Disposable absorbent article

Abstract

An absorbent article is described having a primary topsheet, a backsheet, and an absorbent system therebetween. The primary topsheet has a body-facing surface and a garment-facing surface, and the backsheet has a body-facing surface and a garment-facing surface. The absorbent system includes a first absorbent core having a body-facing surface and a garment-facing surface, and a second absorbent core disposed between the first absorbent core and the backsheet. At least a portion of the primary topsheet and the first absorbent core have one or more embossed channels, including a central channel disposed on the body-facing surface of the primary topsheet. Each of the one or more embossed channels has a bottom surface that is below the body-facing surface of the primary topsheet and above the garment-facing surface of the first absorbent core.

Description

Technical Field

[0001] The present invention relates to a disposable absorbent article suitable for absorbing and containing body exudates.

Background Art

[0002] Various disposable absorbent articles are trusted by consumers to handle or manage body exudates. The users of these absorbent articles can be wide-ranging and can include infants, toddlers, children, teenagers, adults, and the elderly. Thus, the types of fluids or body exudates managed by such articles can likewise vary and can include urine, feces, menstrual blood, and other discharges. Typically, in the case of adults, the articles take the form of sanitary napkins, adult incontinence pads, and adult incontinence diapers or underwear. One of the main factors driving the desirability of these products for the wearer is to give the confidence that when experiencing an event of incontinence or other fluid invasion, its occurrence will not be noticed by others, and more ideally, also by the wearer.

[0003] One way to improve the performance and overall freedom of disposable absorbent articles widely utilized by manufacturers has been the inclusion of superabsorbent polymers that can inhale an increased amount of liquid and as a result form a swollen hydrogel material. The resulting hydrogel serves to hold fluids such as the discharged body fluids within the structure.

[0004] A further way to improve performance is by including embossed channels. The embossed channels can create additional surface area for the liquid invaders to impinge upon. In addition, the embossed channels can function as liquid transport paths that allow the fluid to move quickly to other areas of the absorbent article. However, some materials are not very suitable for embossing. As an example, superabsorbent polymers can, when embossed, have the potential to tear the constituent materials. This can be undesirable from the perspective of quality assurance as well as from the perspective of the consumer.

SUMMARY OF THE INVENTION

PROBLEMS TO BE SOLVED BY THE INVENTION

[0005] As a result, there is a need for an absorbent article that provides a good liquid absorption function and reduces the possibility of tearing of the constituent materials, and includes one or more embossed channels.

MEANS FOR SOLVING THE PROBLEMS

[0006] The disposable absorbent article according to the present invention is suitable for providing leakage protection to a user who experiences relatively small fluid discharges to relatively large fluid discharges. In one example, the absorbent article of the present disclosure includes a primary topsheet having a body-facing surface and a garment-facing surface, a backsheet having a body-facing surface and a garment-facing surface, and an absorption system disposed between the primary topsheet and the backsheet. The absorption system includes a first absorbent core having a body-facing surface and a garment-facing surface, and a second absorbent core disposed between the first absorbent core and the backsheet. The first absorbent core includes a first distribution layer and a first superabsorbent layer, and the first superabsorbent layer forms a part of the garment-facing surface of the first absorbent core. The primary topsheet and the first absorbent core include one or more embossed channels including a central channel disposed on the body-facing surface of the primary topsheet. Each of the one or more embossed channels has a bottom surface that is below the body-facing surface of the primary topsheet and above the garment-facing surface of the first absorbent core.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] This specification concludes with claims that specifically point out and distinctly claim the subject matter regarded as constituting the invention. However, the invention is considered to be further understood from the following description taken in conjunction with the accompanying drawings, in which reference numerals are used to indicate substantially identical elements.

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DETAILED DESCRIPTION OF THE INVENTION

[0008] The disposable absorbent article of the present invention, particularly an incontinence pad or pants, can provide flexibility that allows for an improved comfortable fit, while reducing the likelihood of tearing and / or providing a rough surface from the embossed channels provided in the absorbent article. In particular, the articles of the present invention are expected to exhibit enhanced structural elasticity from the proposed configuration and the orientation of the layers included therein. For the purposes of the present disclosure, reference is made to incontinence pads, disposable absorbent articles or absorbent articles. However, the present invention can be applied to a plurality of absorbent articles including, but not limited to, sanitary napkins, pantiliners, menstrual pads, diapers, training pants, adult incontinence pants, and the like.

[0009] As used herein, the term "garment-facing surface" is used to refer to the surface of the absorbent article of the present disclosure. Specifically, the "garment-facing surface" of the absorbent article is the surface that is closest to the outer garment of the wearer during use. In addition, the term "garment-facing surface" refers to the surface of one or more layers in the absorbent article of the present disclosure, and the "garment-facing surface" of that layer or layers is proximal to the garment-facing surface of the absorbent article relative to the surface on the opposite side thereof.

[0010] As used herein, the term "wearer-facing surface" is used to refer to the surface of the absorbent article of the present disclosure. Specifically, the "wearer-facing surface" of the article is the surface that is closest to the wearer during use. In addition, the term "wearer-facing surface" refers to the surface of one or more layers in the absorbent article of the present disclosure, and the "wearer-facing surface" of that layer or layers is proximal to the wearer-facing surface of the absorbent article relative to the surface on the opposite side thereof.

[0011] As used herein, the term "machine direction" (MD) is used to refer to the direction of the flow of the material passing through the process. In addition, the relative placement and movement of the material can be described as flowing in the machine direction from upstream to downstream of the process through a process.

[0012] As used herein, the term "cross direction" (CD) is used to refer to a direction that is substantially perpendicular to the machine direction.

[0013] The absorbent article of the present disclosure includes a longitudinal axis and a transverse axis that is perpendicular to the longitudinal axis. The absorbent article further includes a primary topsheet having a wearer-facing surface and an opposite garment-facing surface, a backsheet having a wearer-facing surface and an opposite garment-facing surface, and an absorbent system disposed between the topsheet and the backsheet. The absorbent system includes a first absorbent core and a second absorbent core.

[0014] The first absorbent core may have a laminated structure having a wearer-facing surface and an opposite clothing-facing surface. The first absorbent core may comprise a first distribution layer and a first superabsorbent layer. In some forms, an optional layer may be provided between the topsheet and the first absorbent core. The first distribution layer may be disposed closer to the topsheet than the first superabsorbent layer.

[0015] The second absorbent core is joined to the clothing-facing surface of the first absorbent core. Additionally, the second absorbent core may be configured similarly to the first absorbent core. For example, the second absorbent core may comprise a second distribution layer and a second superabsorbent layer. Thus, the second distribution layer may be attached to the clothing-facing surface of the first absorbent core, or alternatively, the second superabsorbent layer may be attached to the clothing-facing surface of the first absorbent core. Alternatively, an additional substrate, such as a film, nonwoven fabric, woven fabric, etc., or combinations thereof, may be provided between the clothing-facing surface of the first absorbent core and the second absorbent core.

[0016] As described above, the absorbent article of the present disclosure includes one or more embossed channels. However, the inventors have surprisingly found that embossing of an absorbent core containing a superabsorbent polymer can cause problems. It is worth noting that the superabsorbent polymer particles contain rough edges. Thus, during the embossing process, when a portion of the layers of the absorbent article is compressed, these rough edges can form pinholes in adjacent layers, such as the topsheet, and / or can form a rough surface. From the wearer's perspective, the formation of pinholes in the topsheet, as well as a rough-feeling / rough-appearance surface, are not desirable.

[0017] As an effort to reduce or eliminate the formation of pinholes / rough feel / rough appearance on the surface of an adjacent layer, such as the topsheet, the inventors have found that this problem can be alleviated by providing a superabsorbent polymer-containing layer more distally from the topsheet. For example, when the topsheet and the first absorbent core are embossed, a secondary topsheet may be provided between the topsheet and the first absorbent core. As another example, when the first absorbent core includes a first distribution layer and a first superabsorbent layer, the first distribution layer may be disposed more proximally to the topsheet than the first superabsorbent layer. Further in this example, the first distribution layer may be disposed between the secondary topsheet and the first superabsorbent layer.

[0018] In such an example where the topsheet and the first absorbent core are embossed, the wearer-facing surface of the absorbent article includes recessed channels. The recessed channels can have a bottom surface that is below the remaining portion of the wearer-facing surface of the absorbent article. The bottom surface may be on top of the garment-facing surface of the first absorbent core. These one or more embossed channels can provide a preferred bending axis for the pad to provide a better fit and reduce the likelihood of leakage. In addition, since these embossed channels are areas of higher material density, they can serve as a path to distribute liquid invaders to areas of the absorption system that would otherwise have to rely on the distribution layer to carry moisture from the area of initial liquid invasion to areas more distal therefrom.

[0019] When the first absorbent core includes a first superabsorbent layer and a first distribution layer, both layers may be embossed. However, to further reduce the possibility that the rough edges of the superabsorbent polymer form pinholes and / or the possibility of forming a wearer-facing surface of the article with a rough feel / rough appearance, only a portion of the first absorbent core may be embossed. For example, the first superabsorbent layer may not undergo this embossing process, but the first distribution layer may be embossed together with the topsheet. In such a configuration, the embossed channels can have a bottom surface that is on the wearer-facing surface of the first superabsorbent layer.

[0020] In addition to the embossed channels on the wearer-facing surface, the first absorbent core and the topsheet may include one or more second embossed channels on the clothing-facing surface of the first absorbent core. For example, one or more of the second embossed channels may extend from the clothing-facing surface of the first absorbent core towards the topsheet. The bottom surface (or top surface) of one or more of the second embossed channels may be below the wearer-facing surface of the topsheet.

[0021] It is worth noting that in addition to the first absorbent core being embossed as described herein, the second absorbent core may also be embossed. However, care should be taken when selecting such a configuration. The embossing process can create the desired bending axis and beneficial fluid pathways while also reducing the amount of void volume within the absorbent system. This loss of void volume can mean a reduction in the capacity of the absorbent article. Particularly in the context of adult incontinence articles, embossing the second absorbent core to the same extent as the first absorbent core can be problematic without considering the loss of void volume due to the embossing process. Accordingly, the configuration of the absorbent article of the present disclosure is contemplated to not include embossed channels in the second absorbent core or at least not include embossed channels to the same extent as the first absorbent core.

[0022] For example, the second absorbent core may have an embossed area more than that of the first absorbent core. As another example, the second absorbent core may include embossing that does not have the same depth as the embossing present in the first absorbent core.

[0023] In addition, a configuration is contemplated in which the second absorbent core can be embossed while the first absorbent core is not embossed. Such a configuration can provide many of the same advantages as the embossing of the first absorbent core with respect to the second absorbent core. However, since the second absorbent core is disposed between the backsheet and the first absorbent core, the second absorbent core is the final storage layer for liquid invaders. Therefore, the void volume of the second absorbent core can affect the final absorption capacity of the entire absorbent article. Further, the embossing of the second absorbent core may not be visible to the user of the absorbent article. Therefore, since the embossing is not visible, the additional function of the embossing may not be easily perceived by the user.

[0024] As described above, the second absorbent core may be configured similarly to the first absorbent core, and may have, for example, a second distribution layer and a second superabsorbent layer. The absorbent system may be configured such that the second distribution layer is joined to the clothing-facing surface of the first absorbent core while the second superabsorbent layer is joined to the backsheet or is disposed at least more proximally with respect to the backsheet than the second distribution layer. Alternatively, the second distribution layer may be joined to the backsheet or positioned more proximally with respect to the backsheet than the second superabsorbent layer, while the second superabsorbent layer may be joined to the clothing-facing surface of the first absorbent core.

[0025] Although not bound by theory, when the superabsorbent layer is adjacent to or disposed more proximally to the backsheet, the risk of pinhole formation in the backsheet is thought to increase. It is to be recalled that superabsorbent polymer particles have rough edges in the dry state. These rough edges can cause pinholes in the backsheet, especially when the backsheet film is relatively thin. The formation of pinholes can increase the likelihood of leakage. Also, even if these rough edges do not form pinholes in the backsheet, these rough edges can roughen the feel of the backsheet and create a very bumpy appearance. This can be uncomfortable for the wearer of the absorbent article. Thus, when a thinner backsheet is desired, it may be beneficial to configure the second absorbent core such that a second superabsorbent layer is joined to the garment-facing surface of the first absorbent core. In such a configuration, a second distribution layer is disposed between the backsheet and the second superabsorbent layer, whereby the possibility of pinholes being formed in the backsheet via the superabsorbent polymer can be reduced. Alternatively, or in combination with the above, the rough feel of the backsheet may be overcome by providing a nonwoven material on the garment-facing surface of the backsheet. This outer nonwoven can reduce the rough feel and / or appearance of the backsheet.

[0026] It is noted that an optional fluid handling layer may be provided between the primary topsheet and the first absorbent core. As an example, a secondary topsheet known in the art may be mentioned. Suitable examples of the secondary topsheet are described in more detail below.

[0027] The first absorbent core and the second absorbent core may be joined to each other in an offset manner. For example, the first absorbent core may be disposed to form the front end portion of the absorption system, and the second absorbent core may be disposed to form the rear end portion of the absorption system. A central portion is formed where the first absorbent core and the second absorbent core overlap. Additionally, the first absorbent core and the second absorbent core may have the same machine direction length. Alternatively, the first absorbent core and the second absorbent core may have different machine direction lengths.

[0028] In addition to, or independently of, the first absorbent core and the second absorbent core being joined in an offset manner, they can have various widths parallel to the transverse axis of the absorbent article. For example, the first absorbent core and the second absorbent core may have equal widths to each other. Alternatively, the first absorbent core and the second absorbent core may have different transverse widths. For example, the first absorbent core may have a transverse width that is smaller than the width of the second absorbent core. The first absorbent core may have a transverse width that is less than about 95 percent, more preferably less than about 90 percent, or most preferably less than about 85 percent of the transverse width of the second absorbent core, specifically including all values within these ranges and any ranges generated thereby. As a further example, the first absorbent core may have a transverse width that is about 50 percent to about 95 percent, more preferably about 50 percent to about 90 percent, or most preferably about 50 percent to about 85 percent of the width of the second absorbent core, specifically including all values within these ranges or any ranges generated thereby.

[0029] When the first absorbent core has a smaller width than the second absorbent core, improved fit can be achieved. For example, when the longitudinal side edges of the first absorbent core are disposed inside the longitudinal side edges of the second absorbent core, the absorbent article can preferentially bend in the region laterally outside the longitudinal side edges of the first absorbent core. This preferential bending can increase the comfort of the absorbent article while also improving the resistance of the absorbent article to leakage.

[0030] Here, the absorbent article of the present disclosure will be further described with reference to the figures described herein. FIG. 1 shows the absorbent article of the present disclosure, and more specifically, shows that the incontinence pad or sanitary napkin 10 (hereinafter mainly referred to as "incontinence pad") can include a longitudinal axis 80 and a transverse axis 90. The longitudinal axis 80 extends generally parallel to the longest dimension of the incontinence pad 10. The transverse axis 90 extends generally perpendicular to the longitudinal axis 80 and lies in the same plane as the incontinence pad 10 in a flat and expanded state on a plane. The transverse axis 90 bisects the length of the incontinence pad 10 when the length of the incontinence pad 10 is parallel to the longitudinal axis 80, and the longitudinal axis 80 bisects the width of the incontinence pad 10 when the width of the incontinence pad 10 is parallel to the transverse axis 90. Further, as shown, the MD direction can be generally parallel to the longitudinal axis 80 of the incontinence pad 10, and the CD direction can be generally parallel to the transverse axis 90.

[0031] The incontinence pad 10 is generally in the shape of an elongated ellipse. However, any suitable shape may be used. Some examples include an hourglass (peanut), an offset hourglass (one end is wider than the other end, and the middle part between both ends is narrow), and the like. The incontinence pad 10 may be symmetric about the longitudinal axis 80 or may be asymmetric about the longitudinal axis 80. Similarly, the incontinence pad 10 may be symmetric about the transverse axis 90 or may be asymmetric about the transverse axis 90.

[0032] The incontinence pad 10 may further include a chassis 20 including a plurality of side edges 22 and 24 extending generally parallel to the longitudinal axis 80. A pair of end edges 26 and 28 join each of the side edges 22 and 24. One end edge 26 joins the side edges 22 and 24 in the first end region 40 of the incontinence pad 10, and the other end edge 28 joins the side edges 22 and 24 in the second end region 48 of the incontinence pad 10, and the second end region 48 is opposite the first end region 40. An intermediate region 44 is disposed between the first end region 40 and the second end region 48.

[0033] The chassis 20 of FIG. 1 is shown in the cross-sectional view of FIG. 2. Among other things, the chassis 20 includes a primary topsheet 203. This primary topsheet has a wearer-facing surface 203A and a clothing-facing surface 203B. This chassis 20 of the pad 10 further includes a backsheet 207, which also includes its own wearer-facing surface 207A and the opposite clothing-facing surface 207B. These two components sandwich the absorbent system 205. In other words, the absorbent system 205 is disposed between the topsheet 203 and the backsheet 207. All three components (i.e., the topsheet 203, the backsheet 207, and the absorbent system 205) form the chassis 20 of the pad 10. Additional layers can be very well included within this chassis 20, particularly between the topsheet 203 and the backsheet 207, but it should be noted that these layers are separated and spaced from the absorbent system. Suitable additional layers can include a secondary topsheet, a capture layer, the entire layer to be described later and additional distribution layers thereon, as well as other useful layers. In the case of the secondary topsheet, it is disposed under the primary topsheet 203 and on the body-facing surface of the system. In certain embodiments, the secondary topsheet (also known as the "secondary topsheet, STS") has a length and width greater than that of the absorbent system 205.

[0034] The chassis 20 further includes a wearer-facing surface 20A and a clothing-facing surface 20B. The wearer-facing surface 20A may include the topsheet 203, and the clothing-facing surface 20B may include the backsheet.

[0035] Absorbent system 205 is formed from a plurality of layers and is oriented to quickly capture body fluid or exudate and distribute it along the length of the system. FIG. 3 shows the absorbent system of the present invention. A plan view of pad 10 is shown with primary top sheet 203 removed to show absorbent system 205 positioned on backsheet 207. FIG. 4 shows a cross-section of this absorbent system 205 in more detail. Absorbent system 205 may include a first absorbent core 60 that may include a first superabsorbent layer 61 disposed on a first distribution layer 62. The first absorbent core 60 has a wearer-facing surface 60A and a garment-facing surface 60B that faces the upper surface. In addition, the first absorbent core 60 has a first end 66 and a second end 67 that faces the first end 66.

[0036] Absorbent system 205 may further include a second absorbent core 70 that may include a second superabsorbent layer 71 and a second distribution layer 72. This second absorbent core 70 also has a wearer-facing surface 70A and a garment-facing surface 70B, a first end 76, and a second end 77 that similarly faces the first end 76. In the embodiments of FIGS. 3 and 4, the first distribution layer 62 is joined to the second distribution layer 72 in an offset manner or configuration along the length of the system. In such a configuration, as described above, since the first superabsorbent layer 61 is closer to the primary top sheet than the first distribution layer 62, care should be taken when subjecting the first absorbent core to an embossing process.

[0037] In another configuration, the second absorbent core 70 may be joined to the first superabsorbent layer 61 instead of the first distribution layer. In such a case, the laminate may be joined to each other in an offset manner as well, except that the first superabsorbent layer 61 may be joined to either the second superabsorbent layer 71 or the second distribution layer 72.

[0038] As used herein, "offset" or "offset configuration" means that the layer or laminate of interest is twisted and, when the layers or laminates overlap one another, their respective first or second ends are not aligned in the z - direction (i.e., the first end of one layer or absorbent core is not adjacent to the second end of an adjacent layer or laminate above or below). This offset joining configuration of the first distribution layer 62 and the second distribution layer 72 provides a joining region where two absorbent cores overlap, forming the central portion 205C of the absorption system 205. The central portion 205C of the system is, as a result, coupled on each side by both the front end portion and the rear end portion 205R of the system. In other words, the front end portion 205F and the rear end portion 205R are disposed at opposite ends of the system 205, respectively. The front end portion 205F is formed from the first end 66 or the second end 67 of the first absorbent core 60, and the rear end portion 205F of the system 205 is formed by the first end 76 or the second end 77 of the second absorbent core 70. In the embodiment of FIG. 3, the first ends 66, 76 of the first and second absorbent cores face each other and form the front end portion 205F and the rear end portion 205R of the absorption system 205, respectively. In an alternative embodiment, the second ends 67, 77 of the first and second absorbent cores may face each other and form the front end portion 205F and the rear end portion 205R of the absorption system 205, respectively. In both cases, the first ends 66, 76 form a male - type connection derived from the nested cut of the first and second absorbent cores. Similarly, the second ends 67, 77 form a female - type connection derived from the nested cut of each of the first and second absorbent cores.

[0039] In one embodiment, the overlapping region or zone forming the central portion 205C of the system 205 may have at least one of the characteristics of higher capacity, greater void volume, or greater thickness than the front end portion 205F and the rear end portion 205F of the absorption system 205. This embodiment is particularly useful for providing enhanced leakage protection in the central portion where female users of such pads typically contact the pad and discharge fluids.

[0040] Article length In addition to the basic portions described herein, the absorbent articles of the present disclosure may exhibit a range of article lengths to accommodate a variety of user body sizes and situations, such as for daytime versus nighttime use. For example, a small pad may have a length of from about 250 mm to about 329 mm in accordance with the article length method. In certain embodiments, the article length is greater than 250 mm, 255 mm, 260 mm, and 265 mm and less than 329 mm, 325 mm, 315 mm, 305 mm, 295 mm, 285 mm, and 275 mm. A medium-sized pad may have a pad length of from about 330 mm to about 370 mm in accordance with the article length method. In certain embodiments, the article length is greater than 330 mm, 335 mm, 340 mm, and 345 mm and less than 370 mm, 365 mm, 360 mm, 355 mm, and 350 mm. In one embodiment, the length of the article is about 348 mm. Also, a large pad may exhibit an article length of from about 371 mm to about 500 mm in accordance with the article length method. In certain embodiments, the article length is greater than 371 mm, 380 mm, 390 mm, and 395 mm and less than 500 mm, 490 mm, 480 mm, 470 mm, 460 mm, 450 mm, 440 mm, 430 mm, 420 mm, and 410 mm. In one embodiment, the article length is about 400 mm. The length of the disposable absorbent article is important for a variety of reasons.

[0041] First, the article should be of sufficient length to cover the intended strike area that the article may experience during use. This means that, given that the product is worn during the day and access to toilet facilities is easier, a shorter pad may be sufficient as long as it is expected that the fluid removed during the time the article is worn is relatively minimal. Additionally, during the day, a shorter pad may also be more suitable when the wearer's body is in a sitting or standing position and the strike area is at approximately a right angle to the fluid exclusion area, i.e., the genitals. Due to reasons such as poor access to toilet facilities, reduced motor function, or increased uncontrollability of urination events due to weakened bladder control, the wearer's need for absorbency increases. Therefore, it is considered desirable to increase the pad length to allow for the incorporation of more absorbent material and an increase in the coverage area where the discharged fluid can be retained. Additionally, disposable absorbent articles worn at night or while the wearer is in bed tend to have the longest pad lengths. This is typically the case when the wearer cannot react quickly enough to access toilet facilities in a timely manner at bedtime or when getting into bed. Furthermore, when liquid is discharged while the wearer is in bed, due to the gravitational pull on the fluid, the discharged fluid typically creeps along the length of the pad towards the buttocks area when the wearer is lying on their back or towards the groin area when the wearer is lying face down, along the surface of the genital area. It should be noted that the article length can typically be considered to correspond to a pad-type product, but it is assumed herein that such a pad can be very well integrated into a pants product that can be worn instead of underwear.

[0042] Embossed pattern As described above, some of the layers of the absorbent article of the present disclosure may be embossed together. Any suitable embossing pattern may be utilized. As an example, a suitable embossing pattern may include substantially arcuate channels. These substantially arcuate channels may have open or closed ends. Within these channels, each region of the highly compressed regions may alternate with the less compressed regions. The central channel may substantially surround the central region of the article to ensure an appropriate width between adjacent channels within the region of expected fluid invasion.

[0043] Additional channels may be provided by a larger pad. For example, some absorbent articles may include a front side region channel and / or a back side region channel. The front side region channel and / or the back side region channel may include arcuate channels very similar to the central channel. To smooth the appearance of the central channel, the front side region channel and / or the back side region channel may have a radius of curvature larger than that of the adjacent ends of the central channel. Thereby, a more rounded appearance may be provided to the overall embossing pattern. Some suitable embossing patterns for use with the absorbent article of the present disclosure are described in more detail in U.S. Patent Application Publication Nos. 2007 / 0005036, 2005 / 0124951, and 2006 / 0116653.

[0044] As described above, the embossed channels can provide many fluid acquisition / distribution benefits, but the embossed channels can also provide a visual cue to the user. Specifically, the central channel can at least partially encompass the area of the intended fluid inlet of the pad. Thus, the channels of the present disclosure can increase in length with an increase in pad length. For example, at smaller sizes (e.g., lengths of about 330 mm or less), the central channel may have a length of 53 percent or less of the total length of the pad, more preferably about 50 percent or less, or most preferably about 47 percent or less of the total length, specifically including all values within these ranges and any ranges generated thereby. For example, the central channel may include a length of about 25 percent to about 53 percent of the total length of the pad, more preferably about 30 to about 50 percent of the total length, or most preferably about 35 percent to about 47 percent of the total length, specifically including all values within these ranges and any ranges generated thereby.

[0045] For larger sizes greater than about 330 mm, the length of the entire embossed pattern, i.e., the central channel, the front region channel, and the rear region channel, may have a length of 80 percent or less of the total length of the pad, more preferably about 75 percent or less, or most preferably about 70 percent or less of the total length, specifically including all values within these ranges and any ranges generated thereby. For example, the embossed pattern of the present disclosure may have a total length of about 30 percent to about 80 percent, about 40 percent to about 75 percent, or most preferably about 50 percent to about 70 percent of the total length of the pad, specifically including all values within these ranges and any ranges generated thereby.

[0046] Figures 6 to 8 show an absorbent article including exemplary embossing patterns. Referring particularly to FIG. 6, an absorbent article 600 having a central channel is shown. The central channel may include a first portion 655 and a second portion 665. The first portion 655 and the second portion 665 may be mirror images of each other, i.e., may be symmetric with respect to the longitudinal axis of the absorbent article 600. However, as described above, when only the first absorbent core is embossed and the first absorbent core and the second absorbent core are offset from each other, the first portion 655 and the second portion 665 may not be symmetric with respect to the transverse axis of the absorbent article 600. For example, as shown in the figure, the central channel may be offset such that a greater proportion of the embossing pattern is proximal to the leading edge (``LE'') side rather than the trailing edge (``TE'') side.

[0047] The first portion 655 and the second portion 665 are disposed between the opposing leg cuffs 620 and 630. In addition, the folds 675 and 685 may be arranged such that the first portion 655 and the second portion 665 overlap the fold 675 but do not overlap the second fold 685.

[0048] As shown in FIG. 7, the absorbent article 700 includes a central channel having a first portion 755 and a second portion 765. In addition, the absorbent article 700 may include a front region channel 705 and a rear region channel 715. As shown in the figure, the radius of curvature of both the front region channel 705 and the rear region channel 715 is greater than the radius of curvature of the ends of the central channel. In this particular example, the first portion 755 and the second portion 765 are not joined at their respective ends. However, the projected radius of the first portion 755 and the second portion 765 joined at their ends is smaller than the radius of the front region channel 705 and the rear region channel 715. Such a configuration can provide an overall rounder appearance to the embossing pattern on the absorbent article 700.

[0049] Similar to the absorbent article of FIG. 6, each of the central channel, the front region channel 705, and the rear region channel 715 is disposed between the opposing leg cuffs 720 and 730. Additionally, the folds 775 and 785 may be configured to overlap the central channel. As noted above, it is worth noting that the embossed channels can generate preferred bending axes. Therefore, if a fold is placed too close to a laterally extending embossed channel, it is considered possible that the folding of the article may not be as desired. For example, if the fold is too close to a laterally extending embossed channel, the folding of the article may become slightly unclear in this region and may not occur at the fold. Therefore, it is considered that the fold should be at least 5 mm away from the laterally extending portion of the embossed channel. For example, the distance 790 between the apex of the rear region channel 715 and the fold 785 should be at least 5 mm. The same is considered to apply to the distance between the apex of the front region channel 705 and the fold 775.

[0050] As shown in FIG. 8, the absorbent article 800 includes a central channel having a first portion 855 and a second portion 865. Additionally, the absorbent article 800 may include a front region channel 805 and a rear region channel 815. As shown, the radius of curvature of both the front region channel 805 and the rear region channel 815 is greater than the radius of curvature of the ends of the central channel. Such a configuration can provide a generally rounder appearance to the embossed pattern on the absorbent article 700.

[0051] In this particular example, the first portion 855 and the second portion 865 are joined at their respective ends. Therefore, unlike the first and second portions of FIGS. 6 and 7, the first and second portions 855 and 865 are not separate channels. Rather, each of the first portion 855 and the second portion 865 is joined at its ends.

[0052] In addition, each of the central channel, the front region channel 805, and the rear region channel 815 is disposed between the opposing leg cuffs 820 and 830. Similar to FIG. 7, the creases 875 and 885 may be configured to overlap the central channel. Similar to FIG. 7, when the ends of the first portion 855 and the second portion 865 are joined, a portion extending in the lateral direction of the channel is considered to be formed. Further, the distance 890 between the apexes of the first portion 855 and the second portion 865 and the crease 885 is considered to be at least 5 mm.

[0053] To maintain a "clean" crease that folds in the desired area, the distance between the crease and the lateral portion of the embossing channel or embossing element can be at least 5 mm. However, to accommodate variability in manufacturing tolerances, the distance can be at least 5 mm, more preferably at least 7 mm, or most preferably at least 9 mm, and specifically includes all values within these ranges and any ranges generated thereby.

[0054] Dry pad thickness In combination with the above-described characteristics, the article of the present invention also exhibits a dry pad thickness of about 4.4 mm to about 9.5 mm in accordance with the pad thickness method. As described above in connection with the desired capture time, it is important for the consumer that the consumer can wear the disposable absorbent product of the present invention with confidence in the absorption performance of the product. Almost as important to the consumer as absorbency is the concept that the article is unobtrusive. This means that the consumer wants to wear the article without being reminded regularly by the consumer himself that he is wearing the article because he needs to wear it without being noticed by others. From this perspective, it is desirable for the article to be as thin as possible. Accordingly, the article of the present invention exhibits a dry pad thickness that exceeds about 5 mm, 5.5 mm, or 6 mm and is less than about 9 mm, 8.5 mm, 8 mm, 7.5 mm, 7 mm, or 6.5 mm.

[0055] Primary topsheet The primary topsheet 203 of the chassis 20 (also referred to herein as the "topsheet") is positioned adjacent to the body-facing surface 203A of the absorbent system 205 and may be joined thereto and to the backsheet 207 by an attachment method (not shown) such as those well known in the art. A preferred attachment method will be described with respect to joining the backsheet 207 to the absorbent system 205. The topsheet 203 and the backsheet 207 may be joined directly to each other at the periphery of the incontinence pad, or they may be joined indirectly together by directly joining them to the absorbent system 205, or to an additional optional layer within the chassis such as a secondary topsheet that extends over the entire or a partial region of the article. This indirect or direct joining can be achieved by attachment methods well known in the art.

[0056] The absorbent article may include any known or other effective primary topsheet that conforms to the wearer's skin, has a soft feel, and is non-irritating. Suitable primary topsheet materials include liquid-permeable materials that are oriented towards the wearer's body, contact the body, and allow body excreta to rapidly penetrate therethrough without the fluid flowing back through the topsheet to the wearer's skin. The primary topsheet enables rapid movement of fluid through the topsheet while allowing a lotion composition to move or migrate onto the outer or inner portion of the wearer's skin. Suitable topsheets can be made of various materials such as woven and non-woven materials; perforated film materials including perforated thermoplastic films, perforated plastic films, and cross-linked fiber perforated films; hydroformed thermoplastic films; porous foams; reticulated foams, reticulated thermoplastic films; thermoplastic scrims; or combinations thereof.

[0057] Suitable perforated film materials for use as the topsheet include perforated plastic films that are non-absorbent and permeable to body excreta and minimize or eliminate backflow of fluid through the topsheet. Non-limiting examples of other suitable formed films, including perforated and non-perforated formed films, are more fully described in U.S. Patent No. 3,929,135, issued to Thompson on December 30, 1975; U.S. Patent No. 4,324,246, issued to Mullane et al. on April 13, 1982; U.S. Patent No. 4,342,314, issued to Radel et al. on August 3, 1982; U.S. Patent No. 4,463,045, issued to Ahr et al. on July 31, 1984; U.S. Patent No. 5,006,394, issued to Baird on April 9, 1991; U.S. Patent No. 4,609,518, issued to Curro et al. on September 2, 1986; and U.S. Patent No. 4,629,643, issued to Curro et al. on December 16, 1986. Commercially available formed film topsheets include topsheet materials sold under the trade name DRI-WEAVE (registered trademark) by the Procter & Gamble Company (Cincinnati, Ohio).

[0058] Non-limiting examples of woven and non-woven materials suitable for use as the topsheet include fibrous materials made from natural fibers, modified natural fibers, synthetic fibers, or combinations thereof. These fibrous materials may be hydrophilic or hydrophobic, but the topsheet is preferably hydrophobic or becomes hydrophobic. Optionally, a portion of the topsheet can be made hydrophilic using any known method for making a topsheet containing a hydrophilic component. One such method involves treating the porous film component of the topsheet of a non-woven material / porous thermoplastic forming film with a surfactant, as described in U.S. Patent No. 4,950,264, issued to Osborn on August 21, 1990. Other suitable methods for describing processes for treating the topsheet with a surfactant are both disclosed in U.S. Patent Nos. 4,988,344 and 4,988,345, issued to Reising et al. on January 29, 1991. The topsheet may have hydrophilic fibers, hydrophobic fibers, or a combination thereof.

[0059] Certain preferred topsheets include staple length polypropylene fibers having a denier of about 1.5, such as Hercules Type 151 polypropylene commercially available from Hercules, Inc. (Wilmington, Del). As used herein, the term "staple length fiber" refers to fibers having a length of at least about 15.9 mm (0.62 inches).

[0060] When the primary topsheet includes a nonwoven fibrous material in the form of a nonwoven web, the nonwoven web may be manufactured by any known procedure for making nonwoven webs, non-limiting examples of which include spunbonding, carding, wet laying, air laying, meltblowing, needle punching, mechanical entanglement, thermo-mechanical entanglement, and hydroentanglement. A specific example of a suitable meltblowing process is disclosed in U.S. Patent No. 3,978,185 to Buntin et al., issued August 31, 1976. The nonwoven material can be compression resistant, as described in U.S. Patent No. 7,785,690, entitled "Compression Resistant Nonwovens," issued August 31, 2010. The nonwoven web can have loops, as described in U.S. Patent No. 7,838,099, entitled "Looped Nonwoven Web," issued November 23, 2010.

[0061] Other suitable nonwoven materials include low basis weight nonwovens, i.e., nonwovens having a basis weight of from about 18 g / m 2 ~ about 25 g / m 2 are included. An example of such a nonwoven material is commercially available under the trade name P-8 from Veratec, Incorporated, a division of International Paper Company, located in Walpole, Massachusetts. Other nonwoven materials are described in U.S. Patent No. 5,792,404 and U.S. Patent No. 5,665,452.

[0062] The topsheet may include tufts as described in U.S. Patent No. 8,728,049, entitled "Absorbent Article Having a Tufted Topsheet," issued on May 20, 2014; U.S. Patent No. 7,553,532, entitled "Tufted Fibrous Web," issued on June 30, 2009; U.S. Patent No. 7,172,801, entitled "Tufted Laminate Web," issued on February 6, 2007; or U.S. Patent No. 8,440,286, entitled "Capped Tufted Laminate Web," issued on May 14, 2013. The primary topsheet may have an inverse-textured web as described in U.S. Patent No. 7,648,752, entitled "Inverse Textured Web," issued on January 19, 2010. The tufts are also described in U.S. Patent No. 7,410,683, entitled "Tufted Laminate Web," issued on August 12, 2008.

[0063] The primary topsheet may have a distinct pattern of hair-like fibrils as described in U.S. Patent No. 7,655,176, entitled "Method of Making a Polymeric Web Exhibiting A Soft and Silky Tactile Impression," issued on February 2, 2010; or U.S. Patent No. 7,402,723, entitled "Polymeric Web Exhibiting A Soft And Silky Tactile Impression," issued on July 22, 2008.

[0064] The primary topsheet may include one or more structurally modified zones, as described in U.S. Patent No. 8,614,365, entitled "Absorbent Article," issued on December 24, 2013. The primary topsheet may have one or more of the planar deformations, as described in U.S. Patent No. 8,704,036, entitled "Sanitary Napkin for Clean Body Benefit," issued on April 22, 2014. The primary topsheet may have a masking composition, as described in U.S. Patent No. 6,025,535, entitled "Topsheet For Absorbent Articles Exhibiting Improved Masking Properties," issued on February 15, 2000.

[0065] The primary topsheet, in combination with another suitable primary topsheet or secondary topsheet, may be formed from a three-dimensional substrate, as detailed in U.S. Provisional Patent Application No. 62 / 306,676, entitled "A Three-Dimensional Substrate Comprising a Tissue Layer," filed on March 11, 2016 in the name of Jill M. Orr. This three-dimensional substrate has a first surface, a second surface, a land region, and includes three-dimensional protrusions extending outwardly from the second surface of the three-dimensional substrate, which are surrounded by the land region. The substrate is a laminate including at least two layers in a facing relationship, and the second layer is a tissue layer facing outwardly from the second surface of the three-dimensional substrate, and the tissue layer includes at least 80% by weight of pulp fibers of the tissue layer.

[0066] The primary topsheet can have and include one or more layers, such as a spunbond-meltblown-spunbond material. The primary topsheet can be perforated, can have any suitable three-dimensional features, and / or can have a plurality of embossments (e.g., a bond pattern). The topsheet can be made perforated by overbonding the material and then breaking the overbond by ring rolling, as disclosed in U.S. Patent No. 5,628,097, issued to Benson et al. on May 13, 1997. Additional lateral extensibility in the chassis 20 (i.e., the primary topsheet and / or the backsheet) can be provided in various ways. For example, either the primary topsheet or the backsheet can be pleated by any of a number of known methods. Alternatively, all or a portion of the chassis (i.e., the primary topsheet and / or the backsheet similarly) can be made from a formed web material or a formed laminate of web materials, such as those described in U.S. Patent No. 5,518,801, issued to Chappell et al. on May 21, 1996. Such formed web materials include discrete laterally extending regions where the original material is altered by embossing or another deformation method to form a pattern of alternating ridges and valleys generally oriented in the longitudinal direction. The formed web materials also include laterally extending non-altered regions located between the laterally extending altered regions.

[0067] Secondary topsheet As described above, the disposable absorbent article of the present disclosure can include additional layers, one of which includes a secondary topsheet. As described above, the secondary topsheet can be separated from and spaced apart from the absorbent system. Further, the secondary topsheet is disposed under the primary topsheet 203 and on the body-facing surface of the system. In some forms, the secondary topsheet can have a basis weight of from about 40 gsm to about 100 gsm, from about 45 gsm to about 75 gsm, or from about 50 gsm to about 60 gsm, specifically including all values within these ranges or any range generated thereby. In some forms, the secondary topsheet can include a homogeneous blend of fibers.

[0068] Exemplary secondary topsheets are described in more detail in U.S. Patent Nos. 10,532,123 and 10,307,309, U.S. Patent Application Publication Nos. 2019 / 0247244, 2018 / 0098893, and 2020 / 0306099.

[0069] Backsheet The backsheet 207 of the chassis 20 may be positioned adjacent to the garment-facing surface of the absorption system 205 and may be joined thereto by an attachment method (not shown) such as those well known in the art. For example, the backsheet 207 may be secured to the absorption system 205 by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an arrangement of discrete lines, spirals, or dots of adhesive. Alternatively, the attachment method may include the use of heat adhesion, pressure adhesion, ultrasonic adhesion, dynamic mechanical adhesion, or any other suitable attachment method known in the art or combinations of these attachment methods. Embodiments of the present disclosure are also contemplated in which the absorption system 205 is not joined to the backsheet 207, the topsheet 203, or both.

[0070] The backsheet 207 may be impermeable or substantially impermeable to liquids (e.g., urine) and may be made of a thin plastic film, but other flexible liquid-impermeable materials can also be used. As used herein, the term "flexible" refers to a material that is compliant and easily conforms to the general shape and contours of the human body. The backsheet 207 can prevent or at least inhibit the exudate absorbed and contained in the absorption system 205 from wetting the clothing that contacts the incontinence pad 10, such as underwear. However, in some cases, the backsheet 207 may allow vapor to escape from the absorption system 205 (i.e., be breathable), and in other cases, the backsheet 207 may not allow vapor to escape (i.e., be non-breathable). Thus, the backsheet 205 may include a polymeric film such as a thermoplastic film of polyethylene or polypropylene. Suitable materials for the backsheet 207 are, for example, thermoplastic films having a thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mil). Any suitable backsheet known in the art can be utilized with the present invention.

[0071] The backsheet 207 acts as a barrier to any absorbed body fluid that can pass through the absorption system 205 to the surface of the clothing, thereby reducing the risk of soiling underwear or other clothing. Further, the barrier property of the backsheet allows the wearer, if desired, to remove the interlabial absorbent article by hand, reducing the risk of soiling the hands. Preferred materials are soft, smooth, flexible, liquid and vapor-permeable materials that provide softness and conformability for comfort and are low-noise so as not to produce undesirable sounds upon movement.

[0072] The backsheet can include a wet-laid fibrous web incorporating a primary wet strength resin, as described in U.S. Patent No. 5,885,265 (Osborn, III.) issued on March 23, 1999. The backsheet may be further coated with a water-resistant resinous material that renders the backsheet water-impermeable to body fluids without preventing the adhesive material from spreading thereon.

[0073] Another suitable backsheet material is a polyethylene film having a thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mil). The backsheet may be embossed and / or matte-finished to provide a more cloth-like appearance. Further, while preventing body fluids from passing through the backsheet, the backsheet may allow vapor to escape from the absorbent system (i.e., the backsheet is breathable). A preferred microporous polyethylene film is available from Tredegar Corporation of Virginia, USA, under the code number XBF-1 12W.

[0074] In the case of a stretchable but inelastic backsheet, one material that may be used is a hydrophobic, stretchable spunlace nonwoven material having a basis weight of about 30 - 40 g / m2 formed from polyethylene terephthalate or polypropylene fibers. This material is breathable, i.e., permeable to water vapor and other gases.

[0075] In the case of an elastic backsheet, one material that may be used is an elastic film sold under the trade name EXX500 by Exxon Corporation. The material of this film is formed from an elastomeric base composition comprising a styrene block copolymer. However, this material is not breathable. Another material that may be used for the elastic backsheet is a plastic film that has been processed to provide elastic-like properties without attaching elastic strands to the film, and includes, for example, formed films made in accordance with U.S. Patent Nos. 4,342,314 (Radel et al.) and 4,463,045 (Ahr et al.).

[0076] The breathable backsheets suitable for use herein include all breathable backsheets well-known in the art. In principle, there are two types of breathable backsheets, a single-layer breathable backsheet that is breathable and water-repellent, and a backsheet having at least two layers that, when combined, provide both breathability and water-repellency. Examples of single-layer breathable backsheets suitable for use herein include those described in British Patent No. A2184389, British Patent No. A2184390, British Patent No. A2184391, U.S. Patent No. 4,591,523, U.S. Patent No. 3,989,867, U.S. Patent No. 3,156,242, and International Publication No. 97 / 24097.

[0077] The backsheet may have two layers, namely a first layer including a gas-permeable pore-forming film layer and a second layer including a breathable pore-forming film layer, as described in U.S. Patent No. 6,462,251 (Cimini) issued on October 8, 2002. Examples of two-layer or multi-layer breathable backsheets suitable for use herein include those exemplified in U.S. Patent No. 3,881,489, U.S. Patent No. 4,341,216, U.S. Patent No. 4,713,068, U.S. Patent No. 4,818,600, European Patent No. 203,821, European Patent No. 710,471, European Patent No. 710,472, and European Patent No. 793,952.

[0078] The backsheet may be a relatively hydrophobic 18 grams per square meter (gsm) spunbond nonwoven web of 2-denier polypropylene fibers. The backsheet may also be a laminate as known in the art.

[0079] The backsheet can be vapor permeable as described in U.S. Patent No. 6,623,464 (Bewick - Sonntag) issued on September 23, 2003, or U.S. Patent No. 6,664,439 (Arndt) issued on December 16, 2003. The backsheet can be formed from any vapor - permeable material known in the art. The backsheet can be a microporous film, a pore - forming film, or other polymer films that are vapor - permeable or made vapor - permeable as known in the art.

[0080] The backsheet can be a non - woven web having a basis weight of about 20 gsm to about 50 gsm. In one embodiment, the backsheet is a relatively hydrophobic 23 gsm spunbond non - woven web of 4 - denier polypropylene fibers available from Fiberweb Neuberger under the name F102301001. The backsheet can be coated with a water - insoluble liquid - swellable material as described in U.S. Patent No. 6,436,508 (Ciammaichella) issued on August 20, 2002.

[0081] The backsheet has a clothing - facing side and an opposite body - facing side. The clothing - facing side of the backsheet includes a non - adhesive region and an adhesive region. The adhesive region can be provided by any conventional means. Pressure - sensitive adhesives have generally been found to function well for this purpose.

[0082] Absorbent system The absorbent system 205 of the present invention can include any suitable shape including, but not limited to, oval, discorectangle, rectangle, asymmetric shape, and hourglass shape. For example, in some forms of the present invention, the absorbent system 205 can include a contoured shape, such as a shape where the middle region is narrower than the end regions. As yet another example, the absorbent system can include a tapered shape having a wider portion at one end region of the pad and tapering towards a narrower end region at the other end region of the pad. The absorbent system 205 can include various stiffnesses in the MD and CD.

[0083] As detailed above, the absorption system 205 can include a first absorbent core and a second absorbent core. Both are generally compressible, conformable, do not irritate the wearer's skin, and are capable of absorbing and retaining liquids such as urine and other certain body excretions including menstrual blood.

[0084] The configuration and structure of the absorption system 205 can vary (e.g., the absorption system 205 can have varying caliper zones, hydrophilic gradients, superabsorbent gradients, or capture zones of lower average density and lower average basis weight). Further, it is also possible to vary the dimensions and absorption capacity of the absorption system 205 to adapt to various wearers. However, the total absorption capacity of the absorption system 205 should be suitable for the design load and intended use of the disposable absorbent article or incontinence pad 10.

[0085] In some forms of the present invention, the absorption system 205 can include, in addition to the first and second absorbent cores, a plurality of multifunctional layers. For example, the absorption system 205 can include a core wrap (not shown) useful for surrounding the first and / or second absorbent cores and any other optional layers. The core wrap can be formed of two nonwoven materials, substrates, laminates, films, or other materials. In one aspect, the core wrap can include only a single material, substrate, laminate, or other material at least partially wrapped therearound.

[0086] The absorption system 205 of the present disclosure can include one or more adhesives, for example, to help immobilize SAP or other absorbent materials within the first and second absorbent cores.

[0087] Absorbent cores containing a relatively high amount of SAP with various core designs are disclosed in U.S. Patent No. 5,599,335 to Goldman et al., European Patent No. 1,447,066 to Busam et al., International Publication No. 95 / 11652 to Tanzer et al., U.S. Patent Application Publication No. 2008 / 0312622 (A1) to Hundorf et al., and International Publication No. 2012 / 052172 to Van Malderen. These can be used to form a superabsorbent layer.

[0088] Additions to the disclosed system are envisioned. Specifically, expected additions to current multi-layer absorbent systems are described in U.S. Patent No. 4,610,678, titled "High-Density Absorbent Structures," issued to Weisman et al. on September 9, 1986; U.S. Patent No. 4,673,402, titled "Absorbent Articles With Dual-Layered Cores," issued to Weisman et al. on June 16, 1987; U.S. Patent No. 4,888,231, titled "Absorbent Core Having A Dusting Layer," issued to Angstadt on December 19, 1989; and U.S. Patent No. 4,834,735, titled "High Density Absorbent Members Having Lower Density and Lower Basis Weight Acquisition Zones," issued to Alemany et al. on May 30, 1989. The absorbent system may further comprise additional layers that mimic a dual-core system housing a capture / distribution core of chemically stiffened fibers positioned over an absorbent storage core, as detailed in U.S. Patent No. 5,234,423, titled "Absorbent Article With Elastic Waist Feature and Enhanced Absorbency," and U.S. Patent No. 5,147,345, both issued to Alemany et al. on August 10, 1993. These are useful as long as they do not negate or compete with the effects of the absorbent cores described below of the present invention.

[0089] The first absorbent core and the second absorbent core The first and / or second absorbent cores may have the same or different cross - sectional widths from each other. For example, the first absorbent core may have a cross - sectional width smaller than that of the second absorbent core or a cross - sectional width larger than that of the second absorbent core. In certain examples, the first absorbent core and the second absorbent core may have the same machine - direction length, but in other examples, the first absorbent core and the second absorbent core have different machine - direction lengths. In the latter examples, the first absorbent core may have a machine - direction length smaller than that of the second absorbent core, or conversely, the first absorbent core may have a machine - direction length larger than that of the second absorbent core.

[0090] The first and second absorbent cores 60, 70 may further include an optional intermediate layer disposed between their respective superabsorbent layers and distribution layers. This optional intermediate layer can generally include materials detailed herein for optional layers of the chassis.

[0091] Furthermore, the absorbent article or incontinence pad of the present invention may further include an optional laminate including a superabsorbent layer and a distribution layer. This optional laminate may take the form of a third, fourth, fifth or further additional laminate. The superabsorbent layer and the distribution layer may exhibit the same or different properties as those previously detailed for the first and second superabsorbent layers and distribution layers. This optional laminate can be disposed on the body - facing surface of the first laminate or the second laminate, or on the garment - facing surface of the first laminate or the second laminate.

[0092] Each of the first and second absorbent cores has a first end portion 66, 76 that is shape-complementary to its respective second end portion 67, 77. More specifically, the first end portion 66 of the first absorbent core is shaped to fit into the second end portion 67 of the same absorbent core. The same fit also applies to the first end portion 76 of the second absorbent core with respect to the second end portion 77 of the second absorbent core. For example, the first end portion 66 of the first absorbent core fits into the second end portion 67 of the first absorbent core. This fit results from a nested cut in the absorbent core that provides a mating or shape-fitting end. This also applies to each of the first end portion 76 and the second end portion 77 of the second absorbent core. Similarly, this feature can also be common in any optional layer that can be incorporated into the absorption system. This nested or nested cutting mechanism of the absorbent core can reduce waste in trimming during manufacturing.

[0093] It has also been found that the first and second absorbent cores can be configured in such a way that their respective first end portions face each other when the first and second distribution layers are overlapped and joined to form an absorption system having a central portion 205C including an overlap region. The front end portion of the system 205F is formed from the first end portion 66, 76 of either the first absorbent core or the second absorbent core. The rear end portion of the system 205R is similarly formed from the other first end portion 66, 76 of the first absorbent core or the second absorbent core. This configuration results in absorbent cores having mating (i.e., male-type connections) ends. The first end portion of each absorbent core has a male-type connection, while the second end portion of each absorbent core has a female-type connection. In such a case, the male-type connection of the first end portion fits (is shape-compatible) into the female-type connection of the second end portion of the same absorbent core. In another embodiment, the front end portion of the system is formed from the first end portion 66, 76 of either the first absorbent core or the second absorbent core, while the rear end portion of the system is formed from the other second end portion 67, 77 of the first absorbent core or the second absorbent core. In this case, since the second end portion is formed as a female-type connection, it does not match the front end portion of the same system.

[0094] In the third embodiment, the front end portion of the system is formed from the second end of either the first absorbent core or the second absorbent core. Similarly, the rear end portion of the system is formed from the second end of the remaining first absorbent core or second absorbent core. This configuration results in an absorbent system having mating (i.e., female connection) ends. However, it should be noted that the width of the first absorbent core and the width of the second absorbent core may be the same or different as described herein. The nested cuts at the first and second ends of each of the first and second absorbent cores have a shape selected from the group consisting of an arc, a semi-circle, a semi-ellipse, a sawtooth, a rectangle, a sine wave, a jigsaw, and combinations thereof.

[0095] In one embodiment, in addition to the topsheet and the backsheet, the system may include a first laminate having a first end that is shaped complementary to the respective second end, the absorbent core including a first superabsorbent layer disposed on the first distribution layer and a second absorbent core having a first end that is shaped complementary to the respective second end, the laminate including a second distribution layer joined to the second superabsorbent layer, the first absorbent core being joined to the second absorbent core in an offset manner along the length of the absorbent article, and the absorbent system having a front end portion formed by the first end of the second absorbent core.

[0096] Regarding the method for manufacturing the absorbent core of the present invention, it has been found that it is preferable to form the first absorbent core and the second absorbent core from a web of material slit along its machine direction length. When the first absorbent core and the second absorbent core include a laminated structure, this method is useful when the first superabsorbent layer and the second superabsorbent layer are the same and the first distribution layer and the second distribution layer are the same. This identity may be for one or more of shape, basis weight, and material. Identity of the material of the distribution layer is preferred. When a single laminate is slit to form a first laminate and a second laminate, these first and second laminates are joined. In certain embodiments, the first and second laminates are joined in an offset manner with respect to each other by their respective distribution layers, as detailed herein, and may be joined via standard mechanical, thermal, or chemical methods known to those skilled in the art.

[0097] In certain embodiments, the first absorbent core or the second absorbent core can include one or more recessed regions extending along the machine direction or the cross direction. These recessed regions can coincide with one or more discontinuous patterns of the superabsorbent layer and the distribution layer (whether of the first absorbent core, the second absorbent core, or both). These recessed regions can also be formed only by embossing the first absorbent core or the second absorbent core. These recessed regions can alternatively be formed by forming slits through the first absorbent core and / or the second absorbent core, forming incisions, ring rolling the absorbent core, or otherwise causing mechanical deformation to the absorbent core. Each method of forming the recessed regions described herein is intended to result in recessed regions that can provide preferential flexure points of the overall article. For example, FIG. 5 shows an alternative cross-sectional view at 2-2 of the alternative system 205’, where the recessed region 88 is either a gap or an embossed channel in the first and second laminates 60’, 70’ of the absorbent system 205’ in the machine direction. These recessed regions 88 need not be present in both the first and second laminates 60’, 70’ along the entirety of their lengths. The recessed region 88 can be present in the machine direction only at the overlap joint of the first and second absorbent cores 60’, 70’. Alternatively, the recessed region 88 can be present in the cross direction along the lengths of the first and second absorbent cores 60’, 70’ or only at the overlap joint of the two cores. In such examples, the absorbent core with the recessed region formed is more easily bendable. In an example where the recessed region 88 is present in only one of the first and second absorbent cores, it is expected that the pad 20 will have a preferential tendency to bend at the recessed region 88. This means that when the first absorbent core is closer to the body than the second absorbent core, the pad may bend away from the body. The opposite can also be true in the event that the second absorbent core 70’ disposed away from the body includes the recessed region and the first absorbent core 60’ does not. In this example, the pad 20 can exhibit a preferential tendency to bend towards the body.Depending on the overall configuration of the pad, in certain examples, some type of flexion may be suitable.

[0098] Superabsorbent layer When the first and second absorbent cores each include first and second superabsorbent layers 61, 71, the first and / or second superabsorbent layer may include a superabsorbent polymer or an absorbent gelling material (AGM). The superabsorbent layer can include AGM particles or AGM fibers. Generally, those AGMs are only used for their fluid absorbency. Such materials form a hydrogel upon contact with a fluid (e.g., urine, blood, etc.). Another highly preferred type of hydrogel-forming, absorbent gelling material is based on hydrolyzed polyacids, particularly neutralized polyacrylic acid. This type of hydrogel-forming polymer material absorbs a fluid (i.e., a liquid) such as water or body fluid upon contact therewith, thereby forming a hydrogel. In this way, the fluid discharged into the fluid absorbent structure herein can be captured and retained. These preferred superabsorbent polymers generally include substantially water-insoluble, slightly cross-linked, partially neutralized hydrogel-forming polymer materials prepared from polymerizable, unsaturated acid-containing monomers. In such materials, the polymer component formed from the unsaturated acid-containing monomer may include an overall gelling agent or may be grafted to other types of polymer moieties such as starch or cellulose. Hydrolyzed polyacrylic acid grafted starch materials are of this latter type. Thus, preferred superabsorbent polymers include hydrolyzed polyacrylonitrile grafted starch, hydrolyzed polyacrylate grafted starch, polyacrylates, maleic anhydride isobutylene copolymers, and combinations thereof. Particularly preferred superabsorbent polymers are hydrolyzed polyacrylates and hydrolyzed polyacrylate grafted starch.

[0099] Regardless of the nature of the polymer components of the preferred superabsorbent polymers, such materials are generally lightly crosslinked. Crosslinking serves to render these preferred hydrogel-forming absorbent materials substantially water-insoluble, and crosslinking also partially determines the gel volume and the extractable polymer properties characteristic of the hydrogels formed therefrom. Suitable crosslinking agents are well known in the art and include, for example, (1) compounds having at least two polymerizable double bonds, (2) compounds having at least one polymerizable double bond and at least one functional group reactive with an acid-containing monomer material, (3) compounds having at least two functional groups reactive with an acid-containing monomer material, and (4) polyvalent metal compounds capable of forming ionic crosslinks. Preferred crosslinking agents are diesters or polyesters of unsaturated monocarboxylic or polycarboxylic acids and polyols, bisacrylamide, and diallylamine or triallylamine. Other preferred crosslinking agents are N,N'-methylenebisacrylamide, trimethylolpropane triacrylate, and triallylamine. Crosslinking agents generally comprise from about 0.001 percent to about 5 percent by mole of the preferred materials. More preferably, the crosslinking agent comprises from about 0.01 percent to about 3 percent by mole of the absorbent gelling material used herein.

[0100] The preferred lightly crosslinked hydrogel-forming absorbent gelling materials are generally used in a partially neutralized form. For the purposes described in the present invention, such materials are considered to be partially neutralized when at least about 25 percent, 50 percent, or even 75 percent of the monomers used to form the polymer are acid group-containing monomers neutralized with a salt-forming cation. Suitable salt-forming cations include alkali metals, ammonium, substituted ammonium, and amines. The proportion of the total monomers used for the monomers containing neutralized acid groups is called the "degree of neutralization". Typically, commercially available superabsorbent polymers have a degree of neutralization of somewhat less than about 90%.

[0101] The preferred superabsorbent polymers used herein are those having a relatively high capacity to absorb fluids encountered in fluid absorbent articles. This capacity can be quantified by reference to the "gel volume" of the superabsorbent polymer. Gel volume can be defined in terms of the amount of synthetic urine absorbed by any given fluid absorbent gelling agent buffer and is defined as grams of synthetic urine per gram of gelling agent.

[0102] The gel volume in synthetic urine can be determined by forming a suspension of about 0.1 - 0.2 parts of dry fluid absorbent gelling material tested with about 20 parts of synthetic urine. This suspension is maintained at room temperature under gentle stirring for about 1 hour, thereby achieving a swelling equilibrium. The gel volume (grams of synthetic urine per gram of fluid absorbent gelling material) is then calculated from the weight fraction of the gelling agent in the suspension and the ratio of the liquid volume excluded from the formed hydrogel to the total volume of the suspension. Preferred superabsorbent polymers useful in the present invention will have a gel volume of synthetic urine of about 20 - 70 grams, more preferably about 30 - 60 grams, per gram of absorbent gelling material.

[0103] The absorbent polymers described above are typically used in the form of discrete particles. Such superabsorbent polymers can be of any desired shape, for example, spherical or hemispherical, cubic, rod-like polyhedra, etc. Shapes having a ratio of maximum dimension / minimum dimension, such as needles and flakes, are also contemplated for use herein. Aggregates of fluid absorbent gelling material particles may also be used.

[0104] The size of the fluid absorbent gelling material particles can vary over a wide range. For industrial hygiene reasons, an average particle size smaller than about 30 micrometers is not desirable. Particles having a minimum dimension greater than about 2 mm can also cause a rough feeling in the absorbent article, which is not desirable from the consumer's aesthetic point of view. Further, the rate of fluid absorption can be affected by the particle size. Larger particles have a very reduced absorption rate. The fluid absorbent gelling material particles preferably have a particle size of about 30 micrometers to about 2 mm for substantially all particles. As used herein, "particle size" means the weighted average of the minimum dimension of the individual particles.

[0105] These superabsorbent layers preferably do not substantially contain airfelt, and thus are different from the mixed layers that may contain airfelt. As used herein, "not substantially containing airfelt" means less than 5%, 3%, 1%, or even less than 0.5% airfelt. Preferably, there is no measurable airfelt in the superabsorbent layer. In the case of the first superabsorbent layer, it is preferably disposed discontinuously on the first distribution layer. As used herein, "discontinuously" or "in a discontinuous pattern" means that the superabsorbent polymer is applied to the first distribution layer in a pattern of regions of cut shapes. These regions of the superabsorbent polymer or regions not containing the superabsorbent polymer can include, but are not limited to, linear strips, non-linear strips, circles, rectangles, triangles, waves, meshes, and combinations thereof. However, the first superabsorbent layer, such as the second superabsorbent layer, may be disposed in a continuous pattern on each respective distribution layer. As used herein, "continuous pattern" or "continuously" means that the material is disposed and / or fixed without interruption to the superabsorbent carrier material and / or the adjacent distribution layer, whereby rather the entire distribution layer is covered by the superabsorbent polymer.

[0106] In certain embodiments, the first and second superabsorbent layers can comprise the same superabsorbent polymer. In other embodiments, the first superabsorbent layer and the second superabsorbent layer can comprise different superabsorbent polymers from each other. This may be in addition to the different deposition patterns described above.

[0107] A superabsorbent layer having a thickness of 0.2 mm, 0.3 mm, 0.4 mm, or 0.5 mm to 1 mm, 1.2 mm, 1.4 mm, 1.8 mm, or 2 mm is disposed. The first superabsorbent layer and the second superabsorbent layer can have the same or different transverse widths when applied to their respective distribution layers. For example, the transverse widths of the first superabsorbent layer and the second superabsorbent layer can be 20 mm, 25 mm, 30 mm, 35 mm, or 40 mm to 50 mm, 60 mm, 65 mm, 70 mm, 80 mm, or 90 mm. Alternatively, in embodiments where the widths of the first superabsorbent layer and the second superabsorbent layer are different from each other in the transverse width, the first superabsorbent layer can have a transverse width smaller than that of the second superabsorbent layer. In particular, the first superabsorbent layer can have a transverse width of less than about 95%, 90%, 80%, 70%, or even less than 60% of the width of the second superabsorbent layer.

[0108] In certain embodiments, one or both of the first superabsorbent layer and the second superabsorbent layer extend over about 50%, 60%, 70%, 80%, 90%, or even more than 95% of the transverse width of the superabsorbent carrier layer and / or the respective adjacent first distribution layer or second distribution layer.

[0109] Like the optional layers that can be included in the chassis, the absorbent system can also include similar optional layers. They can be webs selected from the group consisting of fibrous structures, airlaid webs, wet webs, high-loft nonwovens, needle-punched webs, hydroentangled webs, fiber tows, woven webs, knit webs, flocked webs, spunbond webs, layered spunbond / meltblown webs, carded fiber webs, coform webs of cellulose fibers and meltblown fibers, coform webs of staple fibers and meltblown fibers, and layered combinations of these, i.e., layered webs.

[0110] These optional layers of the system and the chassis may include materials such as creped cellulose wadding, fluffed cellulose fibers, air felts, and textile fibers. The materials of the optional layers may also be, for example, synthetic fibers, thermoplastic microparticles or fibers, three-component fibers, and, for example, combinations of the following polymers: sheath / core fibers having polyethylene / polypropylene, polyethyl vinyl acetate / polypropylene, polyethylene / polyester, polypropylene / polyester, copolyester / polyester, etc., and other two-component fibers. The optional layer can be any combination of the above materials and / or the above plurality of materials (alone or in combination).

[0111] The materials of the optional layers may be hydrophobic or hydrophilic depending on their arrangement within the chassis.

[0112] The materials of the optional layers can include constituent fibers containing polymers such as polyethylene, polypropylene, polyester, and blends thereof. The fibers may be spunbond fibers. The fibers may be meltblown fibers. The fibers may include cellulose, rayon, cotton, or other natural materials, or blends of polymers and natural materials. The fibers may also include superabsorbent materials such as polyacrylate or any combination of suitable materials. The fibers may be single-component, two-component, and / or two-constituent, non-circular (e.g., capillary channel fibers), and may have a major cross-sectional dimension (e.g., the diameter of circular fibers) in the range of 0.1 to 500 micrometers. The constituent fibers of the nonwoven precursor web can also be a mixture of different fiber types that differ in terms of characteristics such as chemistry (e.g., polyethylene and polypropylene), (single and two) components, denier (microdenier and over 20 denier), shape (i.e., capillary and circular), etc. The constituent fibers may be in the range of about 0.1 denier to about 100 denier.

[0113] Optional layers may contain thermoplastic particles or fibers. The materials, specifically the thermoplastic fibers, can be made from various thermoplastic polymers including polyolefins such as polyethylene (e.g., PULPEX (trademark)) and polypropylene, polyesters, copolyesters, and copolymers of any of the foregoing.

[0114] Depending on the desired properties, suitable thermoplastic materials include, for example, hydrophilized hydrophobic fibers such as thermoplastic fibers treated with surfactants or thermoplastic fibers treated with silica, derived from polyolefins such as polyethylene or polypropylene, polyacrylic acid, polyamide, polystyrene, etc. The surface of the hydrophobic thermoplastic fibers can be made hydrophilic by treating with surfactants such as non-ionic surfactants or anionic surfactants, for example, by spraying the surfactant onto the fibers, immersing the fibers in the surfactant, or including the surfactant as part of the polymer melt when manufacturing the thermoplastic fibers. When melted and re-solidified, the surfactant tends to remain on the surface of the thermoplastic fibers. Suitable surfactants include non-ionic surfactants such as Brij76 manufactured by ICI Americas, Inc. (Wilmington, Del), and various surfactants sold under the Pegosperse (trademark) by Glyco Chemical, Inc. (Greenwich, Conn). In addition to non-ionic surfactants, anionic surfactants can also be used. These surfactants may be applied to the thermoplastic fibers at a concentration of about 0.2 to about 1 g / cm 2 per square centimeter of the thermoplastic fibers.

[0115] Suitable thermoplastic fibers may be made from a single polymer (single-component fibers) or from two or more polymers (e.g., two-component fibers). The polymer containing the sheath is typically different from the polymer forming the core and often melts at a lower temperature. As a result, these two-component fibers provide thermal bonding due to the melting of the sheath polymer while retaining the desirable strength properties of the core polymer.

[0116] Suitable two-component fibers for use in the present invention include sheath / core fibers having the following polymer combinations: polyethylene / polypropylene, polyethyl vinyl acetate / polypropylene, polyethylene / polyester, polypropylene / polyester, copolyester / polyester, and the like. Particularly suitable two-component thermoplastic fibers for use herein are those having a core of polypropylene or polyester and a sheath of copolyester, polyethyl vinyl acetate, or polyethylene that melts at a lower temperature (e.g., DANAKLON™, CELBOND™, or CHISSO™ two-component fibers). These two-component fibers may be concentric or eccentric. As used herein, the terms "concentric" and "eccentric" refer to whether the sheath has a uniform or non-uniform thickness throughout the cross-sectional area of the two-component fiber. Eccentric two-component fibers may be desirable in providing higher compression strength with a thinner fiber thickness. Suitable two-component fibers for use herein may be either non-crimped (i.e., non-buckled) or crimped (i.e., buckled). The two-component fibers may be crimped by typical textile means, such as the stuffer-box method or the gear crimper method, to achieve mainly two-dimensional, i.e., "planar," crimping.

[0117] The length of the bicomponent fibers can vary depending on the specific properties desired for the fiber and web forming processes. Typically, in airlaid webs, these thermoplastic fibers have lengths such as from about 2 mm to about 12 mm, for example from about 2.5 mm to about 7.5 mm, and from about 3.0 mm to about 6.0 mm. The nonwoven fibers can be from 5 mm to 75 mm in length, for example 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, or 70 mm in length. The properties of these thermoplastic fibers can also be adjusted by varying the fiber diameter (caliper). The diameter of these thermoplastic fibers is typically defined in terms of denier (grams per 9000 meters) or decitex (grams per 10,000 meters). When used in airlaid manufacturing machines, suitable bicomponent thermoplastic fibers can have decitex in the range of about 1.0 to about 20 decitex, such as about 1.4 to about 10 decitex, and about 1.7 to about 7 decitex.

[0118] The compression modulus of elasticity of these thermoplastic materials, particularly of the thermoplastic fibers, can also be important. The compression modulus of elasticity of the thermoplastic fibers is affected by factors such as not only their length and diameter, but also the composition and properties of the polymer or polymers from which they are made, the shape and configuration of the fibers (e.g., whether concentric or eccentric, whether crimped or uncrimped). The differences in the compression modulus of elasticity of these thermoplastic fibers can be used to vary the properties, particularly the density properties of the corresponding thermally bonded fibrous matrix.

[0119] Optional layers may also include synthetic fibers that typically do not function as binder fibers but change the mechanical properties of the fiber web. Synthetic fibers include cellulose acetate, polyvinyl fluoride, polyvinylidene chloride, acrylics (such as Orlon), polyvinyl acetate, insoluble polyvinyl alcohol, polyethylene, polypropylene, polyamides (such as nylon), polyesters, bicomponent fibers, tricomponent fibers, mixtures thereof, and the like. These include, for example, polyester fibers such as polyethylene terephthalate (such as DACRON™ and KODEL™), high melting point crimped polyester fibers (such as KODEL™ 431 made by Eastman Chemical Co.), hydrophilic nylon (HYDROFIL™), and the like. Suitable fibers may be hydrophilized hydrophobic fibers, such as thermoplastic fibers treated with a surfactant or silica, derived from polyolefins such as polyethylene or polypropylene, polyacrylic acid, polyamide, polystyrene, polyurethane, and the like. In the case of non-bonded thermoplastic fibers, their length can vary depending on the specific properties desired for these fibers. Typically, they have a length of about 0.3 to 7.5 cm, such as about 0.9 to about 1.5 cm. Suitable non-bonded thermoplastic fibers can have a decitex in the range of about 1.5 to about 35 decitex, such as about 14 to about 20 decitex.

[0120] Distribution layer The first distribution layer and the second distribution layer are useful for wicked away body fluids away from the wearer's skin to promote comfort during continued wear after discharge. The distribution layer includes one or more celluloses and comminuted wood pulp. This may be in the form of an airlaid. The airlaid can be joined chemically or thermally. In particular, the airlaid may be a multi-bonded airlaid (MBAL) or a hydrogen-bonded airlaid (HBAL). The distribution layer may further include a fibrous thermoplastic adhesive material that at least partially joins the airlaid to itself and to adjacent distribution layers, superabsorbent layers, or other additional (optional) layers. It should be noted that the same materials suitable for optional layers of the chassis are assumed to be suitable for use in the distribution layer. The weight of each of the first distribution layer and the second distribution layer ranges from 80 gsm, 80 gsm, 100 gsm, 110 gsm, 120 gsm or 130 gsm to 140 gsm, 150 gsm, 160 gsm, 180 gsm, 200 gsm, 220 gsm, or 240 gsm. For each of the distribution layers of the first absorbent core and the second absorbent core, the preferred weight is 135 gsm.

[0121] In addition, in contrast to the superabsorbent layers described heretofore, the distribution layer(s) of the absorbent article of the present disclosure may substantially not contain superabsorbent polymer. As used herein, "substantially not containing superabsorbent polymer" means less than 5%, 3%, 1%, or even less than 0.5% superabsorbent polymer.

[0122] Barrier cuff The incontinence pad 10 may further include a first barrier cuff 230A, a second barrier cuff 230B, and a securing adhesive 211 disposed on the garment-facing surface 20B of the chassis 20. As shown, the securing adhesive 211 may not extend laterally as much as the absorbent system 205. Accordingly, a structure with reduced pad roll is useful.

[0123] The first barrier cuff 230A and the second barrier cuff 230B can be attached to the chassis 20 at any suitable position. For example, as shown, the first barrier cuff 230A and the second barrier cuff 230B may be attached to the wearer-facing surface 20A of the chassis 20. As shown, the first barrier cuff 230A and the second barrier cuff 230B are attached to the top sheet 203. In some forms, the first barrier cuff 230A and the second barrier cuff 230B can be attached to the clothing-facing surface 20B of the chassis 20. For example, the first barrier cuff 230A and the second barrier cuff 230B may be attached to the back sheet 207. Some examples of other suitable barrier cuffs are described in U.S. Patent Nos. 4,695,278, 4,704,115, 4,795,454, 4,909,803, and U.S. Patent Application Publication No. 2009 / 0312730.

[0124] As shown, in some forms, the first barrier cuff 230A includes a first cover 231 and a first elastic member 233. The second barrier cuff 230B includes a second cover 235 and a second elastic member 237. As shown, the first cover 231 may completely surround the first elastic member 233. Similarly, the second cover 235 may completely surround the second elastic member 237.

[0125] The first barrier cuff 230A and the second barrier cuff 230B are shown as separate elements attached to the chassis 20, but any suitable configuration may be utilized. For example, the first cover 231 and / or the second cover 235 may include a portion of the primary top sheet 203 and / or a portion of the back sheet 207. In such forms, the first barrier cuff 230A and / or the second barrier cuff 230B may be integrally formed with the chassis 20. A form in which the first barrier cuff 230A and the second barrier cuff 230B are integrally formed with the chassis 20 is shown in FIG. 2 and will be described later in this specification.

[0126] Referring to FIG. 2, the first elastic member 233 and the second elastic member 237 may be attached to the first cover 231 and the second cover 235 respectively by any suitable means. In one example, the first elastic member may be attached to the first cover 231 by adhesion. Similarly, the second elastic member 237 may be attached to the second cover 235 by adhesion. For example, as shown, the first adhesive portions 251 and 253 may attach the elastic members 233 and 237 to their respective covers 231 and 235. Similarly, the second adhesive portions 255 and 257 may attach their respective covers 231 and 235 to the primary topsheet 203. As will be described later, the first elastic member 233 and the second elastic member 237 can be attached to the first cover 231 and the second cover 235 only in part respectively. Further configurations are contemplated where the first elastic member 233 and / or the second elastic member 237 are attached to the chassis 20 together with or independently of their respective covers 231 and 235.

[0127] Referring to FIG. 2, the elastic members 233 and 237 may be disposed laterally inward of the side edges 205A and 205B of the absorbent system 205. In other configurations, the elastic members 233 and 237 may be disposed laterally outward of the side edges 205A and 205B of the absorbent system 205. In yet other configurations, the elastic members 233 and 237 may be disposed laterally inward of the side edges 205A and 205B of the absorbent system 205 in the first end region 40 and the second end region 48, but may be disposed laterally outward of the side edges 205A and 205B of the absorbent system 205 in the intermediate region 44. Further configurations are contemplated where the elastic members 233 and 237 are disposed laterally inward of the side edges 205A and 205B of the absorbent system 205 in the first end region 40, but are disposed outward of the side edges 205A and 205B of the absorbent system 205 in the intermediate region 44 and / or the second end region 48.

[0128] The elastic member included in the barrier cuff can be adhered using various paste lengths, various pastes, and paste amounts and arrangements. The arrangement of the paste is yet another variable element that should be considered, particularly when designing with the flexibility of the system in mind. The paste adhesion of the elastic member and the cover creates a fixed point on the pad.

[0129] The cover of the barrier cuff of the present invention can be manufactured from various types of non-woven fabrics having different MD and CD flexibilities. The cover can be joined to the topsheet of the absorbent article by, for example, a slot coating of adhesive stripes, paste beads, ultrasonic sealing, or other suitable binders. In certain forms of the present invention, the cover may be joined to the backsheet at the side edges 22 and 24 of the pad, for example, by crimping or using other suitable joining agents such as adhesives (see FIG. 1).

[0130] The elastic member can include any suitable elastic material. Some suitable examples include Spandex (trademark) or other similar polyurethanes, natural or synthetic rubbers, styrene block copolymers, metallocene polyolefins, Lycra (trademark), or any other suitable elastomeric material known in the art. The elastic member preferably has durability during use of the article and exhibits excellent elasticity (recovery after strain) even under a strain as high as 400% to facilitate processing.

[0131] Furthermore, the elastic member of the present disclosure can include any suitable decitex. In other forms, the elastic member can include a decitex of 680 or less. In other forms, the elastic member can have a decitex of 680 to 470, specifically including all numerical values within that range and any range generated thereby.

[0132] The minimum distance between the first barrier cuff 230A and the second barrier cuff 230B can be caused mainly by the anatomical shape of a female. However, a trade-off may occur if the barrier cuffs (and their respective elastic members) are disposed excessively outwardly from the absorption system 205 or excessively inwardly from the absorption system 205. Therefore, the distance between the outermost elastic members of each barrier cuff should be carefully selected. Starting from the narrowest width, the distance between the outermost elastic members of the first barrier cuff 230A and the second barrier cuff 230B should be large enough to allow sufficient access to the absorption system 205 during use, taking into account also the forces that will be applied to the pad. If it is too narrow, access to a portion of the absorption system 205 may be impeded, which may result in leakage even though the barrier cuffs 230A and 230B are present. In some forms of the present invention, the minimum distance between the elastic member of the first barrier cuff 230A that is furthest from the other and the elastic member of the second barrier cuff 230B can be at least 20 mm. Any suitable distance can be utilized. For example, in some forms of the present invention, the distance can be greater than or equal to about 20 mm, greater than about 30 mm, greater than about 33 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, greater than about 54 mm, greater than about 60 mm, greater than about 65 mm, 70 mm or less, or less than about 65 mm, or less than about 60 mm, less than about 55 mm, less than about 50 mm, less than about 45 mm, less than about 40 mm, less than about 35 mm, less than about 30 mm, less than about 25 mm, and specifically includes any value within these ranges or any range generated thereby.

[0133] Fold Yet another factor contributing to fit is the fold or crease of the pad. To make the pad more convenient for the consumer to use and to facilitate transportation and storage, the pad generally includes one or more creases. Further, folding the pad can reduce the potential for elastic creep during storage. However, these creases can act as flexion points where elastic forces can act to deform the pad shape. Also, similar to the fixed points described above, fixed points disposed too far apart from the crease can be problematic. Fixed points disposed too far apart from the crease can increase the torque lever arm acting on the pad in the MD direction, causing pad curling and / or folding back of the pad into a folded state.

[0134] Referring again to FIG. 1, the incontinence pad 10 may further include a first crease 50 and a second crease 55. The first crease 50 may define a boundary between the first end region 40 and the middle region 44. The second crease 55 may define a boundary between the second end region 48 and the middle region 44. The first end region 40 may be defined by the edge 26, the first crease 50, and a portion of the side edges 22 and 24 disposed between the edge 26 and the first crease 50. The middle region 44 may be defined by the first crease 50, the second crease 55, and a portion of the side edges 22 and 24 disposed between the first crease 50 and the second crease 55. The second end region 48 is defined by the second crease 55, the edge 28, and a portion of the side edges 22 and 24 disposed between the edge 28 and the second crease 55. The creases 50 and 55 can be parallel and co-linear (on average) with the creases created by the packaging process of the incontinence pad 10.

[0135] In some forms, the first fold 50 and the second fold 55 may be configured such that the folds 50 and 55 divide the pad into three parts. In other forms, the first fold 50 may be offset towards the edge portion 28, and the second fold 55 may be offset towards the edge portion 28. In such forms, this may enable the second end region 48 to be folded between the intermediate region 44 and the first end region 40 when the pad is in the folded configuration.

[0136] Additional features In some forms of the present invention, a incontinence pad or sanitary napkin may comprise wings. The wings may provide additional leakage protection for the incontinence pad and may also assist in securing the pad to the user's underwear. Any suitable wing configuration known in the art may be used.

[0137] All components may be integrally adhered using an adhesive such as a hot melt adhesive known in the art. The adhesive may be Findlay H2128UN or Savare PM17 and may be applied using the Dynafiber HTW system.

[0138] According to FIG. 2, the pad can be held in place by any suitable support or fixture for such purposes during use. In a particular form of the present invention, the pad is placed within the user's undergarment or panties and is fixed thereto by a fixing adhesive 211. The fixing adhesive 211 fixes the pad within the crotch portion of the user's panties. A part or all of the clothing-facing surface 20B of the chassis 20 is coated with the fixing adhesive 211. Any adhesive or paste suitable for such purposes can be used for the fixing adhesive 211 of this specification, for example, using a pressure-sensitive adhesive. Suitable adhesives include, for example, Century A-305-IV manufactured by Century Adhesives Corporation (Columbus, Ohio), and Instant Lock 34-2823 manufactured by National Starch and Chemical Company (Bridgewater, N.J.). Suitable adhesive fasteners are also described in U.S. Patent No. 4,917,697. Before placing the absorbent article during use, this pressure-sensitive adhesive is covered with a removable release liner to prevent the adhesive from drying before use or from adhering to surfaces other than the crotch portion of the panties. Suitable release liners are also described in U.S. Patent Nos. 4,917,697 and 4,556,146. Any commercially available release liner generally used for such purposes may be used in this specification. Non-limiting examples of suitable release liners are BL30MG-A Silox E1 / 0 and BL30MG-A Silox 4P / O, both manufactured by Akrosil Corporation (Menasha, Wis). The pad can be used by removing the release liner and then placing the absorbent article in the panties so that the adhesive contacts the panties. The adhesive holds the absorbent article in use in a predetermined position within the panties. The release liner may be a wrapping paper that can individually package the pad.

[0139] Again, much of the discussion in this specification relates to incontinence pads and sanitary napkins, but the invention is also envisioned to be useful for disposable diapers, pull-on training pants, adult incontinence diapers and pants, and replaceable pads for incontinence and menstrual fluid collection that are inserted into disposable or durable panties or undergarments and can be removed after use.

Claims

1. An absorbent article (10), having a primary topsheet (203) with a body-facing surface and a garment-facing surface, a backsheet (207) having a body-facing surface and a garment-facing surface, an absorbent system (205) disposed between the primary topsheet and the backsheet, the absorbent system comprising a first absorbent core (60) having a body-facing surface and a garment-facing surface, and a second absorbent core (70) disposed between the first absorbent core and the backsheet, the first absorbent core comprising a first distribution layer (62) and a first superabsorbent layer (61), the first superabsorbent layer forming a portion of the garment-facing surface of the first absorbent core, the primary topsheet and the first absorbent core comprising one or more embossed channels (655, 665; 755, 765; 855, 865) including a central channel (655, 665; 755, 765; 855, 865) disposed on the body-facing surface of the primary topsheet, each of the one or more embossed channels having a bottom surface that is below the body-facing surface of the primary topsheet and above the garment-facing surface of the first absorbent core, an absorbent system (205), the first distribution layer being substantially free of superabsorbent polymer, absorbent article (10).

2. The absorbent article according to claim 1, wherein the topsheet and the first distribution layer comprise the one or more embossed channels such that the bottom surface is above the garment-facing surface of the first distribution layer.

3. The absorbent article according to claim 1 or 2, wherein the topsheet, the first distribution layer, and the first superabsorbent layer comprise the one or more embossed channels.

4. The first absorbent core is joined to the second absorbent core in an offset manner along the length of the absorbent core such that a central portion of the absorbent core is formed from an overlapping joint of the first absorbent core and the second absorbent core. The absorbent article according to claim 1.

5. The front end portion and the rear end portion are respectively disposed at opposite ends of the central portion of the absorption system. The absorbent article according to claim 4.

6. The first absorbent core and the second absorbent core have different widths from each other. The absorbent article according to claim 1.

7. The first superabsorbent layer substantially does not contain an air felt. The absorbent article according to claim 1.

8. The first superabsorbent layer is discontinuously disposed on the first distribution layer. The absorbent article according to claim 1.

9. Each of the first absorbent core and the second absorbent core has a first end portion that is shape-complementary to a respective second end portion of the same absorbent core. The absorbent article according to claim 1.

10. The central channel includes a first portion and a second portion, and the first portion and the second portion are separate from each other. The absorbent article according to claim 1.

11. The one or more embossed channels further include a front region channel and a rear region channel disposed at both longitudinal ends of the central channel. The absorbent article according to claim 1.

12. The central channel has a length that is 25 percent to 53 percent of the total length of the absorbent article. The absorbent article according to claim 1.

13. The front-side region channel and the rear-side region channel are disposed on both sides of the central channel, and the total length of the embossed channel is 80% or less of the total length of the absorbent article. The absorbent article according to claim 1.

14. The total length of the embossed channel is 30% to 80% of the total length of the absorbent article. The absorbent article according to claim 13.

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