attachment of layers of a stretch laminate is discussed herein as having ultrasonic bonds. However, it should be understood that other types of mechanical bonds may be used in combination with ultrasonic bonds to form a stretch laminate, and the following disclosure is applicable to this combination of bonds. For example, a stretch laminate may include ultrasonic and thermal bonds, or ultrasonic and pressure bonds.

[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 comprise 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 spunbond), SSMMS (spunbond 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-roll) processes. One exemplary nonwoven material is a carded nonwoven material made from polypropylene homopolymer. Spunbonds can also be specially designed and / or manufactured to be compatible with an activation process. However, it is believed that greater flexibility in design options can be achieved through the use of elastomeric films according to the present disclosure. For example, spunbonds can be selected for applications where only carded nonwoven materials have been used in the past, or thinner elastomeric films can 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 can 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 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, this adhesive is also suitable for use in fabricating stretch laminates from the elastomeric films and cover layers listed above using conventional stretch laminate manufacturing equipment (such equipment being well known in the art).

[0094] The nonwoven fabric may include added materials such as inks, color change indicators, and skin compositions such as moisturizers, fragrances, lubricants, antimicrobials, insect repellents, and UV protection. The added materials may be disposed on one or more layers of the nonwoven fabric or laminate. The added materials may be disposed on a surface. For example, ink may be applied to the nonwoven fabric by printing. The ink may provide a visual signal to the user, such as the location of a bond or a bond pattern or graphic.

[0095] The bonding pattern of the laminate can coordinate with other portions of the absorbent article. For example, the bonding pattern of the laminate can coordinate with patterns on the chassis, such as the topsheet and / or backsheet, ears, fasteners, and / or waist features. The matching pattern can be a pattern formed by mechanically changing the structure of the material or by adding material to form the pattern, such as by printing.

[0096] 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 (i.e., straining) the elastomeric film layer 300 more than 50% in a direction transverse to its web direction. 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 elastomeric film layer. 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%.

[0097] 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 will contract and recover differently (i.e., have different permanent set values). Compared to the elastically extensible material, the coating is less elastic and therefore recovers less after stretching, i.e., has a larger 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 will force 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.

[0098] 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 thicker, elastically extensible material between them. The skin on the upper side of the cross-section is more easily discerned by the cross-section being more cleanly cut in that region. 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.

[0099] Figure 14A is an SEM micrograph taken at approximately 900x magnification showing a cross-section of a portion of an elastomeric film that has been preactivated. 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 preactivation, the skin, and therefore 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.

[0100] 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.

[0101] 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.

[0102] 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 textured surface of the preactivated elastomeric film, a greater surface area of ​​contact between the elastomeric film and the ink is achieved. Thus, when printing on a preactivated elastomeric film, the image adheres more strongly to the film compared to an image printed on the much smoother surface of a non-preactivated elastomeric film.

[0103] 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 was removed from the elastomeric film 300 layer prior to printing. Therefore, the printed image will not be substantially further deformed 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.

[0104] In some embodiments, the pre-activated elastomeric film can be re-stretched during printing of 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).

[0105] In embodiments of stretch laminates comprising a pre-activated and subsequently 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 textured surface of a pre-activated elastomeric film will anchor more strongly to the film (compared to ink placed on an elastomeric film that is not pre-activated) due to the additional surface area of ​​contact between the elastomeric film and the ink.

[0106] 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).

[0107] 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.

[0108] Regarding the preactivation process, the elastomeric film 300 may be guided through a system of interlocking rollers (i.e., a ring-roll process), where each roller includes a disk packet with multiple interlocking disks arranged on an axis. 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 has a positive effect on the stretch force profile, helping to enable easy stretching of fabricated stretch laminates over large expansion areas. Furthermore, the recovery of the stretch laminate 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.

[0109] 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.

[0110] The pre-activated and optionally printed film may then be cut into filmstrips 502. The filmstrips 502 are guided across a redirecting means 503 and fed as parallel strips to a laminating means 504. The filmstrips 502 are then laminated in the laminating means 504 between cover layers 100, 200 fed above and below the filmstrip. The filmstrips 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., an embodiment of the stretch laminate material detailed herein). As illustrated in FIG. 17 , the filmstrips 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 filmstrips 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.

[0111] The composite material 507 is then fed to an activation means 510, where the composite material is stretched in the elastic region 508 in the transverse direction relative to the web direction. To stretch, the composite material 507 can be guided through a nip between two shaped 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 shaped rollers form gaps through which the composite material 507 is guided essentially without transverse stretch. 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 redistribution. 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.

[0112] 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.

[0113] The laminate may include gathers, where one of the layers is distorted at a greater angle than the remaining layers during lamination. In this manner, the less extensible layer (i.e., the coverstock layer) will form gathers when the laminate is in a relaxed state. In some embodiments, at least a portion of the elastomeric layer is distorted while the nonwoven is in a relaxed state during lamination. The elastomeric layer may be stretched in one or more directions. Pleats then form in the nonwoven layer when the subsequently formed laminate is in a relaxed state. When making a gathered or gathered laminate, the elastomeric layer is stretched in the stretch direction (i.e., the intended direction of stretch in the final product). The stretch direction may be the lateral direction. In a non-limiting example, the elastomeric layer is stretched in a direction corresponding to the lateral direction of the article. In other words, when the laminate is joined to the chassis after lamination, the laminate will be oriented such that the laminate is stretchable in the lateral direction of the article (i.e., the laminate is extensible in the lateral direction).

[0114] Joint 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. Furthermore, the bond shape can be circular, as illustrated in FIG. 18 , or some other hollow shape. Providing a variety of ultrasonic bond shapes can add visual appeal and help distinguish various absorbent articles without compromising bond strength.

[0115] Bond Pattern Groups of ultrasonic bonds, or a combination of ultrasonic bonds and other types of bonds (such as pressure and / or thermal bonds), can be arranged in units, 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 a closed-cell pattern and other areas with an open-cell pattern. FIG. 19 is a schematic illustration of an open-cell bond pattern 600. The pattern 600 shown in FIG. 19 also includes multiple bond shapes, including an elliptical bond shape 602a, a circular bond shape 602b, and a diamond bond shape 602c.

[0116] A "unit" is the smallest building block of a pattern, the geometric arrangement of which defines the characteristic image of the pattern and whose repetition in space 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.

[0117] "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 having 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 a 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.

[0118] 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.

[0119] 21A and 21B illustrate plan views of exemplary side members including a stretch laminate 90, each having two or more bonding patterns. The exemplary side members can be a first elastic side member 914 or a second elastic side member. 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 ​​the closed-cell units, bond density, 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 a second bond pattern, the first and second bond patterns may also have different bond densities. "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.

[0120] Traditional bond patterns consist of multiple ultrasonic bonds arranged in a grid pattern, such as that illustrated in FIG. 22B, or an offset grid pattern, such as that illustrated in FIG. 22A. These patterns have been favored for their ease of manufacture (allowing for relatively fast production while maintaining quality) and their wide applicability to various components of absorbent articles. However, ultrasonic bonds can be used to create a variety of stretch laminate designs that convey signals to end users, such as stretch, softness, and quality. Furthermore, more complex bond patterns have the ability to differentiate a product from competing products. More intricate ultrasonic bond patterns present relatively more challenges with processability and product performance. These intricate ultrasonic bond patterns generally have individual ultrasonic bonds that are more closely spaced together. For example, as previously discussed, closed-cell units can be used in bond patterns such as those illustrated in FIGS. 21A and 21B. These bonds appear close enough together that they appear as a continuous line, even though they are individual bonds. It has been found that if the bonds are placed relatively close to one another, the stretch laminate may be more susceptible to rupture, such as tearing of the elastic film, during use. It is believed that the relatively close spacing of certain bonds creates areas of high stress concentration, which in turn can cause rupture to form in the stretch laminate as the laminate is stretched and held in a stretched state during use.

[0121] For example, a back ear 42 comprising a stretch laminate with a herringbone bond pattern 610 as illustrated in Figure 23A was stretched according to the Back Ear Hang Time Test. After stretching the back ear 42 according to the Back Ear Hang Time Test, a tear 612 formed in the stretch laminate, as illustrated in Figure 23B. A tear refers to any opening or tear formed in at least one of the cover layer and the elastic film. These tears are unacceptable for use in an absorbent article and can cause premature failure of the absorbent article.

[0122] It has been found that the longitudinal and transverse spacing between bonds should be controlled to eliminate and / or minimize these areas of high stress concentration that could lead to rupture in the stretch laminate. More specifically, the proximity of adjacent bonds is controlled depending on their orientation relative to the longitudinal and transverse directions to maintain the visual impression of a continuous line without allowing stress concentrations that could lead to rupture. Each bond adjacent to a primary bond can be identified as either a transversely oriented bond or a longitudinally oriented bond, and the appropriate spacing is determined based on this orientation. Controlling the spacing of adjacent bonds relative to the primary bond allows the stretch laminate, which may be a side panel or an ear, to not burst more than 5 mm following a back ear suspension test.

[0123] Referring to FIG. 24 , a first or primary bond site 614 can be adjacent to a second bond site 616. The bond sites are adjacent such that a straight line can be drawn between the bond sites, and the line does not intersect with another bond site. A second bond site 616, also referred to herein as an adjacent bond site, is defined as being longitudinally oriented relative to a first bond site 614, also referred to herein as a primary bond site, if the first bond site 614 is adjacent to the second bond site 616 and the second bond site 616 is between 0 and 35 degrees from the bond longitudinal axis 618 of the first bond site. The bond longitudinal axis 618 is parallel to the central longitudinal axis 50 of the absorbent article and passes through the center of gravity, also referred to as the geometric center, of the first bond site 614. The bond longitudinal axis 618 can be substantially perpendicular to the stretch direction of the stretch laminate and perpendicular to the bond transverse axis 620. The bond transverse axis 620 is parallel to the transverse axis 48 of the absorbent article and passes through the centroid of the first bond site 614. As illustrated in FIG. 24, a longitudinally oriented bond site 622 is any bond site located within 35 degrees of the bond longitudinal axis 618 of the primary bond site 614. A transversely oriented bond site 624 is any bond site adjacent to a primary bond site that is not within 35 degrees of the bond longitudinal axis 618 of the primary bond site 614, as illustrated in FIG. 24. Each adjacent bond to a primary bond has a bond separation angle θ measured from the bond longitudinal axis 618. Stated another way, a longitudinally oriented bond is a bond adjacent to a primary bond that has a bond separation angle θ of 0 degrees to 35 degrees or less, inclusive, measured from the bond longitudinal axis 618 of the primary bond site 614. A transversely oriented bond is a bond adjacent to a primary bond and having a bond separation angle θ greater than 35 degrees and up to and including 90 degrees.

[0124] Generally, binding sites that are longitudinally oriented relative to the primary binding site should be spaced a greater distance from the primary binding site than binding sites that are transversely oriented relative to the primary binding site. The distance between the secondary binding site and the primary binding site depends on the dimensions of the primary first binding site 614. Each primary binding site has a longest bond dimension D. The longest bond dimension D is the longest dimension of the binding site measured parallel to the bond longitudinal axis 618. For example, as illustrated in FIG. 25, the primary binding site 614 has a longest bond dimension D, which is the longest dimension of the binding site in a direction parallel to the bond longitudinal axis 618. For a circular binding site, as illustrated in FIG. 25, the longest bond dimension D is the diameter of the primary binding site 614. To create an ultrasonic bond pattern that has the appearance of having a continuous line and is resistant to rupture, adjacent longitudinally oriented bonds and primary bonds should have a bond separation distance that is at least 2.1D (or 2.1 multiplied by the longest bond dimension D) and less than 4.1D (or 4.1 multiplied by the longest bond dimension D). Additionally, adjacent transversely oriented bonds and primary bonds should have a bond separation distance that is at least 1.3D (or 1.3 multiplied by the longest bond dimension D) and less than 2.1D (or 2.1 multiplied by the longest bond dimension D).

[0125] FIG. 25 illustrates the zones established by the bond separation angle and bond separation distance, which are based on the longest bond dimension of the primary bond. The first zone 630, illustrated by the crosshatching in FIG. 25, is a zone established by the perimeter of the bond site, up to 2.1D for the area within 35 degrees from the bond longitudinal axis 618, and up to 1.3D for the area greater than 35 degrees and up to and including 90 degrees from the bond longitudinal axis 618. It is undesirable for an adjacent or second bond to be located in the first zone 630. A bond located in the first zone 630 is in close proximity to the primary bond, creating a high likelihood of stress concentrations forming during use, leading to the formation of a rupture. The second zone 632, illustrated by shading in Figure 25, is a zone extending from the first zone 630 up to 2.1D for areas greater than 35 degrees and up to and including 90 degrees from the bond longitudinal axis, and up to 4.1D for areas within 35 degrees from the bond longitudinal axis 618. Bonds may be located in the second zone 632. Bonds located in the second zone 632 are close enough to the primary bond to have the appearance of being continuous, yet are separated a distance from the primary bond that is large enough to reduce stress concentrations and thereby prevent ruptures from forming during typical use.

[0126] Figures 26A-26C illustrate various bond patterns and various zones based on primary bond sites. For example, Figures 26A-26C illustrate a bond pattern 600 having a primary bond 614 and multiple bonds adjacent to the primary bond 614. As illustrated in Figure 26A, none of the adjacent secondary bonds 616 are within the second zone 632; therefore, these secondary or secondary bonds 616 are not close enough to the primary bond to create the visual impression of being in a continuous line with the primary bond. Figure 26B illustrates a herringbone bond pattern including bonds, including adjacent bonds within the first zone 630, when selected as primary bonds. Therefore, this bond pattern may be at risk of rupture due to the close spacing of the bonds. FIG. 26C illustrates another bond pattern including bonds in the second zone 632 positioned relative to each other to create the visual impression of continuity, but positioned at a distance large enough that they are not in the first zone 630 and do not result in rupture during normal use.

[0127] The above disclosure is also applicable to bonds having non-circular shapes. Regardless of the shape of the bond site, the primary bond has a longest bond dimension D measured in a direction parallel to the bond longitudinal axis 618. For example, FIGS. 27A-27C illustrate various shapes of bond sites and their longest bond dimensions D. As previously explained, the longest bond dimension D is the longest dimension of the bond site in a direction parallel to the bond longitudinal axis and is used to determine the first zone 630 and the second zone 623. Referring to FIG. 28A, the longest bond dimension D of the primary bond site or first bond site 614 is determined to establish the first zone 630 and the second zone 632. A first boundary can be established by measuring 1.3D from the perimeter of the primary bond site in a direction perpendicular to the perimeter of the primary bond site. Similarly, a second boundary can be established by measuring 2.1D from the perimeter of the primary bond site in a direction perpendicular to the perimeter of the primary bond site, and a third boundary can be established by measuring 4.1D from the perimeter of the primary bond site in a direction perpendicular to the perimeter of the primary bond site. The bond separation angle limits for longitudinally oriented bonds and laterally oriented bonds are determined. A first zone 630, illustrated by crosshatching, including bond separation angles from 0 degrees to 35 degrees and below, and a second zone 632, illustrated by shading, including bond separation angles from greater than 35 degrees to 90 degrees and below, can then be determined. The first and second zones 630 and 632 can then be visually illustrated as shown in FIG. 28A. This method can be used for any bond shape. FIGS. 28B-28E illustrate first and second zones 630 and 632 of various other shapes.

[0128] Another way to evaluate a bond pattern to determine whether it has bond-free areas to create the visual perception of a continuous line and a pillow-like characteristic that conveys softness is by analyzing a Voronoi diagram, whose values ​​are the output of a Euclidean distance map. As previously discussed, a laminate bond pattern affects the texture formed in both the relaxed and stretched states of the laminate. Beyond the requirement of a single bond and its nearest neighbor, there is also consideration of how the bond locations relate to each other and to the open, unbonded areas. When separate bond sites are close together, they behave as a continuous line not only in appearance to the human eye, but also in how they physically define the bends in the nonwoven. The open, unbonded areas create a soft, pillow-like characteristic that is preferred by consumers for both texture and appearance. This relationship is quantified through image analysis of the binary bond pattern image to generate a Voronoi diagram, an image of cells bounded by lines of pixels that are equal distances to the borders of the nearest bond sites, where the pixel values ​​of the Voronoi diagram are the output from a Euclidian distance map (EDM) of the binary bond pattern image. The EDM is generated when each inter-bond pixel in the binary image is replaced with a value equal to the pixel's distance from the nearest bond site. The distribution of these Voronoi diagram distance values ​​across the two-dimensional span of the pattern quantifies the relationship between the area of ​​closer bonds and open areas.

[0129] Traditionally, as previously discussed, bond patterns have been uniform, such as grid and offset grid patterns. The distribution of distance values ​​from a uniform bond pattern has a relatively low variance, as measured by the relative standard deviation. However, consumers prefer bond patterns that have the perception of continuous lines and are perceived as soft. Bond patterns with these characteristics have a higher relative standard deviation due to bond sites being close together in certain areas and having other areas that are open or have bond sites. Figure 29A illustrates a conventional offset grid bond pattern. A Voronoi diagram is generated for the offset grid pattern according to the inter-bond measurement test method. The inter-bond distance distribution can then be determined. As illustrated in Figure 29A, the relative standard deviation (RSD) percentage is 10.4% for the offset grid pattern. In comparison, Figure 29B illustrates a bond pattern according to the present disclosure, which has bonds with open areas that create the perception of continuous lines and convey a perception of softness to consumers through pillow-like areas. A Voronoi diagram was generated for this bond pattern according to the bond spacing test method, as illustrated in Figure 29B. The relative standard deviation (RSD) percent for this bond pattern is 49.7%, as illustrated in Figure 29B. The bond pattern illustrated in Figure 29B has a higher relative standard deviation percent compared to the bond pattern illustrated in Figure 29A. This difference in relative standard deviation percent is due to differences in the spacing of bonds within the bond pattern. The Voronoi diagram according to the bond spacing test method can also be used to determine the standard deviation of a bond pattern.

[0130] FIGS. 30A-30D illustrate several other bond patterns. More specifically, FIG. 30A illustrates several conventional grid and offset grid patterns (G1, G2, G3, and G4). FIG. 30B illustrates several herringbone-shaped bond patterns (H1-H11). FIG. 30C illustrates heart-shaped bond patterns (R1 and R2). FIG. 30D illustrates several hexagonal bond patterns (X1, X2, X2, and X4). Each of the patterns illustrated in FIGS. 30A-30D can be analyzed according to the inter-bond measurement test method. The results of such an analysis are shown in FIG. 31, which graphically depicts the standard deviation and relative standard deviation percentage for each of the bond patterns. As illustrated in the graph, the relative standard deviation percentage is higher for each of the herringbone-shaped, heart-shaped, and hexagonal bond patterns. Generally, conventional bond patterns, such as grid and offset grid bond patterns, visually form continuous lines and have relatively lower standard deviations and relative standard deviation percentages than bond patterns that include bonds with no or open areas. Furthermore, conventional grid and offset grid patterns generally have lower standard deviations than hexagonal, heart-shaped, and herringbone-shaped bond patterns. Figures 40A-40F illustrate several additional bond patterns contemplated by the present disclosure.

[0131] It has been found that for a bond pattern to have the visual perception of a continuous line and have bond-free areas forming pillow-like features, the relative standard deviation percentage should be greater than about 30%, or between about 30% and about 95%, or between about 30% and about 70%, or between about 40% and about 70%, according to a bond-to-bond measurement test. Furthermore, in some embodiments, the bond pattern has a standard deviation greater than about 1.3 mm, or between about 1.3 mm and about 3.0 mm, according to a bond-to-bond measurement test. It should be understood that an ultrasonic bond pattern having a relative standard deviation percentage greater than about 30% may or may not have two or more bonds spaced apart such that they have a bond separation distance of at least 2.1D and less than 4.1D when the bond separation angle is between 0 and 35 degrees, and / or at least 1.3D and less than 2.1D when the bond separation angle is greater than 35 degrees and up to 90 degrees.

[0132] The area of ​​the laminate containing the bond pattern may have a load force at 50% of about 0.3 N / in or greater, or about 0.4 N / in or greater, or about 0.45 to about 2 N / in, according to the Hysteresis Test Method herein, with the ranges recited herein in increments of 0.05 N / in.

[0133] The area of ​​the laminate containing the bond pattern may have an unload force at 50% of about 0.2 N / in or greater, or about 0.3 N / in or greater, or about 0.35 to about 1 N / in, according to the Hysteresis Test Method herein, with the ranges recited herein in increments of 0.05 N / in.

[0134] The area of ​​the laminate containing the bond pattern may have an Smax of about 50% or more, or about 75% or more, or about 100% to about 300% according to the Hysteresis Test Method herein, with ranges recited herein in 1% increments.

[0135] Breakable Joints A "breakable bond" refers to a bond that can be broken when stretched. FIG. 32 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. 33A-33C illustrate schematic views of the stretch laminate 90 of FIG. 32 having various types of breakable bond regions 700 after being subjected to a lateral pulling force. In FIG. 33A, 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. 33B, 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. 33C, 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.

[0136] Cover layer linear bond pattern 34A-35F 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.

[0137] 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 may be packed under compression to reduce the 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 may also result in reduced distribution costs for manufacturers due to the size of the package.

[0138] Test Method Binding assay The bonding measurement test method is performed on reflected light microscopic images generated using a stereoscopic optical microscope (such as a Zeiss V20 Stereoscope) and an attached camera (such as a Carl Zeiss AxioCam MRc5). Images containing at least one single repeating unit of the bonding impression pattern are acquired while the sample is fully stretched and backed with a black background. If the area of ​​the single repeating 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.

[0139] 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.

[0140] bond separation distance The bond separation distance 3600 is defined as the shortest (minimum) linear distance between the perimeters 3602 of any two individual bond sites, as illustrated in Figure 36. Image analysis software is used to measure and record the bond separation distance 3600. The arithmetic mean of the recorded values ​​is calculated and reported as the bond separation distance 3600, rounded to the nearest 0.1 mm.

[0141] bond separation angle For purposes of this method, the longitudinal axis 3700 is defined as being substantially perpendicular to the primary stretch direction of the laminate. The bond separation angle 3702 between any two bond sites is the angle formed between the bond longitudinal axis 3700 and a line 3404 drawn through the centroids of the two bond sites. Whether this angle is oriented to the right or left of the longitudinal axis 3700, the value should be reported as positive (i.e., the absolute value of the angle). This angle should be selected so that it is always 90° or less from the longitudinal axis 3700. See Figure 37 for a visual representation. This angle is reported to the nearest degree.

[0142] Bond distance measurement method Interbond distance measurements are obtained by analyzing distance-calibrated binary images of the bond impression pattern. If a binary image of the bond impression pattern is not available, it can be generated from a sample image acquired using a flatbed scanner. Prior to and during image acquisition, the sample is fully stretched, clamped in planar extension, and backed with a black background. 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 non-corrugated laminates, the specimen is considered fully stretched without such stretching. Sample images are acquired using a flatbed scanner in reflective mode at 800 dpi (approximately 32 microns per pixel) with 8-bit grayscale (a suitable scanner is an Epson Perfection V850 Pro or equivalent, manufactured by Epson America Inc., Long Beach, CA). The scanner is interfaced with a computer running an image analysis program (a suitable program is ImageJ v.1.52 or equivalent, from the National Institutes of Health, USA). Using image analysis software, the boundary perimeters of all individual bonds located within the sample image are identified, manually traced, filled, and then converted into separate distance-calibrated binary images of the bond impression pattern for analysis.

[0143] 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 (eg, reduced caliper at the bond site).

[0144] Using image analysis software, a Voronoi operation is performed on the binary bond impression image. This generates an image of cells bounded by lines of pixels that are equally distant from the borders of the nearest bond sites, where the pixel values ​​are the output of the Euclidean distance map (EDM) of the binary image. The EDM is generated when each inter-bond pixel in the binary image is replaced with a value equal to the pixel's distance from the nearest bond site. Subsequently, background zeros are removed to enable statistical analysis of the distance values. This is accomplished by using image operations to divide the Voronoi cell image by itself to generate a 32-bit floating-point image, where all of the cell lines have a value of 1, and the remainder of the image is identified as Not a Number (NaN). Finally, this image is multiplied by the original Voronoi cell image to generate a 32-bit floating-point image, where the distance values ​​along the cell lines remain and all zero values ​​are replaced with NaN. The pixel distance values ​​are then converted to actual inter-bond distances by multiplying the values ​​in the image by the pixel resolution of the image (approximately 0.032 mm per pixel), since the values ​​represent the midpoint distance between bonds, and then multiplying the image again by 2. The mean, standard deviation, median, and maximum of all inter-bond distance values ​​for the bond impression pattern images are calculated and reported rounded to the nearest 0.1 mm. The percent relative standard deviation (RSD) of the inter-bond distances is calculated by dividing the standard deviation by the mean and multiplying by 100.

[0145] Hysteresis Test Method Hysteresis testing can be used for a variety of specified strain or load values. Hysteresis testing utilizes a commercially available tensile testing machine (e.g., manufactured by Instron Engineering Corp. (Canton, MA), SINTECH-MTS Systems Corporation (Eden Prairie, MN), or equivalent) interfaced with a computer. The computer is used to control the test speed and other test parameters and to collect, calculate, and report data. Testing is performed under laboratory conditions of 23°C ± 2°C and 50% ± 2% humidity. Test specimens are conditioned for 24 hours prior to testing.

[0146] Identify the corrugated or stretched portions on the absorbent article product that have a bond pattern containing breakable bonds and permanent bonds. Cut test specimens from the area of ​​the absorbent article product to the dimensions listed in the table below for the test being performed.

[0147] Test Protocol 1. Select an appropriate gripper and load cell. The gripper must have one flat surface and be wide enough to grip the specimen along its entire width. It should also provide sufficient force and a suitable surface area to ensure the specimen does not slip during testing. The gripper should be a pneumatic gripper with one flat surface and a counterface designed to concentrate the entire gripping force along a single line perpendicular to the direction of the test stress, with a semicircular projection (radius = 6 mm, e.g., part number 56-163-827 from MTS Systems Corp.) to minimize specimen slippage, or an equivalent gripper. The load cell should be selected so that the tensile response from the specimen being tested is between 5% and 95% of the load cell capacity used. Calibrate the testing machine according to the manufacturer's instructions. 2. Set the distance between the grips (gauge length) for each test performed (table below). 3. Place the specimen on the flat surface of the grip with the uniform width aligned perpendicular to the gauge length. Attach the specimen so that the direction of stretch is the test direction. Secure the specimen in the upper grip, allowing it to hang loosely, and then close the lower grip. 4. Preload: Set a preload sag of 0.05 N per inch and a preload crosshead speed of 13 mm / min. This means that data collection begins when the sag is removed with a force of 0.05 N per inch (at a constant crosshead speed of 13 mm / min). Strain is calculated based on the adjusted gauge length (lini), which is the length of the specimen between the grips of the tensile tester at a force of 0.05 N per inch. This adjusted gauge length is the initial specimen length, which corresponds to 0% strain. The percent strain at any point in the test is defined as the change in length relative to the adjusted gauge length divided by the adjusted gauge length and multiplied by 100. 5. First Cycle Load: Pull the specimen to a given end point (load or strain) at a constant crosshead speed as defined in the table below for the test. Report the extended specimen length between the grips as lmax. b. First Cycle Unloading: The specimen is held at the end of step 5(a) for 30 seconds, then the crosshead is returned to its starting position (0% strain or initial sample length, lini) at the constant crosshead speed defined in step 5(a) above. c. Hold the specimen in the relaxed position for 1 minute. d. Second cycle: Repeat steps 5(a) and 5(b).

[0148] [Table 1]

[0149] A computer data system records the force applied to the sample during the test as a function of the applied strain. From the resulting data generated, the following quantities are collected and reported: i. The length of the specimen between the grips at a preloaded sag of 0.05 N (lini), rounded to the nearest 0.001 mm. ii. The specimen length between the grips (lmax) on the first cycle at a given strain or a given force, rounded to the nearest 0.001 mm. iii. The strain at lmax length is defined as Smax and is calculated as described in the method above. iv. The length of the specimen between the grips (lext) at the second cycle load force of 0.05 N, rounded to the nearest 0.001 mm. v. Force at 50% strain during the first load cycle (reported as load force at 50%) rounded to the nearest 0.01 N / in for laminate performance test setup. vi. Force at 50% strain during the second unloading cycle (reported as unload force at 50%) rounded to the nearest 0.01 N / in for laminate performance test setup.

[0150] Percent (%) setting: (lext-lini) / (lmax-lini) * Defined as 100% and rounded to the nearest 0.01%.

[0151] The test is repeated on three separate samples and the arithmetic mean is reported.

[0152] Post-ear extension test 38A and 38B are schematic, illustrative views showing an exemplary back ear 42 of an absorbent article and identify features relevant to the back ear extension 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.

[0153] 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.

[0154] 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.

[0155] Still referring to Figure 38A, 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.

[0156] 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.

[0157] To prepare the back ear specimens for the back ear extension test, 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 gripping parts 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 gripping parts 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, without applying any lateral tension to the back ear 42, measure the width WS as described herein. 4. Using a NIST traceable steel ruler or equivalent, measure the lengths LFP and LEP 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.

[0158] To perform the back ear extension test, 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 is used to measure the engineering strain and extension of the back ear specimen. 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. 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 greater 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 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 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 and 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. Measure the extension, which is the distance extended from the zero point under a 7.2N load, and calculate as follows to determine the engineering strain under a 2N load: 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.

[0159] 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 can be used to measure the strength of a specimen at relatively high strain rates representative of product applications. This method uses a suitable tensile tester equipped with a servohydraulic actuator, such as an 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 equipped with a 50 lb. force transducer (available, for example, from Kistler North America, Amherst, NY, as product code 9712 B50) and a signal conditioner with a dual-mode amplifier (available, for example, from Kistler North America, as product code 5010). A clamp should be used to secure the specimen during tensile testing. The opposing grips may have the same width as specified or different widths.

[0160] (a) Grip part Line grips are selected to provide clear definition of the gage and avoid excessive slippage. The specimen is positioned with minimal slack between the grips. The tops of the grips are grounded to provide good gage definition while avoiding specimen breakage or shear. The grounded tops provide a radius in the range of 0.5 to 1.0 mm. As shown in Figure 14, a portion of one or both grips may be configured to include a material that reduces the specimen's tendency to slip (e.g., a urethane or neoprene rubber strip with a Shore A hardness of 50 to 70). Unless otherwise specified, 6-inch wide top and bottom grips are used to clamp specimens.

[0161] (b) Tensile test of specimens from absorbent articles The ears are typically 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.

[0162] The specimen is clamped in the top grip at a first grip position inside the fastener attachment joint 3800, as illustrated in Figures 38A and 38B, which show the inner edge 3802 of the fastener attachment joint 3800. The grip line is kept parallel to the longitudinal centerline of the product. If the fastener attachment joint 3800 is angled, the specimen is gripped in the center of the bond area, and the grip line is kept parallel to the longitudinal centerline of the product at the center. The width of the top grip should be equal to the maximum length of the fastener attachment joint (L1) measured parallel to the longitudinal centerline of the article. Any grip width greater than the length of the specimen in the first grip position can be used, provided that the length of the specimen in the first grip position is the same as the maximum length of the fastener attachment joint. The specimen is attached and suspended from the top grip. In the 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 edge of the chassis joint. If the chassis joint is curved, the specimen is gripped at the outer edge of the outermost joint. The bottom grip is longer than the length of the ear in the second grip position. The top and bottom grips are parallel to each other.

[0163] 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 It is calculated by multiplying by the gauge length in mm. Before testing, 5 mm of slack is left between the grips.

[0164] Each specimen is pulled to break. During the test, one of the grippers is held stationary while the opposing gripper 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 for at least four specimens are recorded. If the recorded standard deviation is higher than 5%, a new set of five specimens is tested.

[0165] (c) Length ratio As in the previous step, the grippers are positioned at the first gripper position and the second gripper position. The ratio of the length of the specimen at the second gripper position (L2) to the maximum length of the bond (L1) is the length ratio. Each length is measured to within 0.1 mm using a ruler.

[0166] Back ear suspension time test The back ear suspension test is used to determine the resistance of the back ears 42 to bursting when exposed to an applied force over a period of time. The test is conducted in a temperature-controlled chamber at 38°C ± 2°C and 18% ± 2% relative humidity, referred to herein as the test environment. Samples are conditioned in the test environment for at least two hours prior to testing.

[0167] To prepare the test sample, the tape-style diaper 10 is unfolded and the back ears 42 are identified. This does not stretch the laminate or disturb the natural relaxed state of the back ears 42. Both back ears 42 are removed from the diaper 10 by making a 15 mm straight cut (cut line A 3900) from the inside edge of the back ear laminate 42 and another straight cut (cut line B 3902) directly below the back ear laminate 42. This 15 mm of material extending beyond the inside edge 3906 of the back ear 42 is then used for attachment to a rigid surface 3908. Using scissors, an exacto knife, or the like, the back ears 42 are removed. The portion of the fastening tape 46 not attached to the chassis is also removed by making a straight cut (cut line C 3904) just outside the outside edge of the back ear laminate for both back ears 42. (See, e.g., Figure 39A ).

[0168] 15 mm of material beyond the inside edge 3906 of the back ear test sample is secured to a rigid surface 3908 so that the edge of the fastening tape 46 hangs vertically and freely. A clamp 3910, tape, or equivalent fastener that is at least as wide as the outside edge of the back ear 42 is used to secure the back ear 42 to the rigid surface 3908 without slipping.

[0169] Prepare a weight assembly 3912 that can be adapted to hang vertically from the fastening tape edge. This weight assembly 3912 consists of a mounting fixture 3914 and a hanging weight 3916 with a combined mass of 1035±2 grams. The mounting fixture 3914 connects the weight 3916 to the fastening tape 46. The mounting fixture 3914 must be at least as wide as the fastening tape 46 (see, e.g., FIG. 39B). The weight assembly 3912 must be centered with the fastening tape edge and attached securely enough to prevent slippage during testing, and the hanging weight 3916 must be free to do so without contacting any other object or surface.

[0170] The weight assembly 3912 is attached to the fastening tape edge, and a timer is started as soon as the weight assembly 3912 is released to hang freely. If a defect is present in the test sample and a rupture immediately appears, discard both test samples and prepare another set. The samples are left in the test environment for three hours with the weight assembly force applied. At the end of the three hours, the samples are inspected with the weight assembly still attached. The back ear samples are visually inspected and the presence or absence of any shape of rupture 3918 (aperture, slit, hole, or tear) in the film is recorded (see, for example, Figure 39C). A rupture is defined as occurring in at least one of the cover layer and film layer and having its longest dimension in any direction greater than 1 mm. This procedure is repeated for both back ear test samples, and if a rupture is identified in either of the back ear test samples, the result is recorded as the presence of a rupture.

[0171] 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 "approximately 40 mm."

[0172] 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 excluded or otherwise limited. 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.

[0173] 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.

[0174] combination A1. A stretch laminate for an absorbent article, comprising: a nonwoven material; and an elastomeric film joined to the nonwoven material by a plurality of ultrasonic bonds, wherein the plurality of ultrasonic bonds form a bond pattern comprising a relative standard deviation percent of greater than about 30% according to an Inter-Bond Measurement Test. A2. The stretch laminate of claim 1, wherein the relative standard deviation percent is about 30% to about 70% according to an inter-bond measurement test. A3. The stretch laminate of claim A1 or A2, wherein the percent relative standard deviation is from about 40% to about 70% according to an inter-bond measurement test. A4. The stretch laminate of any one of claims A1-A3, wherein the bond pattern has a standard deviation (mm) of greater than about 1.3 mm according to a bond spacing measurement test. A5. The stretch laminate of any one of claims A1-A4, wherein the bond pattern has a standard deviation of about 1.3 mm to about 3.0 mm according to a bond spacing measurement test. A6. The plurality of ultrasonic bonds forming the bond pattern includes a first bond having a longest bond dimension, D; and a second bonded portion adjacent to the first bonded portion, wherein the bond separation distance between the first bonded portion and the second bonded portion is at least 2.1D and less than 4.1D when the bond separation angle between the first bonded portion and the second bonded portion is between 0° and 35°, or the bond separation distance between the first bonded portion and the second bonded portion is at least 1.3D and less than 2.1D when the bond separation angle between the first bonded portion and the second bonded portion is between 35° and 90°. A7. The stretch laminate of claim A6, wherein the value of D is in the range of about 0.6 mm to about 1.0 mm. A8. The stretch laminate of any one of claims A1-A7, wherein the laminate has a load force at 50% of about 0.3 N / in or greater according to the Hysteresis Test Method. A9. The stretch laminate of any one of claims A1-A8, wherein the laminate has a load force at 50% of about 0.45 N / in to about 2 N / in according to the Hysteresis Test Method. A10. The stretch laminate of any one of claims A1-A9, wherein the laminate has an Smax of about 50% or greater according to the Hysteresis Test Method. A11. The stretch laminate of claim A10, wherein the laminate has an Smax of about 100% to 500% according to the Hysteresis Test Method. A12. The stretch laminate of any one of claims A1-A11, comprising both elastic and non-elastic regions, with multiple ultrasonic bonds located within the elastic regions. A13. The stretch laminate of any one of claims A1-A12, wherein the elastic film is pre-activated prior to being ultrasonically bonded to the nonwoven material, such that when the elastic film is in a stretched state, the elastic film is bonded to the nonwoven material. A14. The stretch laminate of claim A13, wherein the elastic film has activation stripes. A15. An absorbent article comprising the stretchable laminate according to any one of claims A1 to A14. A16. A stretch laminate, 1. An absorbent article comprising: a stretch laminate comprising: a nonwoven material; and an elastomeric film joined to the nonwoven material by a plurality of ultrasonic bonds, wherein the plurality of ultrasonic bonds form a bond pattern comprising a relative standard deviation percent of greater than about 30% according to an Inter-Bond Measurement Test. A17. An absorbent article as described in any one of claims A1-A16, wherein the stretch laminate includes a second nonwoven material, the elastomeric film is positioned intermediate the nonwoven material and the second nonwoven material, and at least some of the multiple ultrasonic bonds do not overlap the elastomeric film but only join the nonwoven material and the second nonwoven material. A18. The absorbent article of claims A1-A17, wherein the stretch laminate forms side panels or ears disposed in the waist region of the absorbent article. A19. The absorbent article of claim A18, wherein the side panels or ears contain no bursts of greater than 5 mm according to the Back Ear Hang Time Test. A20. The absorbent article of any one of claims A1-A19, wherein the stretch laminate forms a central waist element. A21. The absorbent article of claim A20, wherein the elastic waist element is an elastic waist feature in the front waist region or the back waist region of the absorbent article. A22. The absorbent article of claim A21, including an acquisition layer between the topsheet and the absorbent core, a portion of the acquisition layer overlapping a portion of the elastic waist feature. A23. The absorbent article of claim A21, including a core bag between the topsheet and the backsheet, a portion of the core bag overlapping a portion of the elastic waist feature. A24. The absorbent article of claim A22, wherein the absorbent core is non-rectangular. A25. The absorbent article of claim A22, wherein the absorbent article has a front waist region, a back waist region, and a central region between the front and back waist regions, and wherein the absorbent core is wider in at least one of the front waist region and the back waist region than in the central region. A26. The absorbent article of any one of claims A1-A25, wherein the stretch laminate forms a central waist element. A27. A stretch laminate comprising: a first nonwoven material; 1. A stretch laminate comprising: a second nonwoven material; and an elastomeric film joined to the first nonwoven material and the second nonwoven material by a plurality of ultrasonic bonds, wherein the plurality of ultrasonic bonds form a bond pattern comprising a relative standard deviation percent of greater than about 30% according to an Inter-Bond Measurement Test.

Claims

1. 1. A stretch laminate for an absorbent article, comprising: A nonwoven material; 1. A stretch laminate comprising: an elastomeric film joined to a nonwoven material by a plurality of ultrasonic bonds, wherein the plurality of ultrasonic bonds form a bond pattern comprising a relative standard deviation percent of greater than about 30% according to an Inter-Bond Measurement Test.

2. 10. The stretch laminate of claim 1, wherein said percent relative standard deviation is from about 30% to about 70% according to said Inter-Bond Measurement Test.

3. 10. The stretch laminate of claim 1, wherein said percent relative standard deviation is from about 40% to about 70% according to said Inter-Bond Measurement Test.

4. 10. The stretch laminate of claim 1, wherein said bond pattern has a standard deviation (mm) of greater than about 1.3 mm according to said Bond Interval Measurement Test.

5. 10. The stretch laminate of claim 1, wherein said bond pattern has a standard deviation according to said Bond Spacing Measurement Test of from about 1.3 mm to about 3.0 mm.

6. The plurality of ultrasonic bonds forming the bond pattern are a first bond having a longest bond dimension, D; a second coupling portion adjacent to the first coupling portion, a bond separation distance between the first bond and the second bond is at least 2.1D and less than 4.1D when a bond separation angle between the first bond and the second bond is between 0° and 35°; or 10. The stretch laminate of claim 1, wherein the bond separation distance between the first bond and the second bond is at least 1.3D and less than 2.1D when the bond separation angle between the first bond and the second bond is greater than 35° and less than 90°.

7. The stretch laminate of claim 6, wherein the value of D ranges from about 0.6 mm to about 1.0 mm.

8. 10. The stretch laminate of claim 1, wherein the laminate has a load force at 50% of about 0.3 N / in or greater according to a hysteresis test method.

9. 10. The stretch laminate of claim 1, wherein the laminate has a load force at 50% of about 0.45 N / in to about 2 N / in according to the Hysteresis Test Method.

10. The laminate has an S of about 50% or more according to the hysteresis test method. ｍａｘ 10. The stretch laminate of claim 1, having

11. The laminate has an S of about 100% to 500% according to the hysteresis test method. ｍａｘ 11. The stretch laminate of claim 10, having

12. 10. The stretch laminate of claim 1, comprising both elastic and non-elastic regions, said plurality of ultrasonic bonds being located within said elastic regions.

13. 13. The stretch laminate of any one of claims 1 to 12, wherein the elastic film is pre-activated prior to being ultrasonically bonded to the nonwoven material, such that when the elastic film is in a stretched state, the elastic film is bonded to the nonwoven material.

14. 14. The stretch laminate of claim 13, wherein the elastic film has activation stripes.

15. An absorbent article comprising the stretch laminate of any one of claims 1 to 14.

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