ABSORBENT ARTICLE HAVING ELASTIC LAMINATE - Patent application

Abstract

A method for assembling an elastic laminate is disclosed that includes stretching an elastic film in a transverse direction to a first elongation in a spreader mechanism, and advancing the elastic film from the spreader mechanism to an anvil, the anvil including an activated vacuum zone having a maximum width Wv in the transverse direction, the maximum width being divided into a first portion and a second portion, the first portion being in overlapping relationship with and disposed inwardly of the engaging portion in the transverse direction, the first portion having a width VZi in the transverse direction, and the second portion having a width VZo in the transverse direction, wherein the ratio of VZi to VZo is greater than 1.

Description

[Technical field]

[0001] SUMMARY OF THE DISCLOSURE The present invention relates to absorbent articles having stretch laminates, such as stretch ears or waistbands. [Background technology]

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

[0003] Manufacturers often use extensible regions, such as stretchable side panels (i.e., ears), in articles to help achieve a comfortable fit. When worn, the stretchable ears allow the article to extend around the wearer's hips and waist, securing the product in place during use while allowing the wearer comfortable movement. A fastening system is typically bonded to the ears to further secure the product around the wearer. The stretchable ears are typically a laminate of a covering material (e.g., a nonwoven) and an elastomeric material. Similarly, waistbands may include a stretchable laminate of a nonwoven and an elastomeric material and may help the absorbent article fit snugly around the wearer's waist.

[0004] It is common to hold one or more edges of elastomeric materials during the creation or activation of a laminate. That is, the material may be moved in the machine direction, but the edges may be "held" close to or against an anvil or other surface for a period of time to help move the layers in the desired direction and / or to prevent the layers from moving from their desired positions. For example, in forming a gathered laminate, the elastomeric material may be stretched to a higher degree than the coverstock layers during lamination. The equipment may hold one or more edges of the elastomeric material against an anvil during stretching, so that the edges are not stretched. To hold the elastomeric material as needed, manufacturers must hold a fairly large portion. However, the portion of the elastomeric material that is held may not provide stretchability to the final laminate. In other words, the unstretched elastomeric material in the held areas does not contribute to the stretchability of the laminate to the same extent as the stretched portions. Thus, manufacturers cannot efficiently utilize the most expensive component of the laminate, namely the elastomeric material. Summary of the Invention [Problem to be solved by the invention]

[0005] Thus, there is a need to reduce the area of ​​non-stretched elastomeric material in stretch laminates. Also, there is a need for laminates with smaller non-stretched elastomeric material zones that still maintain integrity, breathability, and / or comfort. Additionally, there is a need for an efficient and cost-effective means of providing stretch laminates with smaller non-stretched zones. [Means for solving the problem]

[0006] The invention comprises the features of the independent claims herein.

[0007] The absorbent article includes a topsheet, a backsheet, a chassis including an absorbent core disposed between the topsheet and the backsheet, and an ear joined to the chassis. The ear is a laminate including a first nonwoven and a second nonwoven, and an elastomeric material sandwiched between the first and second nonwoven, the laminate further comprising a plurality of ultrasonic bonds. The elastomeric material has a maximum dimension Y in a stretch direction, and the elastomeric material defines a primary region including an elastic region and one or more non-stretch zones. The elastic region has a maximum dimension X in the stretch direction. The one or more non-stretch zones have a cumulative maximum dimension Wd in the stretch direction. The ratio of Wd to Y is less than or equal to 0.3.

[0008] The absorbent article includes a topsheet, a backsheet, a chassis including an absorbent core disposed between the topsheet and the backsheet, and an ear joined to the chassis. The ear includes a laminate including a first nonwoven and a second nonwoven, and an elastomeric material sandwiched between the first and second nonwoven. The elastomeric material includes a maximum dimension Y in the stretch direction, and the elastomeric material defines an elastic region, the first nonstretch zone includes a maximum dimension Wd1 in the stretch direction, and the second nonstretch zone includes a maximum dimension Wd2 in the stretch direction. The ratio of Wd2 to Wd1 is at least 2.

[0009] A method for assembling an elastic laminate includes: providing a first substrate and a second substrate, each of the first substrate and the second substrate having a first surface and an opposing second surface and defining a width in a transverse direction; wrapping a first surface of a first substrate onto a peripheral surface of an anvil; advancing the elastic film to a spreader mechanism, the spreader mechanism comprising an engagement portion and an elastic material; stretching the elastic material in a transverse direction to a first elongation in a spreader mechanism; advancing the resilient material from the spreader mechanism to an anvil, the anvil comprising an active vacuum zone having a maximum width Wv in a transverse direction, the maximum width being divided into a first portion and a second portion, the first portion being in overlapping relationship with and disposed transversely inward of the engagement portion, the first portion having a transverse width VZi and the second portion having a transverse width VZo, VZi being greater than VZo; positioning an elastic material in contact with the second surface of the first substrate on the anvil; advancing a second substrate to position a first surface of the second substrate in contact with the resilient material and to position a second surface of the first substrate on the anvil; and ultrasonically bonding the first substrate to the second substrate with the elastic material positioned between the first substrate and the second substrate. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is an exploded perspective view of an exemplary laminate according to one non-limiting embodiment of the present invention. [Diagram 2] FIG. 2 is a plan view of an exemplary laminate according to one non-limiting embodiment of the present invention. [Diagram 3] FIG. 2 is an exploded perspective view of an exemplary ear according to another non-limiting embodiment of the present invention. [Figure 4A] 1 is a schematic side view of an apparatus for assembling an elastic laminate according to one non-limiting embodiment of the present invention. [Figure 4B] FIG. 4B is a top view of the device taken along line 4B-4B of FIG. 4A. [Figure 4C] FIG. 4C is a left side view of the device taken along line 4C-4C of FIG. 4B. [Figure 4D] FIG. 4D is a detailed view of the spreader mechanism of FIG. 4C taken along line 4D-4D. [Figure 4E] FIG. 13 is a detailed view of a radially protruding nub on the outer rim of the disk. [Figure 4F] FIG. 4F is a detailed view of the anvil taken along line 4F-4F of FIG. 4B. [Figure 5A] 1 is a schematic side view of an apparatus operative to assemble an elastic laminate, according to one non-limiting embodiment of the present invention. [Figure 5B] 5B is a left side view of the device taken along line 5B-5B of FIG. 5A. [Figure 5C] FIG. 5C is a top view of the device taken along line 5C-5C of FIG. 5B. [Figure 6A] FIG. 1 is a schematic front view of an apparatus operative to stretch an elastomeric material, according to one non-limiting embodiment of the present invention. [Figure 6B] FIG. 1 is a schematic front view of an apparatus used to stretch an elastomeric material, according to one non-limiting embodiment of the present invention. [Figure 7A] FIG. 2 is a schematic perspective view of an anvil according to one non-limiting embodiment of the present invention. [Figure 7B] FIG. 7B is a schematic perspective view of the anvil of FIG. 7A with portions of the interior exposed to show the configurable tube, according to one non-limiting embodiment of the present invention. [Figure 8A] 1 is a schematic side view of an apparatus operative to assemble an elastic laminate. [Figure 8B] 8B is a top view of a first substrate advancing through the folder of FIG. 8A taken along line 8B-8B. [Figure 9] 1 is a schematic plan view of an exemplary absorbent article according to one non-limiting embodiment of the present invention.The absorbent article is shown in a flat, uncontracted state. [Figure 10] 1 is a schematic plan view of an exemplary ear according to one non-limiting embodiment of the present invention, the ear being shown in a relaxed state; [Figure 11] FIG. 1 is a schematic perspective view of a grip suitable for use in the ear extension test method herein. [Figure 12A] FIG. 1 is a schematic perspective view of a grip suitable for use in the angular maximum peak force tensile test method herein. [Figure 12B] FIG. 1 is a schematic side view of a grip and ears configured for the angular maximum peak force tensile test method herein. [Figure 12C]1 is a schematic plan view of an exemplary ear according to one non-limiting embodiment of the present invention, the ear being shown in a relaxed state; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

[0012] "Non-stretch zone" means a portion of a gathered laminate that includes an elastomeric material that was in a substantially relaxed state during lamination. As discussed below, gathered laminates are formed by stretching an elastomeric material to a higher degree than another layer and bonding the elastomeric material to the other layer while the elastomeric layer is being stretched. During such a process, typically portions of the elastomeric material are not stretched to hold the elastomeric layer in place on the device. In the final laminate, these non-stretch portions, along with overlapping portions of other laminate layers, form the non-stretch zones.

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

[0014] "Extensible" means the ability to stretch or extend without rupture or breakage by at least 50% according to step 4(b) of the hysteresis test herein. As used herein, a laminate or substrate is extensible if at least 20% of the area of ​​the laminate meets the definition of extensible herein. In this situation, the percentage of the area of ​​the laminate is determined when the laminate is in a fully stretched state. If the laminate does not meet the definition of elasticity above, but meets the definition of extensibility provided in this paragraph, the laminate is an extensible laminate.

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

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

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

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

[0019] "Fully stretched" in relation to a corrugated laminate means when the corrugations are substantially flattened by stretching the laminate while ensuring that the inelastic substrate of the laminate is not plastically deformed.

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

[0021] "Inner" with respect to a first feature of an article and its location relative to a second feature or location on the article means that the first feature is located closer to the respective axis of the article than the second feature or location along the horizontal xy plane generally occupied by the article when laid out flat on a horizontal surface and stretched to the full longitudinal and lateral dimensions of its component web material against any contraction induced by any included pre-tensioned elastomeric material. Laterally inward means that the first feature is closer to the longitudinal axis, and longitudinally inward means that the first feature is closer to the lateral axis. Conversely, "outer" with respect to a first feature of an article and its location relative to a second feature or location on the article means that the first feature is farther from the respective axis of the article than the second feature or location.

[0022] As used herein, "longitudinal" refers to the maximum linear dimension of the absorbent article in the xy plane of the article. In the absorbent articles described herein, the longitudinal direction extends substantially perpendicularly from the waist edge to the opposing waist edge when the absorbent article is in a flat, uncontracted state, or from the waist edge to the crotch bottom of an article that is folded in half. The longitudinal direction of any component of the absorbent article (e.g., ears, waistband) is determined when the component is joined to the article.

[0023] "Lateral" generally means a direction perpendicular to the longitudinal direction. In the absorbent articles described herein, the lateral direction extends substantially parallel from one side edge to the other.

[0024] "Nonwoven" means a porous fibrous material made from continuous (long) filaments (fibers) and / or discontinuous (short) filaments (fibers), such as from processes such as spunbonding, meltblowing, airlaying, carding, co-forming, hydroentangling, etc. Nonwovens do not have a woven or knitted filament pattern. Nonwovens may be liquid permeable or impermeable.

[0025] "Relaxed" with respect to the laminate means at rest with substantially no external forces acting on the laminate other than gravity.

[0026] As used herein, "stretch direction" refers to the intended direction of elasticity in the final product. For example, the back ears of an absorbent article may be intended to be elastic in the transverse direction to fit around the waist of a wearer. The stretch direction of the laminate may be transverse and / or longitudinal. It should be understood that the product may be elastic in multiple directions. In such cases, the stretch direction is the primary intended direction of elasticity in response to the expected application of forces required for use.

[0027] The term "machine direction" (MD) is used herein to refer to the direction of flow of material through a process. In addition, the relative orientation 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.

[0028] The term "cross direction" (CD) is used herein to refer to a direction generally perpendicular to the machine direction.

[0029] Laminate As shown in FIG. 1, the laminate 10 comprises a first nonwoven 12 and an elastomeric layer 14. The laminate comprises a second nonwoven 16, and the elastomeric layer 14 may be sandwiched between the first and second nonwovens. Additional layers may be included (e.g., additional nonwovens, nonelastic materials, elastic or extensible materials, etc.). The laminate may be extensible. In various embodiments, the laminate is elastomeric. Two or more laminate layers may be bonded by a number of bonds 30, as shown in FIG. 2. The bonds include ultrasonic bonds 31 that may bond the nonwoven layers through the elastomeric layer. Ultrasonically bonded laminates may be formed by any suitable process, including, but not limited to, those disclosed in commonly assigned U.S. Patent Application Nos. 62 / 374,010 and 62 / 419,515. The bonds may include thermal bonds, pressure bonds, or combinations thereof. The bonds can be of any suitable shape or size. In some embodiments, the bonds are non-circular. Additionally or alternatively, the bonds can have a longitudinal dimension that is greater than their lateral dimension, or vice versa. The ears 130 and / or waistband 180 of the absorbent article can comprise the laminate of the present invention.

[0030] Any suitable nonwoven fabric may be used in the laminate 10. Suitable nonwoven fabrics may include basis weights of at least about 8 gsm, or up to about 30 gsm, or up to about 22 gsm, or up to about 17 gsm, or from about 10 gsm to about 22 gsm, with ranges recited for each increment within the range. Suitable nonwoven fabrics include, but are not limited to, spunbond, spunlaid, meltblown, spunmelt, spunlaced, solvent spun, electrospun, carded, film fibrillated, melt film fibrillated, air laminated, dry laminated, wet laminated staple fiber, hydroentangled, and other nonwoven web materials formed in part or entirely from polymeric fibers as known in the art. In a non-limiting example, the nonwoven fabric comprises a meltblown layer. Additionally or alternatively, the nonwoven fabric may comprise a spunbond layer. In a non-limiting example, the nonwoven fabric comprises two or more spunbond layers. In further non-limiting examples, one or more of the nonwovens may comprise an SMS configuration. Alternatively, one or more of the nonwovens may not have a meltblown layer. In some embodiments, the nonwovens consist essentially of spunbond layers. In some non-limiting examples, both the first nonwoven and the second nonwoven comprise at least two spunbond layers, or three or more spunbond layers.

[0031] The nonwoven web may be formed primarily of polymeric fibers. In some embodiments, suitable nonwoven fibrous materials may include, but are not limited to, polymeric materials such as polyolefins, polyesters, polyamides, nylons, or specifically polypropylene (PP), polyethylene (PE), polylactic acid (PLA), polyethylene terephthalate (PET), and / or blends thereof. In some embodiments, the fibers may be formed from PP / PE blends such as those described in U.S. Pat. No. 5,266,392. The nonwoven fibers may be formed from or include components such as aliphatic polyesters, thermoplastic polysaccharides, or other biopolymers as additives or modifiers. Further useful nonwoven fabrics, fiber compositions, fiber and nonwoven fabric formations, and related methods are described in U.S. Patent Nos. 6,645,569, 6,863,933, and 7,112,621, and U.S. Patent Application Nos. 10 / 338,603, 10 / 338,610, and 13 / 005,237. The individual fibers of the nonwoven layer may be monocomponent or multicomponent (including bicomponent). Multicomponent fibers can be bicomponent, for example, including various polymeric components in a core and sheath arrangement or a side-by-side arrangement. The individual components can include polyolefins, such as polypropylene or polyethylene, or copolymers thereof, or polyesters, thermoplastic polysaccharides, or other biopolymers. Additionally, the nonwoven fabric may include a blend of various fibers, for example, selected from the polymer fiber types listed above. In some embodiments, at least some of the fibers may exhibit a spiral crimp having a helical shape. According to one example, the fibers can include bicomponent fibers that are individual fibers, each of which includes different materials, typically a first polymeric material and a second polymeric material. The use of side-by-side bicomponent fibers is believed to be beneficial for imparting spiral crimp to the fibers.Examples of potentially suitable crimped or "drafted" bicomponent fibers and nonwovens formed therefrom are described in U.S. Patent Nos. 5,382,400, 5,418,045, 5,707,468, 6,454,989, 6,632,386, 5,622,772 and 7,291,239. For purposes of this specification, the use of nonwovens formed from bicomponent or multicomponent pleated fibers, such as those described in the immediately preceding cited patents and / or patent applications, may be desirable as one or both nonwoven layers, since they can feel particularly soft to the touch (providing a comfortable inner and aesthetically pleasing outer appearance to the wearer) and are generally quite flexible. In other non-limiting examples, the nonwoven may not have crimped fibers.

[0032] When the laminate 10 includes more than one nonwoven, the nonwovens may have the same basis weight or different basis weights. Similarly, the nonwovens may have the same layer configuration (e.g., SSS) or different layer configurations (e.g., SMS).

[0033] The elastomeric layer 14 includes one or more elastomeric materials that provide elasticity to at least a portion of the layer 14. Non-limiting examples of elastomeric materials include films (e.g., films derived from rubber and / or other polymeric materials, polyurethane films), elastomeric coatings applied to another substrate (e.g., hot melt elastomers, elastomeric adhesives, printed elastomers, or elastomers coextruded onto another substrate), elastomeric nonwovens, scrims, etc. The elastomeric materials may be formed from any suitable known elastomer, including, but not limited to, elastomeric polymers including styrene derivatives (SIS, SBS, SEBS, SEEPS, SEPS, SIBS, etc.), polyesters, polyurethanes, polyetheramides, polyolefins (homo, random, block, copolymers, etc.), combinations thereof, or coextruded VISTAMAXX®. Exemplary elastomers and / or elastomeric materials are disclosed in U.S. Pat. Nos. 8,618,350, 6,410,129, 7,819,853, 8,795,809, 7,806,883, 6,677,258, and U.S. Patent Publication No. 2009 / 0258210.Commercially available elastomeric materials include KRATON (styrenic block copolymer; available from Kraton Chemical Company, Houston, TX), SEPTON (styrenic block copolymer; available from Kuraray America, Inc., New York, NY), VECTOR (styrenic block copolymer; available from TSRC Dexco Chemical Company, Houston, TX), ESTANE (polyurethane; available from Lubrizol, Inc., Ohio), PEBAX (polyether-based block amide; available from Arkema Chemicals, Philadelphia, PA), HYTREL (polyester; available from DuPont, Wilmington, DE), VISTAMAXX (homopolyolefin and random copolymer, and blends of random copolymers, available from EXXON Mobile, Spring, TX), VERSIFY (homopolyolefin and random copolymer, and blends of random copolymers, available from Dow Chemical Company, Midland, Michigan), and INFUSE (Dow Chemical block copolymers available from the Company.

[0034] In a non-limiting example, the elastomeric layer 14 comprises a film 15. The film may include a single layer or multiple layers. The film may be extensible or elastic in the transverse and / or longitudinal directions. The film may be pre-activated, for example as disclosed in U.S. Pat. No. 9,533,067. In a non-limiting example, the elastomeric layer may have an average F200 of about 3 N / inch to about 5 N / inch, or about 3.7 N / inch to about 4.3 N / inch, according to the Elastomeric Layer Hysteresis Test Method herein, recorded for each range at every 0.1 N / inch increment within this range. PS and / or an average F200 of about 1 N / inch to about 2.75 N / inch FC Includes.

[0035] The elastomeric layer may be shorter than the laminate itself in one or more dimensions of the laminate. For example, the elastomeric layer may include a maximum dimension Y in the stretch direction, and the laminate may include a maximum dimension W in the stretch direction. In various embodiments, the stretch direction is the transverse direction. The maximum dimension is measured when the laminate is in a relaxed state. In a non-realistic example, Y may be at least 10 mm less than W. In certain embodiments, Y is at least about 20%, or about 25% to about 100%, or about 35% to about 85%, or about 80% or less of W, recited in 5% increments within this range for each range. In various embodiments, the stretch direction is the transverse direction. Additionally or alternatively, the elastomeric layer may have dimensions equal to one or more dimensions of the laminate. For example, the elastomeric layer may have substantially the same longitudinal length of the laminate across the transverse width of the laminate. In some embodiments, the elastomeric layer may have a basis weight of from about 5 to about 150 gsm, or from about 10 to about 100 gsm, or less than about 150 gsm, with each range recited in 5 gsm increments within the range.

[0036] Referring to FIG. 2, the laminate 10 may comprise a primary region 18 defined by the perimeter of the elastomeric material 14 and one or more inelastic regions 20, 22. The primary region 18 comprises an elastic region 32 and one or more inextensible zones 34. In the elastic regions, the laminate is elastically extensible. In the inextensible zones, the laminate may not be elastic despite the presence of the elastomeric layer. In some embodiments, the area of ​​the primary region includes at least about 20%, or from about 30% to about 100%, or up to about 80%, of the total area of ​​the laminate, with ranges recited in 5% increments within this range. In a relaxed state, the elastic region 32 may comprise a maximum dimension X in the direction of stretch. In non-limiting examples, the ratio of X to Y is at least about 0.7, or about 0.75, or from about 0.5 to about 0.95, with ranges recited in 0.05 increments within this range.

[0037] One or more non-stretch zones 34 may include an aggregate maximum dimension Wd in the stretch direction. The aggregate maximum dimension is the sum of the maximum dimensions in the stretch direction of the individual non-stretch zones taken when the laminate is in a relaxed state, without overlap in the stretch direction. In some embodiments, the one or more non-stretch zones include a first non-stretch zone 34a and a second non-stretch zone 34b. The first non-stretch zone may have a first maximum dimension Wd1 in the stretch direction, and the second non-stretch zone may have a second maximum dimension Wd2 in the stretch direction. In the embodiment shown in FIG. 2, the aggregate maximum dimension Wd is the sum of Wd1 and Wd2. In a non-limiting example, the elastic region is disposed between the first non-stretch zone and the second non-stretch zone. For example, as shown in Figure 2, a first non-stretch zone 34a is laterally inboard of the elastic region when the laminate is attached to an article, and a second non-stretch zone 34b is laterally outboard of the elastic region. The maximum dimensions of the individual non-stretch zones may be substantially co-located along a line perpendicular to the stretch direction (e.g., if the stretch direction is transverse, Wd1 and Wd2 may be co-located longitudinally).

[0038] The first maximum dimension Wd1 may be the same as the second maximum dimension Wd2. Alternatively, the first maximum dimension Wd1 may be different from the second maximum dimension Wd2. In a non-limiting example, Wd2 is greater than Wd1. For example, if the ear of the absorbent article comprises a laminate, the second non-stretch zone may be wider in the lateral direction to allow the fastening system to be more securely bonded to the ear and overlapped with the elastomeric material. Bonding the fastening system to the ear in the primary region 18, particularly in the non-stretch zone 34b, improves the overall strength of the ear / fastening system combination during use and / or application. Without being bound by theory, it is believed that failure of the ear formed from the ultrasonically bonded laminate occurs first in the inelastic region near the outer edge 11, since the intact nonwoven resists stretching of the elastomeric layer, and thus bonding of the fastening system in the non-stretch zone reduces stress on the inelastic portion of the ear. Non-limiting examples include a ratio of Wd2 to Wd1 of at least about 3, or at least about 2, or about 1.5, or from about 1.25 to about 3, with ranges recited in increments of 0.5. By attaching the fastening system to the primary region, there is necessarily less reliance on the shape of the back ear to provide suitable strength.

[0039] In various embodiments, Wd can be about 13 mm or less, or about 12 mm or less, or about 10 mm or less, or about 6 mm or less, or about 2 mm to about 13 mm, or about 3 mm to about 12 mm, or about 5 mm to about 10 mm, with each range being recited in 1 mm increments within this range. Additionally or alternatively, Wd1 or Wd2 can be about 6.5 mm or less, or about 6 mm or less, or about 3 mm or less, or about 2 mm or less, about 1 mm to about 6.75 mm, or about 1.5 mm to about 6.5 mm, with each range being recited in 0.1 increments within this range.

[0040] In non-limiting examples, the ratio of Wd to Y is 0.45 or less, or 0.375 or less, or 0.27 or less, or 0.25 or less, or 0.2 or less, or about 0.05 to about 0.45, or about 0.1 to about 0.4, with each range recited in increments of 0.05 within this range. d and The ratio to X is 0.9 or less, or 0.4 or less, or 0.25 or less, or from about 0.05 to about 0.9, or from 0.2 to about 0.4, with each range recited in increments of 0.05 within this range. The ratio of Wd to X may be less than or equal to 0.55.

[0041] The laminate may have an angular maximum peak force of at least about 12 N, or at least about 20 N, or at least about 25 N, or at least about 30 N, or at least about 40 N, or at least about 45 N, or from about 12 N to about 75 N, or from about 20 N to about 70 N, or from about 30 N to about 65 N, or from about 35 N to about 45 N, with each range being recited in 1 N increments within this range according to the Angular Maximum Peak Force Test Method herein. Additionally or alternatively, the laminate may include an elongation at 1000 gm force of at least about 30 mm, or at least about 40 mm, or from about 20 mm to about 60 mm, or from about 30 mm to about 50 mm, with each range being recited in 1 mm increments within this range according to the Ear Elongation Test Method herein.

[0042] Importantly, angular maximum peak force and / or elongation may be achieved even with smaller dimensioned non-stretch zones as described herein. Additionally, by reducing the non-stretch zone by only 2-3 mm on one edge of the elastomeric material, it may be possible to move the elastic region inward (e.g., laterally inward on an absorbent article ear) and / or increase the overall dimension of the elastic region in the stretch direction. In embodiments where the laminate forms an absorbent article ear, the fastening system joined to the ear exerts tensile forces in the stretch direction when stretched for intended use. By reducing the non-stretch zone, such tensile forces may be distributed more evenly on the elastomeric material, which may reduce shear stress and / or tendency to kink or rope (i.e., decrease in height in a direction perpendicular to the stretch direction), which in turn improves fit and reduces skin bruising / mottling. Additionally, by improving tensile force distribution, lower basis weight elastomeric materials may be used. Additionally, by positioning the elastic region inward or outward, the elongation versus tensile force curve can be shifted such that a given elongation can be achieved with less or more force than known configurations, thereby providing more freedom in design.

[0043] Table 1 provides a comparison of known ear laminates with examples of the present invention.

[0044] [Table 1]

[0045] As shown in Figure 2, the laminate may further comprise one or more inelastic regions. In certain embodiments, the laminate 10 comprises a first inelastic region 20 that extends laterally outward from a first laminate edge 9 of the laminate and is adjacent to the primary region 18 at a first elastomeric material edge 17. The laminate may further include a second inelastic region 22 that may extend laterally inward from a second laminate edge 11 and is adjacent to the primary region 18 at a second elastomeric material edge 19. The first and second inelastic regions may be made of the same material(s) or may be made of different materials.

[0046] Referring to FIG. 3, the laminate 10 includes a reinforcement layer disposed between the elastomeric material and at least one of the nonwoven layers. strong department 50. strong department It helps provide strength to the laminate. strong department Non-limiting examples of the additional bond 52 include an additional bond such as an adhesive, heat or pressure bond, an additional substrate layer 54 including a separate layer of material and / or a folded material, and combinations thereof. The additional substrate layer 54 may include a nonwoven, an elastomeric material, or combinations thereof. The additional substrate layer 54 may include the same material as the first nonwoven, the second nonwoven and / or the elastomeric layer, or the additional substrate layer 54 may include a different material than any of the foregoing layers.

[0047] The laminate 10 includes a gathered laminate 24 in which one of the layers (ideally the elastic layer) is distorted more than the remaining layers during lamination. Thus, the low extensibility layer (i.e., nonwoven 12, 16) forms gathers when the laminate 24 is in a relaxed state. In some embodiments, at least a portion of the elastomeric layer is distorted while the nonwoven(s) are in a relaxed state during lamination. The elastomeric layer may be stretched in one or more directions. Pleats are then formed in the nonwoven layer when the subsequently formed laminate 24 is in a relaxed state. When making a 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 transverse direction. In a non-limiting example, the elastomeric layer is stretched in a direction corresponding to the transverse direction of the article. In other words, after lamination, when the laminate is joined to the chassis, the laminate is oriented such that the laminate can stretch in the cross direction of the article (ie, the laminate is extensible in the cross direction).

[0048] In certain embodiments, the laminate has a thickness of at least about 1 mm according to the air permeability test method herein. 3 / m 2 / min, or about 1m 3 / m 2 / min ~ approx. 125m 3 / m 2 / min, or about 2m 3 / m 2 / min ~ approx. 50m 3 / m 2 per minute, and for each range, the air permeability value is 1 m 3 / m 2 Enumerate each increment.

[0049] In some embodiments, the laminate may be adhesive-free.

[0050] The laminate may include an opacifying material to reduce transparency through the laminate, especially in the stretched state. An opacifier such as TiO2 may be added to one or more of the laminate layers before, during, or after the formation of the layer. Additionally or alternatively, the opacity of the precursor material may be enhanced through formulation, basis weight, number of layers, layer configuration (e.g., SMS vs. SS), or any combination thereof. In a non-limiting example, the nonwoven layer may be modified in areas where no elastomeric material is present, thereby reducing transparency in those areas. Additionally or alternatively, the laminate layers may be configured to match in color and / or opacity, resulting in a uniform appearance throughout the laminate, even in areas where all laminate layers are absent.

[0051] Method for making a laminate To help provide further context for the subsequent discussion of the method configurations, below is presented a description of an apparatus that may be configured to operate according to the methods disclosed herein. Figures 4A-4C show schematic side views of an apparatus 400 configured to assemble a laminate of the present invention. As shown in Figures 4A-4C, the apparatus includes an anvil 402 having a cylindrically shaped outer peripheral surface 404 and adapted to rotate in a first direction Dir1 about a first axis of rotation 406. Although the first direction Dir1 is shown as clockwise in Figure 4A, it should be understood that the anvil 400 may be configured to rotate such that the first direction Dir1 is counterclockwise. As discussed in more detail below, a substrate (e.g., a nonwoven) and an elastomeric material may be combined on the rotating anvil 402 to form an elastic laminate. The anvil roll 402 has a maximum lateral width Wa between a first side 408 and a second side 410. The anvil 402 may be a single lane 453 in which only one laminate is produced at a time on the anvil 402, or may include multiple lanes 453 in which two or more strips of elastomeric material (or strips of other laminate layer(s)) can be processed, respectively, in which multiple laminates can be formed, for example, similar to that described in U.S. Patent No. 10,568,775 to Lenser et al.

[0052] As shown in FIG. 4B, the anvil 402, more specifically the outer peripheral surface 404, may also be fluidly connected to a vacuum pressure source 405. Thus, vacuum air pressure may be used to help hold the substrate and elastic material on the outer peripheral surface 404 of the anvil 402 during actuation. For example, with reference to FIGS. 4B-4C and 6A, the outer peripheral surface 404 of the anvil roll 402 may include a plurality of apertures 414 fluidly connected to the vacuum pressure source 405. The apertures 414 in turn define an active vacuum zone 415 that may extend in the transverse direction CD across a maximum width Wv. For clarity, dashed lines 415x, 415y are shown in FIG. 4C to represent exemplary boundaries of the active vacuum zone 415. The maximum width Wv of the active vacuum zone may be less than the maximum CD width Wa of the anvil. The lanes on the anvil may have a maximum CD width WL extending between machine direction barriers or nubs that extend along the anvil or across the maximum CD width of the stretched material strip being processed, whichever is greater. The maximum width Wv of the active vacuum zone may be less than the maximum CD width WL of the lane. The maximum width Wv of the active vacuum zone may be about 20%, or about 15%, or about 10% or less of the maximum width WL of the lane. In various embodiments, the active vacuum zone does not overlap the transverse centerline 450 of the anvil and / or does not overlap the transverse centerline 451 of one or more lanes 453. In this manner, the active vacuum zone presses down on the edges of the substrate and / or elastic material, which may be sufficient to ensure that the remaining portion (e.g., the center portion) of the elastomeric material and / or substrate is pressed down against the anvil. Although shown as coinciding in Figures 4A-4C for clarity, it should be understood that the lane centerline 451 may not coincide with the centerline of the anvil 450, even if the anvil includes only one lane.

[0053] For example, as shown in FIG. 4C, the anvil 402 can also include a second operating vacuum zone 415a. The second operating vacuum zone can include any of the features and dimensions disclosed with respect to the operating vacuum zone 415. The second operating vacuum zone can be separated from the operating vacuum zone 415 by a lateral distance DS that can be at least about 10%, or at least about 25%, or at least about 50%, or from about 10% to about 70% of the maximum width WL of the lane, with the ranges recited in 5% increments within this range. In non-limiting examples, DS is from about 10 mm to about 60 mm, or from about 25 mm to about 40 mm, with each range recited in 5 mm increments within this range.

[0054] As seen in Figures 6A and 6B, the anvil may further comprise a number of non-activated apertures 413. The non-activated apertures are not fluidly connected to a vacuum pressure source and / or are not closed at the surface 404 during assembly according to the present invention. The anvil may be configured to allow for the use of different apertures for different processes. Thus, the anvil may include both activated apertures 414 and non-activated apertures 413, with the activated apertures 414 forming an activated vacuum zone. Additionally or alternatively, the anvil may comprise a machined anvil 402a configured to define activated and non-activated vacuum regions through the use of configurable tubes 460, as discussed in more detail below with reference to Figures 7A-7C.

[0055] Returning to FIGS. 4A-4C, the elastomeric material 200 (which may be the elastomeric material 14) may be actuated via a spreader mechanism 412 (or via other known actuation processes such as ring rolling). The elastomeric material may include a base elastic layer and a surface layer, also known as a skin. During actuation, the elastomeric material may be stretched or elongated to plastically deform the skin, resulting in compaction into micro-corrugations when viewed under a microscope. Such micro-corrugations may help reduce the contribution of the skin to the elongation forces of the elastomeric material. With continued reference to FIGS. 4A-4C, the apparatus 400 may also include a spreader mechanism 412. As discussed in more detail below with reference to FIG. 5B, the spreader mechanism 412 may operate to actuate the elastic material by transversely stretching the elastic material from an initial CD width Wi to a first elongation W1 during an elastic laminate assembly process. Optionally, the stretched elastic material may be consolidated to a second elongation W2, which may be less than the first elongation. Returning to FIG. 4A, the elastic material is advanced from the spreader mechanism 412 onto the substrate on the rotating anvil 402. It should be appreciated that the apparatus 400 may include multiple spreader mechanisms configured in various manners, such as those disclosed in U.S. Patent Application Nos. 62 / 374,010, 62 / 406,025, and 62 / 419,515. In a non-limiting example, the elastomeric material may be actuated using a ring rolling process, such as that described in U.S. Patent No. 10,568,776 to Lenser et al. It should be appreciated that two or more strips of elastomeric material may be stretched in individual lanes 453 by the spreader mechanism 412 of each lane. The spreader mechanisms may be disposed at different MD positions.

[0056] As shown in Figures 4A-4E, the spreader mechanism 412 may be configured with tilted disks. For example, the spreader mechanism 412 may include a first disk 416 and a second disk 418, where the first disk 416 is displaced from the second disk 418 along the axis of rotation 406. The first disk 416 is adapted to rotate about an axis of rotation 416a, and the second disk 418 is adapted to rotate about an axis of rotation 418a, where the first and second disks 416, 418 rotate in a second direction Dir2 opposite the first direction Dir1. Although the second direction Dir2 is shown as counterclockwise in Figure 4A, it should be understood that the disks 416, 418 may be configured to rotate such that the second direction Dir2 is clockwise. Additionally, the first disc 416 includes an outer rim 416b extending axially between an inner edge 416c and an outer edge 416d, and the second disc 418 includes an outer rim 418b extending axially between an inner edge 418c and an outer edge 418d.

[0057] As shown in Figures 4A-4D, the first and second disks 416, 418 are inclined relative to one another such that the outer rims 416b, 418b are separated from one another by an increasing distance D from a minimum distance Dmin at a first location 420 to a maximum distance Dmax at a second location 422. As discussed below, an elastic material, such as an elastic film, may be advanced in the machine direction onto the outer rims 416b, 418b during operation. Because the first and second disks 416, 418 are inclined, rotation of the disks 416, 418 causes the rims 416b, 418b to pull on edge regions of the elastic material, actuating the elastic material by stretching the elastic material in the cross direction CD. The disks 416, 418 may include engagement portions 419 configured to help grip opposing edge regions of the elastic material during operation. For example, with particular reference to Figures 4D and 4E, the first disk 416 and the second disk 418 may each include a channel 424 extending radially inward from the rim 416b, 418b. The channel 424 may then be fluidly connected to the vacuum pressure source 405. Thus, vacuum air pressure may be used to help hold the elastic material on the rim 416b, 418b during operation. The disks 416, 418 may also include a support member 426 extending across the channel 424 to help prevent the elastic material from being drawn into the channel 424 by the vacuum air pressure. As shown in Figures 4D and 4E, the disks 416, 418 may also include a nub 428 projecting radially outward from the rim 416b, 418b. Thus, the nubs 428 may also act to help prevent the edge regions of the elastic material from sliding along the rims 416b, 418b while stretching the elastic material. It should be appreciated that additional nubs 428 may be positioned on the inside or outside of the channel 424. Additionally, nubs 428 may also be positioned on the support member 426.

[0058] As described above, the stretched elastic material and the substrate may be combined on the anvil 402. The combined substrate and elastic material may then be bonded together on the anvil 402 to form an elastic laminate. As shown in FIGS. 4A and 4B, the apparatus 400 may include one or more ultrasonic mechanisms 430 adjacent the anvil 402. It should be understood that the ultrasonic mechanism 430 may include one or more horns 432 and may be configured to apply ultrasonic energy to the combined substrate and elastic material on the anvil 402. As shown in FIG. 4F, the anvil roll 402 may include a plurality of pattern elements 434 extending radially outward from the outer peripheral surface 404 of the anvil 402. Thus, the ultrasonic mechanism may apply energy to the horn 432 to cause the horn 432 to resonate at a frequency and amplitude such that the horn 432 rapidly vibrates in a direction generally perpendicular to the substrate and elastic material being advanced over the horn 432 on the rotating anvil 402. The vibration of the horn 432 generates heat to fuse and bond the substrate and elastomeric material together in the area supported by the pattern elements 434 on the anvil 402. It should be understood that each aspect of the ultrasonic mechanism may be configured in a variety of ways, such as those disclosed in U.S. Pat. Nos. 3,113,225, 3,562,041, 3,733,238, 6,036,796, 6,508,641, and 6,645,330. Multiple lanes may each have their own ultrasonic mechanism, in non-limiting examples. In some configurations, the ultrasonic mechanism may be configured as a linear vibrating sonotrode, such as available from Herrmann Ultrasonic, Inc. In some configurations, the sonotrode may include multiple sonotrodes nested together in the transverse direction CD.

[0059] The apparatus can be operated in a variety of ways to assemble the laminate. A suitable spreader configuration is disclosed in U.S. Patent No. 10,568,776 to Lenser et al.

[0060] In various embodiments shown in FIG. 5A, a first substrate 202 (which may be a first nonwoven 12) advances in a machine direction MD onto a rotating anvil 402. More specifically, the first substrate 202 includes a first surface 204 and an opposing second surface 206, and the first substrate 202 advances to wrap the first surface 204 onto the circumferential surface 404 of the rotating anvil 402. During the assembly process, a spreader mechanism 412 actuates an elastomeric material 208 (e.g., an elastomeric layer 14, a film 15) by stretching the elastic material 208 to a first elongation in a cross direction CD. The elastic material 208 is positioned to contact the second surface 206 of the first substrate 202. The elastic laminate 200 (i.e., laminate 10) may then be formed by ultrasonically bonding the first substrate 202 and the elastic film 208 together with a second substrate 210 (e.g., second nonwoven 16) on an anvil 402. More specifically, the second substrate 210 includes a first surface 212 and an opposing second surface 214, and the second substrate 210 is advanced to bring the first surface 212 into contact with the elastic material 208 and the second surface 206 of the first substrate 202.

[0061] With continued reference to FIG. 5A, as the anvil 402 rotates, the first substrate 202, the elastic material 208, and the second substrate 210 are advanced between the outer peripheral surface 404 of the anvil 402 and the ultrasonic horn 432. The ultrasonic horn 432 then bonds the first substrate 204, the stretched elastic film 208, and the second substrate 210 together to form the elastic laminate 200. The elastic laminate 200 may then be advanced from the anvil 402 to additional absorbent article assembly processes. In a relaxed state, the central region of the elastic material 208 is contracted (i.e., corrugated) in the cross direction CD. It should be appreciated that during the ultrasonic bonding process, the bond imparted to the elastic laminate 200 from the ultrasonic horn 432 may correspond to a pattern and / or shape defined by a plurality of pattern elements 434 extending radially outward from the outer peripheral surface 404 of the anvil 402. It should be understood that the elastic laminate 200 may include various portions of components bonded together in various ways and with different or the same bond patterns. For example, the elastic material 208 may be bonded together with the first and / or second substrates 202, 210, and the first substrate 202 may be bonded directly to the second substrate 210 in the area of ​​the elastic laminate 200. It should be understood that the apparatus 400 may be adapted to produce various types of bond configurations, such as those disclosed in U.S. Patent No. 6,572,595.

[0062] As shown in FIG. 5B, the spreader mechanism 412 actuates the elastic material 208 in the transverse direction CD by stretching the elastic material 208 from an initial width Wi having an initial elongation Ei to a first width W1 having a first elongation E1. With particular reference to FIG. 5A and FIG. 5C, the elastic material 208 includes a first edge 216a and a second edge 216b separated from the first edge 216a in the transverse direction CD. In addition, the elastic material 208 includes a first edge region 208a adjacent to the first edge 216a and a second edge region 208b adjacent to the second edge 216b. The first edge region 208A is separated from the second edge region 208B in the transverse direction CD by a central region 208C. 5A and 5B, the elastic material 208 can define an initial width Wi in the cross direction CD between the first edge 216a and the second edge 216b upstream of the spreader mechanism 412. The elastic material 208 advances in the machine direction MD onto the spreader mechanism 412 at or downstream of the first position 420. It should be understood that the elastic material 208 can be at the initial width Wi in the cross direction CD while advancing onto the spreader mechanism 412. It should also be understood that the elastic material 208 can be in a relaxed state upstream of the spreader mechanism 412.

[0063] As shown in Figures 5B-5C, the first edge region 208a of the elastic material 208 advances onto the outer rim 416b of the first disk 416 of the spreader mechanism 412, and the second edge region 208b advances onto the outer rim 418b of the second disk 418. The outer rims 416b, 418b of the first and second disks 416, 418 of the spreader mechanism 412 may include an engagement portion 419, such as including a radially protruding nub 428. Thus, as shown in Figure 5C, the first edge region 208a of the elastic material 208 may be held in place on the outer rim 416b by the engagement portion. Similarly, the second edge region 208b of the elastic material 208 may be held in place on the outer rim 418b by the engagement portion.

[0064] 6A and 6B, each of which shows a lane 453, the outer peripheral surface 404 of the anvil 402 may be fluidly connected to a vacuum source 405 such that vacuum air pressure may be applied to the first substrate 202 on the anvil 402. Additionally, if the first substrate 202 is configured as a porous substrate such as a nonwoven fabric, vacuum air pressure may also be applied to the elastic material 208 on the anvil 402, thus helping to maintain the elastic material 208 in an elongated state while on the anvil 402. Further, as discussed above, the anvil includes one or more actuated vacuum zones 415, 415a.

[0065] The working vacuum zone includes a maximum width Wv in the transverse direction. In various embodiments, the working vacuum is nominally to the first and second portions 452, 454. The first portion 452 extends inwardly from the area of ​​overlap between the engagement portion 419 and the working vacuum toward the lane centerline 451. The first portion includes the width of VZi in the transverse direction. The second portion 454 is the remaining width of the working vacuum zone. That is, the second portion is the widest portion that extends outwardly (away from the lane centerline 451) of the engagement portion 419. The second portion includes the width of VZo in the transverse direction. The width of the first portion VZi is greater than the width of the second portion VZo. The ratio of VZi to VZo is greater than 1. In non-limiting examples, the ratio of VZi to VZo is greater than 2, or greater than 3, or greater than 5. In some embodiments, no more than one MD row of vacuum apertures is positioned outside the engaged portion of the spreader disk. In a non-limiting example, VZo is about 0.5 mm to about 3 mm, with the range recited in 0.1 mm increments within this range. In a further non-limiting example, VZo is zero and there is no applied vacuum outside the engaged portion. In these configurations, the width of the non-stretch zones Wd1, Wd2 is less than the width of the second portion of the applied vacuum VZo. Although VZo may be relatively small as described, the elastomeric material may still be compressed against the anvil due to the lower static pressure of the leakage airflow between the edge of the elastomeric material and the anvil, where the airflow may be at high velocity. The edge of the elastomeric material may also be sealed against the anvil by the vacuum static pressure of the source. The high velocity leakage airflow may initiate sealing via high static pressure.

[0066] Additionally, the first portion 452 may not extend to the lane centerline 451 and / or the anvil centerline 450. In a non-limiting example, the first portion 452 is outboard of the spreader disc inner edges 418c, 416c (i.e., away from the anvil centerline) at the outermost of the respective spreader disc inner edges 418c, 416c.

[0067] 6A, in use, the active vacuum zone 415 is positioned in overlapping relationship with one of the elastomeric edge regions 208b, 208a. The second active vacuum zone 415a may be positioned in overlapping relationship with the other of the edge regions. A majority of the active vacuum width is disposed inward of the respective elastomeric edge 216a, 216b.

[0068] Without being bound by theory, the first portion provides sufficient operational normal force to hold the elastic material 208 against the anvil 402 to prevent slippage of the elastic material, and the second portion primarily ensures that the elastic material rests flat against the first substrate, which may reduce wrinkling, misaligned edges, folding, and gathering. The second portion also aids in the transfer of the elastomeric material from the anvil.

[0069] In addition to the above, the elastic material 208 must be tracked during processing to ensure continued control of the elastic material by the vacuum. Breakdown of the operable control of the elastic material may result in the elongated elastic material shrinking to a narrower width than desired before lamination, which may result in an unusable final product. Known methods and apparatus do not take into account that the CD width of the operating vacuum region may be significantly wider and / or require higher pressure differentials compared to the vacuum zone of the spreader, particularly for tooth-assisted tilted-disk spreader mechanisms. Reducing the width VZo may improve process robustness by making the apparatus less susceptible to normal mistracking or misalignment of the web or material edge. The wrap angle around the teeth on the spreader disk, aided by the narrow area of ​​MD-oriented vacuum holes, may make the operative engagement of the spreader with the elastic material substantially more effective and help control the position of the elastic material relative to the anvil. Additionally, by moving the actuation vacuum inward, the width of the non-stretch zone may be reduced and less elastomeric material may be used, resulting in a more efficient use of the elastomeric material.

[0070] Although the apparatus 400 may be configured to operate on-line as part of an absorbent article assembly process, it is understood that aspects of the apparatus 400 herein may be configured in various manners and may operate to assemble the elastic laminate 200 from various types of materials and / or components. For example, it is understood that in some configurations, the elastic laminate assembly operations may be performed separately from the final assembly process, such as by assembling the elastic laminate offline, where the elastic laminate may be stored until needed for production. For example, the elastic laminate assembly operations may be accomplished on a separate assembly line, separate from a dedicated processing line for manufacturing disposable absorbent articles. After assembly on a separate line, the elastic laminate may be delivered to the absorbent article processing line, such as in the form of a roll of continuous elastic laminate. It is understood that such rolls of continuous elastic laminate may be planetary wound or cross-wound. It is also understood that the elastic laminate assembly process may be performed on-line during the article assembly process.

[0071] 7A-7C, as described above, the anvil may include a machined anvil 402a and may include a configurable tube 460 for defining the working and non-working vacuum regions. Known configurable anvils are formed from multiple rectifier disks. One or more of the rectifier disks may be used to operatively connect a reduced static pressure plenum with a substrate or elastic material surface. To avoid a unique anvil for each product size / design, such anvils generally provide vacuum to multiple rectifier disks and use a blocking element to determine which rectifier disk is operationally active. A drawback of this scheme is that the rectifier disks may form void areas on the circumference of the anvil, where no working vacuum ports exist. If the edge of the elastic material overlaps the void area, a tight seal may not be formed between the anvil and the elastic material, and additional airflow may be drawn around the edge. Such additional airflow may act to reduce the static pressure differential between the surfaces (e.g., 204, 206) of the elastic material, thus potentially causing snapback and loss of desired elongation of the elastic material. Additionally, leakage may occur due to transfer from the vacuum source to the vacuum port.

[0072] In some embodiments, a block-off device, either integral with or separate from the anvil exterior surface 404, can be used to fill void areas within the straightening disc, which may allow for further reduction in non-stretch zones as the vacuum can be more efficiently utilized and directed to desired locations of the elastic material.

[0073] Alternatively, the anvil may include a machined anvil 402a fabricated from a solid block of metal. A substantial advantage of such fabrication is the reduction of air leakage around the edges of the film, thus allowing for better vacuum sealing and / or reduced planning area of ​​the resulting non-stretch zone. A machined anvil allows for the use of a configurable tube 460 rather than a straightening disk. The tube 460 includes a port 462 removably disposed within the anvil and fluidly connected to a vacuum source. The port 462 is also fluidly connected to the outer periphery of the anvil through a radial connector 466. A number of shutoff mechanisms 464 (e.g., valves) may be used to direct vacuum pressure to the actuating aperture 414, thereby forming actuating and / or non-actuating vacuum zones. Additionally or alternatively, the tube 460 may be replaced with a second tube having an alternative configuration of vacuum ports to activate and deactivate alternative operable vacuum apertures around the anvil. An advantage of this form of embodiment may be the elimination of void areas around the anvil. Eliminating the void areas may result in reduced leakage airflow around the edges of the elastic material, allowing for higher pressure differentials between the surfaces 204, 206 of the elastic material. Additionally, by providing a vacuum within the roll, less leakage may be expected, and therefore more efficient use of the vacuum. This mechanism is believed to improve the normal force of the stretched elastic material on the anvil, even with minimal or no non-stretch zone width, thus allowing for improved motion control of the stretched elastic material. Additionally, as noted above, the use of one or more configurable tubes allows one anvil to be utilized for different production designs. For example, the vacuum ports on the configurable tubes may be activated in different configurations, or different tubes may be used with the same anvil. In this manner, a laminate may be formed in one lane and other laminates may be formed with multiple lanes on the same anvil. Similarly, laminates formed on the same anvil may differ in dimensions, extensibility, configuration of non-stretch zones, etc.

[0074] In one or more embodiments, one or more reinforcing materials 50 may be added to the laminate. Suitable methods for forming and incorporating reinforcing material layers are disclosed in U.S. Patent No. 10,561,537 to Lenser et al. As shown in FIG. 8A, a first reinforcing layer 312 (e.g., reinforcing substrate layer 54) may be advanced onto the second surface 206 of the first substrate 202. It should be understood that the first reinforcing layer 312 may be formed in a variety of ways. For example, the first reinforcing layer 312 is shown as a separate strip of material advanced onto the first substrate 202. The separate strip of material may be a fastening tape. Additionally or alternatively, additional reinforcing layers 314, 316 may also be advanced onto the anvil roll 402 with the first substrate 202. Similarly, it should be understood that the first substrate 202 and / or reinforcing layers 312, 314, 316 may also be advanced around the guide roller 144 as shown in FIG. 8A. In a non-limiting example shown in FIG. 8B, the substrate 202 may advance through a folding device 442 that operates to fold portions of the substrate 202 to form one or more reinforcing layers 314, 316. The folding device may operate to fold the first longitudinal edge 320 and / or the second longitudinal edge 322 of the substrate laterally inwardly in a transverse direction, resulting in fold lines 330 and fold portions 324, 326 that extend in the machine direction and in the longitudinal direction, as shown in FIG. 8B. The fold portions function as reinforcing layers 314, 316. The second substrate 210 may be folded in the same manner to form one or more reinforcing layers. One or more reinforcing layers may be positioned between the second surface 206 of the first substrate and the edge regions of the elastomeric material 208b, 208a. Additionally or alternatively, one or more reinforcing layers may be positioned between the first surface 212 of the second substrate 210 and the edge regions 208b, 208a of the elastomeric material.

[0075] Articles containing laminates 9, the laminate 10 of the present invention may be incorporated into an absorbent article 100, such as a disposable absorbent article. The laminate may be attached to one or more layers of a chassis 120 by chassis attachment bonds 102. The chassis attachment bonds may include ultrasonic bonds, adhesive bonds, mechanical bonds, or combinations thereof.

[0076] 9 is a plan view of an exemplary, non-limiting embodiment of an absorbent article 100 of the present invention in a flat, uncontracted state. The body-facing surface 115 of the absorbent article 100 faces towards you. The absorbent article 100 includes a longitudinal centerline 105 and a lateral centerline 110.

[0077] The absorbent article 100 comprises a chassis 120. The absorbent article 100 and chassis 120 are shown as having a first waist region 114, a second waist region 118 opposite the first waist region 114, and a crotch region 116 located between the first waist region 114 and the second waist region 118. The waist region 114 and the waist region 118 generally comprise those portions of the absorbent article that encircle the waist of the wearer when worn. The waist region 114 and the waist region 118 may include elastic members 155 that gather around the waist of the wearer to improve fit and containment. The crotch region 116 is the portion of the absorbent article that is generally positioned between the legs of the wearer when the absorbent article is worn.

[0078] The outer periphery of the chassis 120 is defined by longitudinal edges 112 and waist edges (a first waist edge 113 in the first waist region 114 and a second waist edge 119 in the second waist region 118). The chassis 120 may have opposing longitudinal edges 112 oriented generally parallel to the longitudinal centerline 105. However, for a better fit, the longitudinal edges 112 may be curved or angled to create an "hourglass" shaped article when viewed in plan as shown, for example, in FIG. 14. The chassis 120 may have opposing lateral edges 113, 119 (i.e., the first waist edge 113 and the second waist edge 119) oriented generally parallel to the lateral centerline 110.

[0079] The chassis 120 may comprise a liquid permeable topsheet 124, a backsheet 126, and an absorbent core 128 between the topsheet 124 and the backsheet 126. The topsheet 124 may be joined to the core 128 and / or the backsheet 126. The backsheet 126 may be joined to the core 128 and / or the topsheet 124. It should be appreciated that other structures, elements, or substrates may be positioned between the core 128 and the topsheet 124 and / or between the core 128 and the backsheet 126. In some embodiments, an acquisition distribution system 127 is disposed between the topsheet 126 and the absorbent core 128.

[0080] In certain embodiments, the chassis 120 comprises the main structure of the absorbent article 100, with other features added to form a composite absorbent article structure. The topsheet 124, backsheet 126, and absorbent core 128 may be assembled in a variety of known configurations, but absorbent article constructions are generally described in U.S. Patent Nos. 3,860,003, 5,151,092, 5,221,274, 5,554,145, 5,569,234, 5,580,411, and 6,004,306. One or more masking layers or materials may be provided within the absorbent article. The masking layer may be a layer that provides cushioning when the absorbent article is contacted from a garment-facing or wearer-facing surface. The masking layer can "mask" any roughness that may be caused by absorbent materials such as superabsorbent polymers. The masking layer can "hide" the visibility of bodily exudates when viewing the wearer-facing or garment-facing surface of the absorbent article. 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 comprise 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 of the backsheet. The masking layer may be a layer that forms the garment-facing or wearer-facing side of the core. The masking layer may be a separate material positioned intermediate the garment-facing surface of the core and the liquid impermeable backsheet.

[0081] Components of disposable absorbent articles may be at least partially composed of biosourced content as described in U.S. Patent Publication Nos. 2007 / 0219521 (A1), 2011 / 0139658 (A1), 2011 / 0139657 (A1), 2011 / 0152812 (A1), and 2011 / 0139659 (A1), including, but not limited to, topsheets, backsheet films, backsheet nonwovens, ear / ear laminates, leg gasket systems, superabsorbents, acquisition layers, core wrap materials, adhesives, fastening systems, and landing zones. In at least one embodiment, the disposable absorbent article component comprises a biobased content value using ASTM D6866-10, Method B, of about 10% to about 100%, or about 25% to about 75%, or about 50% to about 60%. To apply the ASTM D6866-10 methodology to determine the biobased content of any component, a representative sample of the component must be obtained for testing. In at least one embodiment, the disposable absorbent article component may be ground into fine particles of less than about 20 mesh using well-known grinding methods (e.g., a WILEY® mill) and a representative sample of suitable mass may be removed from the randomly mixed particles.

[0082] The laminate 10 of the present invention may form or be a part of one or more components of an article, including, but not limited to, the front ears, back ears, and / or waist features.

[0083] Top sheet The topsheet 124 is generally the portion of the absorbent article 100 that may be at least partially in contact with or more proximal to the wearer. The topsheet 124 is generally supple, soft-feeling, and non-irritating to the wearer's skin. Additionally, at least a portion of the topsheet or the entirety of it may be liquid permeable, allowing liquid body exudates to readily penetrate through its thickness. Suitable topsheets may be manufactured from a wide range of materials, such as, for example, porous foams, reticulated foams, hole-formed plastic films, woven materials, nonwoven materials, woven or nonwoven materials of natural fibers (e.g., wood or cotton fibers), synthetic fibers or filaments (e.g., polyester fibers, or polypropylene fibers, or bicomponent PE / PP fibers, or mixtures thereof), or combinations of natural and synthetic fibers. The topsheet may have one or more layers. The topsheet may be hole-formed, may have any suitable three-dimensional features, and / or may have a plurality of embossments (e.g., bonded patterns). The topsheet may be apertured by strong 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 may be coated with a skin care composition, an antimicrobial agent, a surfactant, and / or other benefit agent. The topsheet may be hydrophilic or hydrophobic, or may have hydrophilic portions or layers and / or hydrophobic portions or layers. If the topsheet is hydrophobic, there will typically be apertures so that body exudates can pass through the topsheet.

[0084] Absorbent Core The absorbent core 128 may include a wide variety of liquid absorbent materials commonly used in disposable diapers and other absorbent articles. Examples of suitable absorbent materials include comminuted wood pulp, commonly referred to as airfelt crepe paper cotton, meltblown polymers including coforms, chemically stiffened, modified, or crosslinked cellulose fibers, tissue including tissue wrappers and tissue laminates, absorbent foams, absorbent sponges, superabsorbent polymers, absorbent gelling materials, or any other known absorbent material or combination of materials. In one embodiment, at least a portion of the absorbent core is substantially cellulose-free, contains less than 10% by weight cellulose fibers, less than 5% by weight cellulose fibers, less than 1% by weight cellulose fibers, trace amounts of cellulose fibers, or contains no cellulose fibers. It should be understood that trace amounts of cellulosic materials do not substantially affect at least one of the thinness, flexibility, and absorbency of the substantially cellulose-free portion of the absorbent core. Among other advantages, when at least a portion of the absorbent core is substantially free of cellulose, this portion of the absorbent core is believed to be significantly thinner and more flexible than a similar absorbent core that contains more than 10% by weight of cellulose fibers. The amount of absorbent material, e.g., absorbent particulate polymer material, present in the absorbent core may vary, but in certain embodiments is present in the absorbent core in an amount greater than about 80% by weight of the absorbent core, or greater than about 85% by weight of the absorbent core, or greater than about 90% by weight of the absorbent core, or greater than about 95% by weight of the core. In some embodiments, the absorbent core may comprise one or more channels 129, which are substantially free of absorbent particulate polymer material. The channels 129 may extend in the longitudinal or transverse direction. The absorbent core may further comprise two or more channels. The channels may be straight, curved, angled, or any operable combination thereof. In a non-limiting example, two channels are symmetrically disposed about the longitudinal axis.

[0085] Exemplary absorbent structures for use as the absorbent core 28 are described in U.S. Pat. Nos. 4,610,678, 4,673,402, 4,834,735, 4,888,231, 5,137,537, 5,147,345, 5,342,338, 5,260,345, 5,387,207, 5,397,316, and U.S. patent application Ser. Nos. 13 / 491,642 and 15 / 232,901.

[0086] Back sheet The backsheet 126 is generally positioned such that it may be at least a portion of a garment that faces the surface of the absorbent article 100. The backsheet 126 may be designed to prevent exudates absorbed by and contained within the absorbent article 100 from soiling articles that may come in contact with the absorbent article 100, such as bed sheets and undergarments. In certain embodiments, the backsheet 126 is substantially water impermeable. The backsheet may be or include a thin plastic film, such as, for example, a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm. Other suitable backsheet materials 126 may include breathable materials that allow vapors to escape from the absorbent article 100 while preventing exudates from passing through the backsheet 126.

[0087] The backsheet 126 may also be constructed of two or more layers. The backsheet 126 may comprise an outer cover and an inner layer. The outer cover may be made of a soft nonwoven material. The inner layer may be made of a substantially liquid impermeable film, such as a polymeric film. The outer cover and inner layer may be joined together by adhesive or any other suitable material or method. The outer cover material may include bond patterns, holes, and / or three-dimensional features. The outer cover may be a hydroentangled nonwoven material.

[0088] Ears / fasteners The absorbent article 100 may include one or more ears 130, including, for example, a front ear 132 disposed in a first waist region and / or a back ear 134 disposed in a second waist region. The ears 130 may be integral with the chassis or may be separate elements joined to the chassis 120 at chassis attachment bonds 102 that may join one or more layers of the ear to the chassis. The ears 130 may be extensible or elastic. The ears 130 may be formed from one or more nonwoven webs, woven webs, knit fabrics, polymeric and elastomeric films, perforated films, sponges, foams, scrims, or combinations and / or laminates of any of the foregoing.

[0089] In some embodiments, the ear 130 may include an elastomer, which makes the ear extensible. In certain embodiments, the ear 130 may be formed of an extensible laminate, such as a nonwoven / elastomeric laminate or a nonwoven / elastomeric / nonwoven laminate, which also makes the ear extensible. The ear 120 may be stretchable in the lateral direction of the article. In some embodiments, the ear is elastic in the lateral direction. In further embodiments, the ear 130 may extend further in the lateral direction than in the longitudinal direction. Alternatively, the ear may extend more in the longitudinal direction than in the lateral direction. In certain non-limiting examples, the ear may include one or more inelastic regions along with separate elastic regions.

[0090] In some embodiments, the ears comprise a laminate of one or more nonwovens and one or more elastic materials, such as laminate 10 having any of the features or laminate layers described herein for the laminates of the present invention.

[0091] Any suitable nonwoven may be used in the ear 130. Suitable nonwovens may include a basis weight of at least about 8 gsm, or at least about 30 gsm, or up to about 17 gsm, or from about 10 gsm to about 17 gsm, with ranges recited in increments within the range. Typically, a lower basis weight nonwoven reduces the overall strength of the ear. However, the inventors have discovered that ears designed according to the principles herein may achieve high strength despite a lower basis weight nonwoven. When the ear 130 includes two or more nonwovens, the nonwovens may include the same basis weight or different basis weights. Similarly, the nonwovens may include the same layer structure or different layer structures. Additionally, the nonwovens in the ears may include nonwovens of the same or different features in the backsheet, topsheet, leg gasket system, and / or waist features.

[0092] In various embodiments, the ears comprise ultrasonically bonded ears. Ultrasonically bonded ears are disclosed, for example, in U.S. Patent Application Serial No. 15 / 674559. The ears may be gathered laminates 24. Alternatively, the ears may be actuated by the process disclosed, for example, in U.S. Patent Publication No. 2013 / 0082418. In various embodiments, the ears comprise the laminates 10 of the present invention and may be formed by the methods disclosed herein.

[0093] The ears may be joined to the chassis at chassis attachment bonds 102. In some non-limiting examples, the chassis attachment bonds are located in inelastic regions of the ears.

[0094] The absorbent article 100 may also include a fastening system 148, which when fastened interconnects the first waist region 116 and the rear waist region 118 to create a waist circumference that can encircle a wearer while the absorbent article 100 is being worn. The fastening system 148 may comprise fastening elements 150, such as, for example, tape tabs, hook and loop fastening components, interengaging fasteners such as tabs and slots, buckles, buttons, snaps, and / or hermaphroditic fastening components, although any other known fastening means are generally acceptable. The absorbent article may further comprise landing zones where the fastening elements can be engaged and / or release tapes that protect the fastening elements from insults prior to use. Some exemplary surface fastening systems are disclosed in U.S. Patent Nos. 3,848,594, 4,662,875, 4,846,815, 4,894,060, 4,946,527, 5,151,092, and 5,221,274. An exemplary interengaging fastening system is disclosed in U.S. Patent No. 6,432,098. In some embodiments, the fastening system 148 and / or the elements 150 are foldable.

[0095] The fastening system 148 may be joined by any suitable means to any suitable portion of the article 100. The fastening system may be joined at the ears between layers.

[0096] Leg Gasket System The absorbent article 100 may include a leg gasket system 170 attached to the chassis 120, which may include one or more cuffs. The leg gasket system may include a pair of barrier leg cuffs 172. Each barrier leg cuff may be formed by a piece of material that is bonded to the absorbent article, and thus may extend upwardly from the wearer-facing surface of the absorbent article and may provide improved containment of fluids and other exudates near the junction of the wearer's torso and legs. The barrier leg cuffs are bounded by a proximal edge that is directly or indirectly joined to the topsheet 124 and / or backsheet 126, and a free edge 175 that is intended to contact the wearer's skin and form a seal. In some embodiments, the free edge 175 includes a folded edge. The barrier leg cuffs 172 extend at least partially between the front waist edge 113 and the back waist edge 119 of the absorbent article on either side of the longitudinal centerline 105 and are at least in the crotch region. The barrier leg cuffs may be joined to the chassis of the article at their proximal edges by a bond which may be accomplished by a combination of adhesives, melt bonding, or other suitable joining processes.

[0097] The barrier leg cuffs may be integral with the topsheet 124 or backsheet 126 or may be separate materials joined to the chassis of the article. Each barrier leg cuff 172 may include one, two or more elastic elements 155 adjacent its free edge 175 to provide a better seal.

[0098] In addition to the barrier leg cuffs 172, the article may comprise gasket cuffs 176 joined to the chassis of the absorbent article, in particular the topsheet 124 and / or backsheet 126, and positioned externally relative to the barrier leg cuffs 172. The gasket cuffs 176 may provide a better seal around the wearer's thighs. The gasket cuffs may comprise a proximal edge and a free edge 177. The free edge 177 may comprise a folded edge. Each gasket cuff may comprise one or more elastic elements 155 in the chassis of the absorbent article between the topsheet 124 and the backsheet 126 in the region of the leg openings. All or a portion of the barrier leg cuffs and / or gasket cuffs may be treated with a lotion or another skin care composition.

[0099] In a further embodiment, the leg gasketing system comprises a barrier leg cuff integrated with the gasket cuff.Suitable leg gasketing systems that may be part of the absorbent article are disclosed in U.S. Patent Application Serial Nos. 62 / 134,622, 14 / 077,708, U.S. Patent Nos. 8,939,957, 3,860,003, 7,435,243, and 8,062,279.

[0100] Elastic waist mechanism As shown in FIG. 9, the absorbent article 100 may include at least one elastic waist feature 180 that helps provide improved fit and containment. The elastic waist feature 180 is generally intended to contract to dynamically fit the waist of the wearer. The elastic waist feature includes a waistband, a waist cuff having a pocket formed from a portion of the waist feature 180 that is detached from the chassis 120, and a waist panel designed to fit securely around the wearer's abdomen. Non-limiting examples of elastic waist features are disclosed in U.S. Patent Application Nos. 13 / 490,543, 14 / 533,472, and 62 / 134,622. The waist feature 180 may be joined to the chassis 120 at the first waist region 114 and / or the second waist region 118. The waist feature may be used in conjunction with ears 130 to provide the desired stretch and flexibility to properly fit the article to the wearer. The waist feature may be laterally and / or longitudinally extensible or elastic. The waist feature 180 may comprise the laminate 10 of the present invention and be formed by the methods disclosed herein.

[0101] Test Method Ear extension test method Ear elongation is measured using a constant rate of extension tensile tester with a computer interface such as MTS Alliance under Test Works 4 software (MTS Systems Corp., USA) fitted with an appropriate load cell. The load cell should be selected to operate between 10% and 90% of the specified maximum load. All tests are performed in a conditioned room maintained at about 23°C ± 2°C and about 50% ± 2% relative humidity. In this specification, the width and length of the specimen are the transverse width and longitudinal length. Precondition the specimens to about 23°C ± 2°C and about 50% ± 2% relative humidity for 2 hours prior to testing.

[0102] Flat or linear grips should be used. Figure 11 presents a schematic of suitable top grip 700 and bottom grip 710. The gripping surfaces may be serrated / diamond shaped to hold the sample or may have a rubber liner (1 / 32 inch thick 60-70A durometer Nepron rubber) on at least one of the two gripping surfaces to hold the sample in place.

[0103] The ears are typically bonded to the chassis via heat or adhesive or similar bonds. To collect the sample, the product is laid flat on a cutting mat. The sample is collected by cutting the product approximately 20-30 mm below the bottom edge of the ear, as shown in Figure 10. The left ear is separated from the right ear by cutting the cut sample down the center.

[0104] The folded fastening system (eg, release tape covering the fastening elements) should be unfolded.

[0105] See Figure 10-11: 1. Insert the outer edge of the ear, including the fastener, into the moving clamp (top clamp) in the tensile tester so that the clamp is centered in the tensile tester fixture and engage the clamp to grip the specimen. The clamp width selected is at least 25.4 mm and preferably not more than 1 inch wider than the length of the inner edge of the fastener. The face of the clamp (which will grip the specimen) should be aligned to within 1 mm with the inner edge of the fastener, the longitudinal midpoint of the LFP should be aligned with the center of the clamp, and the unclamped portion of the back ear should hang freely from the clamp. 2. Insert the inner edge of the ear into the fixed clamp (lower clamp) of the tensile tester. Select the fixed clamp width so that no part of the back ear extends beyond the width of the clamp. Orient the specimen so that the face of the clamp (after gripping the specimen) is aligned to within 1 mm with the bond line 720 and that when a transverse line is drawn from the midpoint of the LFP, it extends vertically and is aligned with the center of the fixture holding the lower clamp. 3. Adjust the lower grip position so that the specimen is gripped at the outer edge of the chassis mounting joints 102. If the chassis mounting joints are curved, the specimen is gripped at the outer edge of the outermost joint. 4. Zero the crosshead position, load, and engage the lower clamp to grip the specimen. 5. Set the tensile tester to extend the specimen at a rate of 254 mm / min and collect data at a frequency of at least 100 hz. 6. Start the test so that the clamps of the tensile tester extend the specimen at the defined rate and collect the data in a data file. 7. Determine the elongation at a force load of 1000 gm from the data.

[0106] At least five replicate specimens are tested for each product example. The average elongation at 1000 gm force load and the standard deviation of at least four specimens are recorded. If the recorded standard deviation is higher than 20%, a new set of five specimens is tested.

[0107] Angle maximum peak force tensile test method Angle maximum peak force tensile testing is used to measure the strength of the specimen at relatively high strain rates representative of the product application. This method involves the use of a suitable tensile tester with an actuator that allows speeds in excess of 1 m / sec. An instrument model #AA-TS-ECH14-600 available from Allied Automation, Indianapolis, can be used as the tensile tester. A 50 lb force transducer (such as a 1500ASK-50) is attached to the tensile tester. The grips shown in Figure 12A should be used to hold the specimen during the tensile test. The grip faces can be serrated to hold the sample or have a rubber liner (of 1 / 32 inch thick 60-70A durometer Nepron rubber) on at least one of the two grip faces to hold the specimen in place. The top grip 800 is fixed and is 38 mm wide to hold the fastening end of the product. The bottom grip 810 can move and is wide enough to hold the full width of the sample. The bottom grip fixture can also be rotated 15 degrees to measure diagonal tensile strength.

[0108] (a) Tensile test of specimens from absorbent articles The ears are generally bonded to the chassis via heat or adhesive or similar bonding. To collect the sample, lay the product flat on a cutting mat. The sample is collected by cutting the product approximately 20-30 mm below the bottom edge of the ear as shown in the image. Separate the left back ear from the right ear by cutting in the center as described in the Ear Stretch Test Method herein. Any folded fastening system (e.g. release tape covering the fastening elements) should be unfolded.

[0109] 12B-12C, the specimen is clamped in the top grip at a first gripping position G1, which is the inner edge 152 of the fastener projection engagement area 150. The gripping line G1 is kept parallel to the longitudinal centerline of the product. If the fastener engagement area is angled, the specimen is gripped at the center of the area and the gripping line is kept parallel to the longitudinal centerline of the product at the center. The specimen is attached and suspended from the top grip. In the relaxed state, the opposing edges of the specimen are attached to the bottom grip. The bottom grip position G2 is adjusted so that the specimen is gripped at the outer edge of the chassis interface. If the chassis interface is curved, the specimen is gripped at the outer edge of the outermost interface. The bottom grip is wider than the length of the ears at the second gripping position G2. The top and bottom grips are parallel to each other. Once the sample is attached, the bottom grip is moved towards the top grip to allow slack in the material. At this point, the bottom grip with the sample held in it is rotated 15 degrees to take an angled measurement.

[0110] Test specimens as follows: Measure the vertical distance G2 (perpendicular to the grip line) from the first grip position G1 to the second grip position G2 to the nearest 0.1 mm using a ruler and use it as the gage length for the test. Test the specimen at a test speed that provides a strain rate of 4 to 10 s-1 for the gage length selected for the specimen. The test speed in mm / s is calculated by multiplying 4 to 10 s-1 by the gage length in mm. For example, a 125 mm gage length specimen tested at a strain rate of 4 s-1 requires a test speed of 500 mm / s. On the other hand, a 50 mm gage length specimen tested at a strain rate of 10 s-1 also requires a test speed of 500 mm / s.

[0111] Each specimen is pulled to failure. One of the grips (the one with the tape) is held stationary during the test while the opposing grip is moved. Force and actuator displacement data generated during the test are recorded with a data acquisition frequency of at least 1 kHz. The resulting load data can be expressed as load at break in Newtons. For example, a total of five replicate specimens are tested. The maximum peak force and standard deviation of at least four specimens are recorded as maximum peak force with angle. If the recorded standard deviation is higher than 10%, a new set of five specimens is tested.

[0112] Basis Weight Test Method Each sample is weighed to within ±0.1 milligrams using a digital balance. The length and width of the specimen are measured using digital vernier calipers, or equivalent to within ±0.1 mm. All tests are performed at 22±2°C and 50±10% relative humidity. Basis weight is calculated using the following formula:

[0113]

number

[0114] A total of eight linear specimens of at least 10 mm x 25 mm are used to calculate the basis weight of the substrate.

[0115] The average basis weight and standard deviation are recorded.

[0116] Hysteresis Test Method This setting applies to both general hysteresis testing and elastomer layer hysteresis testing. An appropriate tensile tester is used, such as an MTS model Alliance RT / 1 with TestWorks4® software or equivalent, interfaced with a computer. The tensile tester is placed in a climate controlled room at 22°C ± 2°C and 50 ± 10% relative humidity. The instrument is calibrated according to the manufacturer's instructions. The data acquisition rate is set to at least 50 Hertz. The gripper used for the test is wider than the sample. A gripper with a width of 2 inches (50.8 mm) may be used. The gripper is a pneumatic gripper with one flat and counter face designed to focus the total gripping force along a single line perpendicular to the direction of the test stress, from which protrudes a semicircular shape (radius = 6 mm, e.g. part number: 56-163-827 from MTS Systems Corp.) to minimize sample slippage, or an equivalent gripper. The load cell is selected so that the force being measured is within 10%-90% of the load cell's capacity or load range being used. Zero the load reading on the instrument to compensate for the mass of the equipment and grips.

[0117] The test specimen is attached to the grips in such a manner that there is no slack and the measured load is 0.00N to 0.02N. The basis weight of the test specimen is measured according to the basis weight method described above. The test specimen is attached to the center of the grips so that the stretch direction of the specimen is parallel to the applied tensile stress.

[0118] General hysteresis test: 1. Cut test specimens to dimensions of 10 mm in the direction of intended stretch of the sample by 25.4 mm in the direction perpendicular to the direction of intended stretch of the sample. Collect specimens from either the inelastic or elastic regions. 2. Set the distance between the grips (gauge length) to 7 mm. 3. Clamp the specimen with minimal slack with the intended stretch direction aligned with the MTS strain direction, as described above. 4. a. Preload step: Set the sag preload at 5 gram force. This means that data collection will begin when the sag is removed with 5 gram force (at a constant crosshead speed of 13 mm / min). The strain is proportional to the adjusted gage length (l ini ), where the adjusted gage length is the length of the specimen between the grips of the tensile tester at 5 grams force. This adjusted gage 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 gage length divided by the adjusted gage length multiplied by 100. b. First cycle loading: Pull the specimen to 50% strain at a constant crosshead speed of 70 mm / min. The length of the specimen stretched between the grips is l max Report as. c. First cycle unloading: The specimen is held at 50% strain for 30 seconds, then the crosshead is moved to its starting position (0% strain or initial specimen length, l) at a constant crosshead speed of 70 mm / min. ini ) and hold the test specimen in the relaxed position for 1 minute. d. Second cycle loading: Pull the specimen to 50% strain at a constant crosshead speed of 70 mm / min. The length of the specimen stretched between the grips at 7 g force is l ext Report as. e. Second cycle unloading: The specimen is then held at 50% strain for 30 seconds and then the crosshead is returned to its starting position (ie, 0% strain) at a constant crosshead speed of 70 mm / min.

[0119] A computer data system records the force applied to the sample during the test as a function of the applied strain. Length is reported to the nearest 0.001 mm. From the resulting data generated, the % cure is calculated using the following formula: In units of 0.01%, (l ext -l ini ) / (l max -l ini ) × 100%. The test is repeated on at least three separate samples and the average value and standard deviation are reported.

[0120] Elastomer Layer Hysteresis Test: 1. Cut test specimens to dimensions of at least 32 mm in the direction of the intended stretch of the sample by 25.4 mm (1 inch) in the direction perpendicular to the direction of the intended stretch of the sample. 2. Set the distance between the grips (gauge length) to 25.4 mm (1 inch). 3. Clamp the specimen with minimal slack with the intended stretch direction aligned with the MTS strain direction, as described above. 4. a. Preload step: Set the sag preload at 5 gram force. This means that data collection will begin when the sag is removed with 5 gram force (at a constant crosshead speed of 13 mm / min). The strain is proportional to the adjusted gage length (l ini ), where the adjusted gage length is the length of the specimen between the grips of the tensile tester at 5 grams force. This adjusted gage length is the initial specimen length, which corresponds to 0% strain. The strain rate during pre-strain testing is defined as the length relative to the adjusted gage length divided by the adjusted gage length multiplied by 100. b. Pre-strain load: Pull the specimen to 500% strain at a constant crosshead speed of 508 mm / min (10 in / min). The load at 200% is F200 PS Report as inches (N / in) c. Pre-strain unloading: At a constant crosshead speed of 508 mm / min, return the crosshead to the original gauge length of 25.4 mm. d. Open the bottom grips and hold the specimen in the unstrained condition for 1 minute. e. Re-grip the sample as above with minimal deflection and minimal load. f. Repeat the preload step and adjust the new gauge length (l ini ) and use it to calculate the % strain for the first and second cycles. g. First cycle loading: Pull the test specimen to 200% strain at a constant crosshead speed of 508 mm / min. The load at 200% is F200 FC Report as inches (N / in) h. First cycle unloading: The specimen is then held at 200% strain for 30 seconds and then the crosshead is returned to its starting position (ie, 0% strain) at a constant crosshead speed of 508 mm / min. i. Second cycle: Hold the sample at 0% strain for 30 seconds and retest the first cycle as described above in steps "e" and "f."

[0121] The computer data system records the load (force) applied to the sample during the test as a function of the applied strain. From the resulting data generated, F200 PS and F200 FC Report.

[0122] The test was repeated on at least three separate samples and the average of each was recorded along with the standard deviation. PS and average F200 FC Report as.

[0123] Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0124] All documents cited herein, including any cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest or disclose such invention, either alone or in combination with any other reference(s). Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0125] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. An absorbent article (100), a chassis (120) comprising a topsheet (124), a backsheet (126), and an absorbent core (128) disposed between the topsheet and the backsheet; A lug (130) joined to the chassis, A laminate (10) comprising a first nonwoven (12) and a second nonwoven (16) and an elastomeric material (14) sandwiched between the first nonwoven and the second nonwoven, the laminate further comprising a plurality of ultrasonic bonds (31) joining the nonwoven layers via the elastomeric material, wherein: the elastomeric material has a maximum dimension Y in a direction of extension; the elastomeric material defines a primary region (18) including an elastic region (32) and one or more inextensible zones (34); the elastic region has a maximum dimension X in the direction of stretch, and the one or more inextensible zones have an aggregate lateral width of Wd; The ratio of Wd to Y is 0.3 or less; and an ear portion (130), The stretch direction includes a lateral direction of the absorbent article, Wd is 13 mm or less, The ratio of Wd to X is 0.55 or less, The laminate has an angular maximum peak force of at least 40N.

2. 2. The absorbent article of claim 1, wherein Wd is 6.5 mm or less.

3. The one or more non-stretch zones include a first inextensible zone (34a) disposed laterally inward of said elastic region and having a width Wd1; The absorbent article according to claim 1 or 2, further comprising a second non-stretchable zone (34b) disposed laterally outward of said elastic region and having a lateral width Wd2, said Wd1 being different from Wd2.

4. The absorbent article of claim 3 , wherein Wd2 is greater than Wd1.

5. 5. The absorbent article of claim 4, wherein the ratio of Wd2 to Wd1 is at least 2.

6. The absorbent article according to any one of claims 1 to 5, wherein the laminate further comprises a reinforcing portion (50) disposed between the elastomeric material and the first nonwoven fabric or the second nonwoven fabric.

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

8. A method for assembling a laminate of absorbent articles according to any one of claims 1 to 7, comprising the steps of: providing a first substrate (202) and a second substrate (210), each of the first substrate (204, 212) and the second substrate (210) having an opposing first surface (204, 212) and an opposing second surface (206, 214) and defining a width in a transverse direction; wrapping the first surface of the first substrate onto a peripheral surface (404) of an anvil (402); advancing a resilient material (208) into a spreader mechanism (412), said spreader mechanism including an engagement portion (419); stretching the elastic material in the transverse direction to a first elongation (E1) in the spreader mechanism; advancing the resilient material from the spreader mechanism to the anvil, the anvil comprising an active vacuum zone (415) having a maximum width Wv in the transverse direction, the maximum width being divided into a first portion (452) and a second portion (454), the first portion being in overlapping relationship with and disposed inside the engagement portion in the transverse direction, the first portion having a width VZi in the transverse direction and the second portion having a width VZo in the transverse direction, VZi being greater than VZo; positioning the elastic material in contact with the second surface of the first substrate on the anvil; advancing the second substrate to position the first surface of the second substrate in contact with the elastic material and position the second surface of the first substrate on the anvil; and ultrasonically bonding the first substrate to the second substrate with the elastic material positioned between the first substrate and the second substrate.

9. The method of claim 8 , wherein the engagement portion comprises one or more radially protruding nubs (428).

10. 10. The method of claim 8 or 9, wherein the anvil comprises a plurality of apertures (414) in fluid communication with a vacuum source in the working vacuum zone.

11. 11. The method according to any one of claims 8 to 10, wherein the ratio of VZi to VZo is greater than 5.

12. 12. The method of any one of claims 8 to 11, wherein the anvil comprises a configurable tube (460) in fluid communication with an outer surface of the anvil via a radially extending connector (466), the method further comprising using the configurable tube to provide the operating vacuum zone.

13. 13. The method according to any one of claims 8 to 12, wherein the anvil has a maximum width Wa in the transverse direction, and wherein the maximum width Wv of the active vacuum zone is not more than 20% of the maximum width Wa of the anvil.

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