Disposable floating absorbent core and disposable absorbent assembly including the disposable floating absorbent core, and method for manufacturing the disposable absorbent assembly - Patents.com

Abstract

An absorbent article is disclosed. The absorbent article has a core and a chassis. One or more discrete bond zones connect the core to the chassis, and one or more unbonded zones of the core are not connected to the chassis, thereby forming a floating core. The core is not elastically bonded to the chassis. A method of manufacturing the absorbent article may include selectively bonding the chassis to the core at the discrete bond zones.

Description

[Technical Field]

[0001] SUMMARY The present disclosure relates to a disposable absorbent article that includes a stretchable chassis and an absorbent core, and a method for making the disposable absorbent article.

[0002] REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 62 / 438,253, filed December 22, 2016 (currently pending), which is incorporated by reference in its entirety for all purposes. [Background technology]

[0003] When elastic members incorporated into the chassis of an article (such as a diaper) are stretched or contracted, such elastic forces may be transmitted to the absorbent core of the article, which may cause discomfort to a user of the article. Thus, reducing or eliminating the transmission of such elastic forces from the chassis to the absorbent core can increase user comfort. Summary of the Invention

[0004]

[0003] Embodiments of the present disclosure relate to an absorbent article. The absorbent article has a core and a chassis. One or more separate zones connect the core to the chassis. One or more unconnected zones of the core are not connected to the chassis. These zones may be part of or located on the core.

[0005] Another embodiment of the present disclosure relates to an absorbent article having a chassis and a floating or floating core.

[0006] Another embodiment of the present disclosure relates to an absorbent article having a chassis and a core, wherein the core is not elastically coupled to the chassis.

[0007] Another embodiment of the present disclosure relates to a method of manufacturing an absorbent article, the method comprising selectively bonding a chassis to a core at discrete bonding zones.

[0008] Another embodiment of the present disclosure relates to an absorbent article having an absorbent core, a stretchable chassis, and a dynamic void space formed between the absorbent core and the stretchable chassis, as well as a method of manufacturing the absorbent article.

[0009] Certain aspects of the present disclosure provide absorbent articles having an absorbent core composite and a stretchable chassis. The absorbent core composite is also referred to herein as an absorbent core, a core, a floating core, a floating absorbent core, or a core composite. The absorbent core composite may include not only a core absorbent material but also an additional layer or material, such as an impermeable layer, bonded to or uniformly secured to the core absorbent material. As used herein, "stretchable chassis" refers to an absorbent article chassis having elastics incorporated laterally and longitudinally within the waist and / or crotch region of the chassis, for example, between two distinct layers of the chassis (e.g., glued or otherwise attached to the chassis). The core is bonded to the chassis by at least one distinct bond zone that bonds the core to the chassis. The core has at least one unbonded zone that is not bonded to the chassis. Preferably, 5% to 40% of the surface area of ​​the bottom surface of the core is bonded to the chassis, and 60% to 95% of the surface area of ​​the bottom surface of the core is not bonded to the chassis. The chassis provides elasticity to the core at the bonded zone. In some aspects, the periphery of the core is bonded to the chassis, and this periphery is not included in the unbonded free region of the core.

[0010] In some aspects, the unbonded surface area of ​​the core is not constrained by the chassis and can move relative to the chassis, such that the core can move vertically relative to the chassis and the chassis can move without moving the unbonded zone of the core.

[0011] In some aspects, the unbonded surface area of ​​the core includes a uniformly unbonded area on the bottom surface of the core. As used herein, the term "large unbonded area" refers to a continuous portion of the surface area on the bottom surface of the core that is not bonded to the stretchable chassis (e.g., the free area shown in Figure 4A). That is, the entire surface area can move without resistance from the stretchable chassis.

[0012] In some aspects, the unbonded surface area of ​​the core has an unbonded free width ranging from 50% to 95% of the width of the core for a core length that is greater than 50% of the total length of the core. In one particular aspect, the unbonded surface area of ​​the core has an unbonded free area equal to greater than 50% of the total surface area of ​​the base of the core.

[0013] In some aspects, the unbonded surface region of the core has an unbonded free width ranging up to 80% or 85% of the width of the core for a core length up to 60% of the total length of the core.

[0014] In some aspects, the unbonded surface region of the core has an unbonded free width ranging from 65% to 85% of the width of the core for a core length up to 70% of the total length of the core.

[0015] In some aspects, the unbonded surface region of the core has an unbonded free width ranging from 50% to 95% of the overall width of the core for a core length up to 80% of the overall length of the core.

[0016] In some aspects, the unbonded surface region of the core has an unbonded free width ranging from 50% to 95% of the overall width of the core for a core length up to 90% of the overall length of the core.

[0017] In some aspects, the unbonded surface region of the core has an unbonded free width ranging from 50% to 95% of the total width of the core for a core length up to 95% of the total length of the core. When numerical ranges or limitations are explicitly stated, such explicit ranges or limitations should be understood to include repeating ranges or limitations of the same magnitude that fall within the explicitly stated range or limitation (e.g., 50-95 includes 55-90, 66, over 70, etc.).

[0018] In one particular aspect, when the chassis elastic is in a contracted state, a void space is positioned between the absorbent core and the elastic chassis, the void space coinciding with the unbonded zone of the absorbent core.

[0019] Some aspects of the present disclosure provide absorbent articles having an absorbent core and a stretchable chassis that provides elasticity to the core at one or more bonded zones. A void space is formed between the stretchable chassis and the absorbent core. The void space coincides with the unbonded zones of the core where the core is not bonded to the chassis. The void space is a dynamic void space that responds to the expansion and contraction of the elastic of the stretchable chassis, so that the void space responds to the movement of the wearer's body when the absorbent article is worn.

[0020] Certain aspects of the present disclosure provide a method for manufacturing an absorbent article, the method comprising the steps of: bonding an absorbent core to a stretchable chassis at one or more separate bond zones; and unbonding the absorbent core from the chassis at one or more unbonded zones; wherein 5% to 40% of the bottom surface area of ​​the core is bonded to the chassis, and 60% to 95% of the bottom surface area of ​​the core is not bonded to the chassis.

[0021] In some aspects, the method further includes forming a void space between the elastic chassis and the absorbent core. The void space corresponds to an unbonded zone of the core where the core is not bonded to the chassis. The void space is a dynamic void space that responds to the expansion and contraction of the elastic of the elastic chassis.

[0022] The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description that follows may be better understood. Below, additional features and advantages are described which form the subject matter of the claimed invention. Those skilled in the art will understand that the conception and specific embodiments disclosed may readily be utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the present invention as set forth in the appended claims. The novel features believed characteristic of the products, systems, and methods, both as to their organization and manner of operation, together with other objects and advantages thereof, will be better understood from a consideration of the following description in connection with the accompanying drawings. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

[0023] The particular description set forth above so that the features and advantages of the systems, products and / or methods of the present disclosure can be understood in detail can be made by reference to embodiments of the invention, which are illustrated in the accompanying drawings that form a part hereof. It should be noted, however, that the drawings illustrate only various exemplary embodiments and, therefore, should not be considered as a limitation of the disclosed concepts, as the disclosed concepts may also include other efficacious embodiments. [Brief explanation of the drawings]

[0024] [Figure 1A]FIG. 1 is a plan view of a first embodiment featuring two bond zones between the absorbent core and the underlying material, the bond zones being located toward the leading and trailing edges of the absorbent core, with a large central region of the core remaining unbonded to the underlying material. [Figure 1B] FIG. 1 is an exploded perspective view of a first embodiment featuring two bond zones between the absorbent core and the underlying material, the bond zones being located toward the leading and trailing edges of the absorbent core, with a large central region of the core remaining unbonded to the underlying material. [Figure 2A] A plan view of a second embodiment featuring one bond zone between the absorbent core and the underlying material, where the bond zone is located along the central axis of the core and the side edges of the absorbent core are unbonded to the underlying material. [Figure 2B] An exploded perspective view of a second embodiment featuring one bond zone between the absorbent core and the underlying material, the bond zone being located along the central axis of the core and showing the side edges of the absorbent core unbonded to the underlying material. [Figure 3A] A plan view of a third embodiment featuring three bond zones between the absorbent core and the underlying material, where the bond zones are located in the central core region and toward the front and rear edges of the absorbent core, and where the side edges of the core and large areas of the intermediate front and intermediate rear sections of the core are unbonded to the underlying material. [Figure 3B] FIG. 10 is an exploded perspective view of a third embodiment featuring three bond zones between the absorbent core and the underlying material, the bond zones being located in the central core region and toward the front and rear edges of the absorbent core, with the side edges of the core and large areas of the intermediate front and intermediate rear sections of the core being unbonded to the underlying material. [Figure 4A] FIG. 10 is a plan view of a fourth embodiment featuring one bond zone between the absorbent core and the underlying material, with the bond zone located in the central region of the core and the broad front and back regions of the core remaining unbonded to the underlying material. [Figure 4B] FIG. 10 is an exploded perspective view of a fourth embodiment featuring one bond zone between the absorbent core and the underlying material, the bond zone being located in the central region of the core, with the broad front and rear regions of the core remaining unbonded to the underlying material. [Figure 5A] A plan view of a fifth embodiment featuring two bond zones between the absorbent core and the underlying material, where the bond zones are located toward the side edges of the central region of the core, and the larger central region of the core and larger regions of the front and rear portions of the core are unbonded to the underlying material. [Figure 5B] An exploded perspective view of a fifth embodiment featuring two bond zones between the absorbent core and the underlying material, the bond zones being located toward the side edges of the central region of the core, and the larger central region of the core and larger regions of the front and rear portions of the core being unbonded to the underlying material. [Figure 6A] FIG. 10 is a plan view of a sixth embodiment featuring six bond zones between the absorbent core and the underlying material, with four of the bond zones located at the corners of the absorbent core and two more bond areas located in the central region near each side edge of the core, and with the wide central region, intermediate front region, and intermediate back region of the core remaining unbonded to the underlying material. [Figure 6B] FIG. 10 is an exploded perspective view of a sixth embodiment featuring six bond zones between the absorbent core and the underlying material, with four of the bond zones located at the corners of the absorbent core and two more bond zones located in the central region near each side edge of the core, and with the wide central region, intermediate front region, and intermediate back region of the core remaining unbonded to the underlying material. [Figure 7] 1B is a cross-sectional view taken along line A-A of FIG. 1A, illustrating how the core is also wrinkled by contraction of the elastic material when bonded to an underlying wrinkled or pleated elastic surface. [Figure 8]2B is a cross-sectional view taken along line A'-A' of FIG. 2A, illustrating how, when the core is partially bonded to an underlying wrinkled or pleated elastic surface, it is wrinkled by contraction of the underlying elastic material in the bonded zones, but not so much by wrinkles of the material in the non-bonded zones. [Figure 9A] 6B is a cross-sectional view taken along line A″-A″ of FIG. 6A, illustrating how, when the core is partially bonded to an underlying wrinkled or pleated elastic surface, it is wrinkled by contraction of the underlying elastic material in the bonded zones, but not so much by wrinkles of the material in the unbonded zones. [Figure 9B] FIG. 6B is another view of the cross-sectional view taken along line A″-A″ of FIG. 6A, illustrating how when the core is partially bonded to an underlying wrinkled or pleated elastic surface, it is wrinkled by contraction of the underlying elastic material in the bonded zones, but not so much by wrinkles of the material in the unbonded zones. [Figure 10A] FIG. 13 is a plan view of the seventh embodiment showing the elastic members in the chassis. [Figure 10B] FIG. 13 is an exploded perspective view of the seventh embodiment showing the resilient members in the chassis. [Figure 11A] FIG. 13 is a plan view of an eighth embodiment showing elastic members in the chassis and in the crotch region between the polyethylene film and the chassis. [Figure 11B] FIG. 13 is an exploded perspective view of an eighth embodiment showing elastic members in the chassis and in the crotch region between the polyethylene film and the chassis. [Figure 12A] FIG. 13 is an exploded perspective view of a ninth embodiment showing elastic members in the chassis and in the crotch region between the polyethylene film and the absorbent core. [Figure 12B] FIG. 13 is an exploded perspective view of a tenth embodiment showing elastic members in the chassis and in the crotch region between the absorbent core and the topsheet. [Figure 13]FIG. 19 is an exploded perspective view of the eleventh embodiment showing the bonding zone of the core between the polyethylene film and the chassis. [Figure 14A] FIG. 12 is a plan view of a three-piece diaper according to a twelfth embodiment. [Figure 14B] FIG. 22 is an exploded perspective view of the twelfth embodiment as a three-piece diaper. [Figure 15A] FIG. 20 is a plan view of a thirteenth embodiment of a three-piece diaper in which elastic members are present in the crotch region. [Figure 15B] FIG. 22 is an exploded perspective view of the thirteenth embodiment as a three-piece diaper with elastic members in the crotch region. [Figure 16A] FIG. 1 is a plan view of one embodiment of an absorbent core having an embossed pattern. [Figure 16B] FIG. 2 is a side view of one embodiment of an absorbent core joined to a chassis and having an embossed pattern that forms channels. [Figure 17A] A plan view of an absorbent article featuring one bond zone between the absorbent core and the underlying material, where the bond zone is located along the central axis of the core, the side edges of the absorbent core are unbonded to the underlying material, and the bond zone is positioned below the impermeable layer rather than above it. [Figure 17B] An exploded perspective view of an absorbent article featuring one bond zone between the absorbent core and the underlying material, where the bond zone is located along the central axis of the core, the side edges of the absorbent core are unbonded to the underlying material, and the bond zone is positioned below the impermeable layer rather than above the impermeable layer. [Figure 18] 1A, 1B, and 1C are side views illustrating the movement of a wearer of an absorbent article and the resulting forces exerted on the absorbent article. [Figure 19] 1A and 1B are front views showing the movement of a wearer of an absorbent article and the state of forces exerted on the absorbent article as a result of such movement. [Figure 20A]6A is a cross-sectional view taken along line A"-A" of FIG. 6A, showing how, when the core is partially bonded to an underlying wrinkled or pleated elastic surface, it is wrinkled by contraction of the underlying elastic material in the bonded zone, but not so much by wrinkles of the material in the non-bonded zone, opening up void spaces. [Figure 20B] 6B is a cross-sectional view taken along line A″-A″ of FIG. 6A, illustrating how, when the core is partially bonded to the underlying elastic surface, it is stretched and elongated by the stretching and stretching of the underlying elastic material in the bond zone, resulting in the void space being closed. [Figure 21A] 6B is a cross-sectional view taken along line A″-A″ of FIG. 6A, illustrating the forces exerted on the core when it is wrinkled or pleated due to contraction of the underlying elastic material in the bonding zone, and showing flow lines for the fluid contained within the void space. [Figure 21B] 6B is a cross-sectional view taken along line A''-A'' of FIG. 6A, illustrating the forces exerted on the core when stretched or elongated due to the stretching of the underlying elastic material in the bond zones. [Figure 22] A cross-sectional view of an absorbent article similar to the cross-sectional view taken along line A''-A'' in Figure 6A, but showing an impermeable layer attached to the absorbent core and floating above the void space. DETAILED DESCRIPTION OF THE INVENTION

[0025] The products and methods according to the present invention will now be more fully described with reference to the accompanying drawings, which illustrate various exemplary embodiments. However, the inventive concepts may be embodied in many different forms and should not be construed as limited by the illustrated embodiments described herein. Instead, these embodiments are provided so that this disclosure will be thorough and complete, fully conveying the scope of the various concepts to those skilled in the art and illustrating the best and preferred embodiments. For example, many of the exemplary descriptions provided herein relate to training pants or diapers for babies and toddlers. However, aspects of the described concepts are equally applicable to the design and manufacture of adult incontinence products and other similar products.

[0026] The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description that follows may be better understood. Below, additional features and advantages are described which form the subject matter of the claimed invention. Those skilled in the art will understand that the conception and specific embodiments disclosed may readily be utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the present invention as set forth in the appended claims. The novel features believed characteristic of the products, systems, and methods, both as to their organization and manner of operation, together with other objects and advantages thereof, will be better understood from a consideration of the following description in connection with the accompanying drawings. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

[0027] Aspects of the present disclosure are particularly suitable for or related to disposable absorbent articles, such as infant diapers, training pants for babies and toddlers, and adult incontinence diapers and pants. Certain embodiments can provide an elastic composite, elastic composite or body, or web of elastic distribution pattern within these products, which can improve the fit and comfort of the product, its supportability and sealability, as well as increase the cost and manufacturability of the product and / or enhance the aesthetic qualities of the product.

[0028] Disposable absorbent articles contemplated herein include training pants, pull-on diapers, disposable underwear, and adult incontinence garments. With regard to training pants, these garments are used by infants to facilitate the child's transition from using diapers to wearing regular pants (i.e., during toilet training). Training pants and other disposable pull-on pants have closed sides that allow a user or caregiver to pull the garment up around the user's legs to don the garment or slide the garment down around the user's legs to remove the garment. These articles and garments are collectively referred to herein as "absorbent pants" or "pant products."

[0029] Elastic members may be incorporated into different portions of the absorbent garment. For example, the elastic members may be positioned longitudinally along the diaper generally outside the absorbent core to affect the seal around the user's buttocks, legs, or both. In addition, several elastic members (e.g., in the form of elongated elastic threads or strands) may be positioned laterally throughout the waist region (including the side waist regions) of the absorbent garment. The resulting elasticity allows the garment to stretch when donned and worn. The elasticity allows the garment to accommodate variations in waist and leg sizes of users while still providing a snug fit around the waist and legs.

[0030] When elastic members are incorporated into a portion or region of an absorbent garment, that portion or region typically becomes a distinct functional component of the garment. These elastic components include side panels or ear portions, waistbands, and fastening tabs. Elastic composites, due in part to their multi-component structure, may require dedicated sub-processes for their manufacture that must be accommodated by the larger garment manufacturing process. Alternatively, the elastic composite may be manufactured separately or simply in a separate sub-process that is detached from the central garment manufacturing system. In either case, a source of elastic composite material may be provided as an input to the garment manufacturing process.

[0031] U.S. Patent Nos. 7,462,172 and 7,361,246, and U.S. Patent Application Publication No. 2012 / 0071852, provide background information regarding elastic composites (and the manufacture of such composites) of a type related to the present invention. Accordingly, these prior art documents are incorporated by reference and made a part of this specification, but only to the extent that the cited subject matter provides background information and / or exemplary composites and processes that are used in or suitable for use with the composites, systems, and methods of the present invention. Thus, the incorporated subject matter does not limit the scope of the embodiments of the present invention.

[0032] For purposes of this description, the terms "elastic composite," "elastic composite body," and "stretchable article" refer to a multi-layer or multi-component construction incorporating elastomeric materials or elastic members. In this construction, multiple elastic members, e.g., yarns or strands, are connected to or adjacent to one or more materials, e.g., a backsheet and a topsheet. In this manner, the elastic members impart elasticity to the connected or adjacent layers and thus to that portion of the garment or article. Such elastic structures may be separate, attachable components of the garment or article, or may be separate portions or sections of the garment body article or a larger, integral component of the garment.

[0033] Furthermore, as used herein, the term "web" refers to an elongated, transportable sheet or network. The term "substrate" refers to a supporting web, sheet, or layer to which elastic adheres or otherwise supports the elastic, such as a web or backsheet layer to which elastic adheres or otherwise supports the elastic. Furthermore, the web may be of an elastic composite and / or may provide a series of multiple, separate elastic composite bodies. In embodiments described herein, such elastic composite bodies may be separated from the web to form the basis of a disposable absorbent article, such as a diaper or absorbent pants.

[0034] In one aspect, the present disclosure relates to a disposable absorbent core and chassis combination. The present disclosure also relates to a disposable absorbent article or garment comprising the disposable absorbent core and chassis. In various or alternative applications, the disposable absorbent article or garment can take the form of a diaper, training pants, adult incontinence products, feminine hygiene products, and other similar disposable absorbent products.

[0035] 1A and 1B are plan and exploded perspective views, respectively, of one embodiment of an absorbent article 10. The absorbent article 10 has a chassis 17 and a core 18. As will be explained in more detail below, one aspect of certain suitable embodiments is that the absorbent component of the core 18 is not substantially connected to an elastic component chassis 17, e.g., an elastic / stretchable component of the chassis 17, which extends laterally across the core 18 and forms part of the outer shell of the absorbent article 10 (e.g., the outer shell of a diaper).

[0036] The chassis 17 has waist regions 23a, 23b and a crotch region 20. During use, the waist regions 23a, 23b may be attached around the user's waist, for example by adhesive tabs, so that the absorbent article 10 can be donned. In some embodiments, the chassis 17 has an outer backsheet layer 11 attached to the inner backsheet layer 12, for example by an adhesive. The chassis 17 may be designed to prevent fluid from passing from the core 18 through one or more of the outer backsheet layer 11 and the inner backsheet layer 12 and out of the absorbent article 10. In some embodiments, the outer backsheet layer 11 and the inner backsheet layer 12 may be formed of a fluid- and / or liquid-impermeable film (e.g., a polyethylene film) that may extend across the entire width of the absorbent article 10, a cloth-like material, or a combination thereof. In some aspects, a permeable layer is used in place of the impermeable layer 13. The outer backsheet layer 11 and the inner backsheet layer 12 may be vapor permeable (“breathable”), allowing vapor to pass through the chassis 17 without releasing fluids and / or liquids stored within the core 18. Each of the outer backsheet layer 11 and the inner backsheet layer 12 may be made of a liquid-impermeable but vapor-permeable nonwoven material, such as a spunbond-meltblown (SB) nonwoven, a spunbond-meltblown-spunbond (“SMS”) nonwoven, a spunbond-meltblown-meltblown-spunbond (“SMMS”) nonwoven, microfibers, nanofibers, or splittable fibers, spunmelt or spunlace material, carded material, a fluid- and / or liquid-impermeable film (e.g., a polyethylene film), or combinations thereof. For example, in one embodiment, the inner backsheet layer 12 is made of, but is not limited to, a SB nonwoven, an SMS nonwoven, or a polyethylene film, and the outer backsheet layer 12 is made of, but is not limited to, a SB nonwoven or an SMS nonwoven.

[0037] In some embodiments, the absorbent article 10 includes an impermeable layer 13, which may be a polyethylene film. The impermeable layer 13 may be substantially impermeable to fluids and / or liquids. The impermeable layer 13 may be bonded to the inner backsheet 12, for example, by an adhesive.

[0038] The impermeable layer 13 may be bonded to the absorbent core 14 by, for example, one or more bond regions 19a, 19b. As shown in Figures 1A and 1B, the bond zones 19a, 19b are positioned toward the side edges 24a, 24b (e.g., the leading and trailing edges) of the absorbent core 14, leaving a large central region of the absorbent core 14, shown here as the impermeable layer 13, unbonded to the material underlying the chassis 17. The bond zones 19a, 19b in Figures 1A and 1B are shown as strips extending generally between the longitudinal edges 25a, 25b of the absorbent core 14. The bond zones 19a, 19b may be formed of, for example, but not limited to, a hot melt adhesive.

[0039] The core 18 may further include a topsheet 15 and leg cuffs 16 joined to the absorbent core 14, for example, by a hot melt adhesive. The leg cuffs 16 may be joined to the topsheet 15 along the topsheet longitudinal edges 27, for example, by a hot melt adhesive, and the leg cuffs may extend between the topsheet lateral edges 28. The topsheet 15 and leg cuffs 16 may be made of the same material as the outer backsheet layer 11 and inner backsheet layer 12, or they may be made of different materials.

[0040] The chassis 17 incorporates one or more elastic members 21 (as shown in FIG. 7 ), such as elastic strands or elastic films. In operation, when a user wears the absorbent article 10, the elastic members 21 of the chassis 17 may become crinkled or gathered, for example, as the user walks while wearing the absorbent article 10. As shown in FIG. 7 , the portion of the absorbent core 14 that is bonded to the portion of the chassis 17 having the elastic members 21 (e.g., elastic strands or films) that are crinkled or gathered also becomes crinkled or gathered. Without being bound by theory, it is believed that the bond between the absorbent core 14 and the chassis 17 allows for the transmission of crinkling or gathering from the elastic members 21 of the chassis 17 to the absorbent core 14. Such crinkling or gathering of the absorbent core 14 may cause discomfort to the user of the absorbent article 10. By individually adjusting the number and location of bonding zones between the absorbent core 14 and the material underlying the chassis 17, the propagation of wrinkling or gathering of the absorbent core 14 due to contraction of the elastic members 21 of the chassis 17 can be reduced or eliminated.

[0041] As shown in FIG. 7, adjacent layers of the absorbent article 10 may be bonded together with a hot melt adhesive 22 .

[0042] 2A and 2B are plan and exploded perspective views, respectively, of a second embodiment of an absorbent core 10 including a single bond zone 19 between the absorbent core 14 and the chassis 17. The single bond zone 19 in FIGS. 2A and 2B is disposed along the central axis 29 of the absorbent core 14, leaving the side edges of the absorbent core 14 unbonded to the chassis 17. FIG. 8 is a cross-sectional view taken along line A'-A' in FIG. 2A and illustrates how, when the absorbent core 14 is partially bonded to the underlying wrinkled or pleated elastic members 21 at the bond zone 19, it is wrinkled or pleated by contraction of the elastic members 21 in the bond zone 19. In areas of the absorbent core 14 that are not bonded to the chassis 17, e.g., unbonded zones 31a and 31b, propagation of wrinkles or pleats from the elastic members 21 to the absorbent core 14 is reduced or eliminated. A core 18 including an absorbent core 14 having regions that are not bonded to the chassis 17 (e.g., unbonded zones 31a, 31b) may be referred to herein as a "floating core" or "floating absorbent core." As used herein, "floating core" or "floating absorbent core" refers to an absorbent core that is bonded to an underlying layer of the absorbent article 10 (in this case, the stretchable chassis 17) only at discrete locations, points, and / or regions. As used herein, the term "floating" refers to a floating absorbent core in which multiple regions of the floating absorbent core are not bonded to an underlying layer of the absorbent article 10, such that the unbonded regions of the floating absorbent core are free to move perpendicularly relative to the position of the underlying layer of the absorbent article 10. Thus, the unbonded zones of the floating absorbent core 14 are referred to as "floating." That is, referring to FIG. 21A , the unbonded regions of the floating absorbent core 14 are free to move along direction 950 relative to the stretchable chassis of the absorbent article 10. In some aspects, the absorbent article 10 has an absorbent core 14 that is not uniformly or extensively attached to the stretchable chassis 17 .

[0043] In some aspects, the bottom surface 114 (shown in FIG. 9A ) of the floating absorbent core 14 has one or more portions of its surface area bonded (at bond zones 19) to the elastic chassis 17 and one or more portions of its surface area unbonded (unbonded) to the elastic chassis 17. In some aspects, 90% or less of the surface area of ​​the bottom surface 114, based on the total surface area of ​​the bottom surface 114, is bonded to the elastic chassis 17 (i.e., bonded to the impermeable layer 13, the upper backsheet 12, the lower backsheet 11, the elastic members 21, or any other portion of the chassis 17 located below the floating absorbent core 14 and / or below the void space 500). In certain aspects, based on the total surface area of ​​the bottom surface 114, 85% or less, 80% or less, 75% or less, 70% or less, 65% or less, 60% or less, 55% or less, 50% or less, 45% or less, 40% or less, 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less of the bottom surface 114 is bonded to the stretchable chassis 17. The percentage of the bottom surface 114 that is bonded to the stretchable chassis 17 can range from about 5% to about 90%, from about 10% to about 80%, from about 20% to about 70%, from about 30% to about 60%, or from about 40% to about 50%. In certain aspects, the percentage of the bottom surface 114 that is bonded to the stretchable chassis 17 ranges from 10% to 30%. In each case, the remainder of the surface area of ​​the bottom surface 114 is not bonded to the stretchable chassis 17. For example, if 10% to 30% of the surface area of ​​bottom surface 114 is bonded to stretchable chassis 17, then 70% to 90% of the surface area of ​​bottom surface 114 is not bonded to stretchable chassis 17.

[0044] 3A and 3B are plan and exploded perspective views, respectively, of a third embodiment of an absorbent article 10 including three bond zones 19a, 19b, and 19c between the absorbent core 14 and the underlying material of the chassis 17. The bond zones 19a-19c in FIGS. 3A and 3B are located within the central region of the core 18, two are located toward the side edges 24a, 24b, and one is located at the center of the core 18, leaving the longitudinal edges 25a, 25b of the core 18 and large areas of the mid-front and mid-back sections of the core 18 unbonded to the underlying material of the chassis 17.

[0045] 4A and 4B are plan and exploded perspective views, respectively, of a fourth embodiment of an absorbent article 10 including a single bond zone 19 between the absorbent core 14 and the material underlying the chassis 17. The bond zone 19 in FIGS. 4A and 4B is located in a central region of the core 18, with broad front and back regions of the core 18 remaining unbonded to the material underlying the chassis 17.

[0046] 5A and 5B are plan and exploded perspective views, respectively, of a fifth embodiment of an absorbent article 10 including two bond zones 19a, 19b between the absorbent core 14 and the material underlying the chassis 17. The bond zones 19a, 19b in Figures 5A and 5B are located in the central region of the core 18 toward the longitudinal edges 25a, 25b, leaving the central region of the core 18 and larger areas of the front and rear portions of the core 18 unbonded to the material underlying the chassis 17.

[0047] 6A and 6B are plan and exploded perspective views, respectively, of a sixth embodiment of an absorbent article 10 including six bond zones 19a-19f for bonding the absorbent core 14 to the underlying material of the chassis 17. Four bond zones, 19a, 19b, 19e, and 19f, are located at the corners of the absorbent core 14. Two bond zones, 19c and 19d, are located within the central region of the absorbent core 14 toward the longitudinal edges 25a and 25b of the core 18, leaving a larger central region, an intermediate front region, and an intermediate back region of the core 18 unbonded to the underlying material of the chassis 17. FIG. 9A is a cross-sectional view taken along line A"-A" of FIG. 6A, illustrating how the absorbent core 14, when partially bonded to the underlying gathered or pleated elastic members 21, is gathered by contraction of the elastic members 21 in bond zones 19a and 19b. The propagation of wrinkling or gathering to the absorbent core 14 due to contraction of the elastic members 21 is reduced or eliminated in areas of the absorbent core 14 that are not bonded to the chassis 17, such as the unbonded zones 31.

[0048] FIG. 9B is another cross-sectional view taken along line A″-A″ of FIG. 6A . As shown in FIG. 9B , in some respects, the bond between the elastic member 21 and the layers surrounding the elastic member 21, in this case the outer backsheet layer 11 and the inner backsheet layer 12, is continuous. In contrast, as shown in FIG. 9A , in other respects, the bond between the elastic member 21 and the layers surrounding the elastic member 21, in this case the outer backsheet layer 11 and the inner backsheet layer 12, is discontinuous (e.g., intermittent), such that no channel 100 is formed between the elastic member 21 and the surrounding layers, the outer backsheet layer 11 and the inner backsheet layer 12, or between the elastic member 21 and the surrounding layers. In one particular respect, the void space 500 directs liquid contained therein away from the target area, where the majority of the liquid volume is located within the absorbent core 14 (the damaged area where initial absorption of exudate into the absorbent core 14 occurs). For example, a void space 500 having longitudinally oriented tubes (i.e., fluid channels 200) directs liquid contained therein longitudinally along such tubes. In some aspects, at least one side of the void space 500 is unsealed. In some aspects, at least one side of the void space 500 is sealed. For example, in the case of a void space 500 having longitudinally oriented tubes (i.e., fluid channels 200), the longitudinal edges of such void space 500 may be sealed or relatively sealed, while the ends of the void space 500 (i.e., the edges of the void space 500 located at the ends of the tubes (fluid channels)) may be unsealed.

[0049] By individually adjusting the number and placement of the bond zones 19 between the absorbent core 14 and the material underlying the chassis 17, the transmission of wrinkles or gathers to the absorbent core 14 caused by the elastic members 21 of the chassis 17 can be reduced or eliminated.

[0050] 10A and 10B are plan and exploded perspective views, respectively, of a seventh embodiment of the absorbent article 10. The chassis 17 may have one or more elastic members 21a, 21b located in the waist regions 23a, 23b of the absorbent article 10 and one or more elastic members 21c, 21d located in the crotch region 20 of the absorbent article 10. As shown, the absorbent core 14 is bonded to the chassis 17 via bond zones 19a, 19b in areas of the chassis that do not have elastic members 21a-21d.

[0051] 11A and 11B are plan and exploded perspective views, respectively, of an eighth embodiment of an absorbent article 10. The absorbent article 10 of FIGS. 11A and 11B is identical to the absorbent article of FIGS. 10A and 10B, except that the embodiment shown in FIGS. 11A and 11B further includes one or more elastic members 21e beneath the core 18 in the crotch region 20 of the absorbent article 10. The elastic members 21e may be straight, linear elastic strands as shown, or may be curved. The elastic members 21e can be positioned in various locations within the absorbent article 10. As shown, the elastic members 21e are positioned between the impermeable layer 13 and the outer backsheet layer 11. The elastic members 21e of the core 18 may be isolated from all of the elastic members 21a-21d of the chassis 17. As used herein, the term "isolation" of the elastic member 21e of the core 18 from all of the elastic members 21a-21d of the chassis 17 refers to an arrangement of the elastic members 21a-21e such that the elastic member 21e is not in contact with the elastic members 21a-21d of the chassis 17, does not intersect with the elastic members 21a-21d of the chassis 17, or a combination thereof. When the elastic member 21e is isolated from the elastic members 21a-21d, the elastic member 21e is not elastically coupled to the elastic members 21a-21d. As used herein, the term "elastically coupled" means that the elastic members 21a-21d can transmit elastic effects (e.g., stretching, contraction, pleating, crinkling, etc.) to other elements of the absorbent article 10.

[0052] Figures 12A and 12B are exploded perspective views of ninth and tenth embodiments of the absorbent article 10, respectively. The absorbent article 10 of Figures 12A and 12B is identical to the absorbent article of Figures 11A and 11B except for the location of the elastic member 21e. In Figure 12A, the elastic member 21e is located between the impermeable layer 13 and the absorbent core 14. In Figure 12B, the elastic member 21e is located between the absorbent core 14 and the topsheet 15. The configuration of the elastic member 21e shown in Figure 12B is suitable for use with an Oyster Elastic Core.

[0053] Figure 13 is an exploded perspective view of an eleventh embodiment of the absorbent article 10. The absorbent article 10 of Figure 13 is identical to the absorbent article of Figure 12B except for the location of the bond zones 19a, 19b. In Figure 13, the bond zones 19a, 19b are located between the fluid impermeable layer 13 and the inner backsheet layer 12, whereas in Figure 12B, the bond zones 19a, 19b are located between the absorbent core 14 and the impermeable layer 13.

[0054] The bond zones 19 can take various forms and be positioned in areas within the absorbent article 10 between all of the elastic members 21 of the chassis 17 and the absorbent core 14 so that the gathering, stretching, and other stretching effects of the elastic members on the chassis 17 are not directly or completely transmitted to the absorbent core 14.

[0055] 14A and 14B are plan and exploded perspective views, respectively, of a twelfth embodiment of an absorbent article 10. As shown, the absorbent article is a three-piece diaper having a front chassis 17a forming a front waistband, a back chassis 17b forming a back waistband, and a core 18. The front chassis 17a has elastic member 21a, the back chassis 17b has elastic member 21b, and the impermeable layer 13 has elastic members 21c and 21d. The configuration of the absorbent article 10 shown in FIGS. 14A and 14B is suitable for use as, for example, a pant-type diaper. The use of separate, selected bond zones 19a and 19b between the absorbent core 14 and other portions of the core 18 (e.g., the impermeable layer 13) can reduce or eliminate stretching effects (e.g., stretching, gathering, or wrinkle propagation) on the absorbent core 14.

[0056] Figures 15A and 15B are a plan view and an exploded perspective view, respectively, of a thirteenth embodiment of the absorbent article 10. The absorbent article 10 shown in Figures 15A and 15B is identical to the absorbent article shown in Figures 14A and 14B, except that the absorbent article 10 of Figures 15A and 15B further includes one or more elastic members 21e between the absorbent core 14 and the topsheet 15.

[0057] In some embodiments, the absorbent core 14 may be substantially unbonded to the elastic members 21 of the chassis 17, particularly those elastic members 21 of the chassis 17 that extend laterally across the core 18 and form part of the outer shell of the absorbent article 10. For example, but not by way of limitation, the absorbent core 14 may be bonded to components of the chassis 17 only at discrete bond zones 19, thereby forming bonded zones 19, and not bonded to the chassis 17 in other zones, thereby forming unbonded zones 31. In some embodiments, each bond zone 19 may have a surface area that is less than the sum of the surface areas of all unbonded zones 31 of the absorbent article 10. In some embodiments, the sum of the surface areas of all bond zones 19 of the absorbent article 10 may be less than the sum of the surface areas of all unbonded zones 31 of the absorbent article 10. For example, an embodiment with an absorbent core 14 having a surface area of ​​400 mm x 100 mm may have two bond zones 19a, 19b at the front and rear longitudinal ends of the absorbent article 10 (e.g., as shown in Figures 1A and 1B), each having a surface area of ​​30 mm x 100 mm, and may have an unbonded zone 31 between bond zones 19a, 19b with a surface area of ​​340 mm x 100 mm. Alternatively, an embodiment of the absorbent article 10 may have a centrally located bond zone 19 in the form of a strip (e.g., as shown in Figures 2A and 2B) having a surface area of ​​400 mm x 5 mm, and two unbonded zones 31a, 31b, each having a surface area of ​​400 mm x 47.5 mm.

[0058] In some embodiments, the core 18 and / or absorbent core 14 may be a unitary, continuous, single-piece structure, such that the core 18 and / or absorbent core 14 is self-supporting between the bonded zone 19 and the unbonded zone 31. For example, but not limited to, the core 18 and / or absorbent core 14 may be an Oyster core or a Dry MT core. In other embodiments, the core 18 and / or absorbent core 14 may be a pulp / superabsorbent polymer (SAP) core. In embodiments in which the core 18 and / or absorbent core 14 is a pulp / SAP core, the pulp / SAP core may be wrapped and / or surrounded by a support structure, such as a nonwoven fabric, before being bonded to the chassis 17. In some embodiments, the composition of the core 18 and / or absorbent core 14 may be formulated to provide regions of the core 18 and / or absorbent core 14 that function as stiffeners. For example, certain regions of the core 18 and / or absorbent core 14 may comprise highly absorbent particles (e.g., SAP) or denser absorbent material. In some embodiments, such regions of the core 18 and / or absorbent core 14 may include particles, fibers, or layers of other materials that increase the density, thickness, and / or firmness of those regions of the core 18 and / or absorbent core 14. In some embodiments, hot melt adhesive 22 may be applied within or on the core 18 and / or absorbent core 14. In some embodiments, targeted regions of the core 18 and / or absorbent core 14 may include an increased amount of hot melt adhesive 22 compared to other regions of the core 18 and / or absorbent core 14. In certain embodiments, the core 18 and / or absorbent core 14 may be comprised of pockets and / or aggregates of SAP, as known in the art. The shape and size of such pockets and / or aggregates, as well as their composition, may be varied in different regions of core 18 and / or absorbent core 14 to achieve desired stiffness and bending properties, as is known in the art. The pocket pattern defined by the bonding pattern may be designed to achieve desired stiffness properties.Additionally, the bonding method (e.g., point bonding, solid bonding, etc.) may also vary. Such pockets and / or agglomerates may be made according to methods known to those skilled in the art, such as those described in U.S. Patent Application Publication No. 2014 / 0303582(A1) and U.S. Patent No. 8,148,598, the contents of which are incorporated herein by reference in their entireties.

[0059] During use, the surface topology and shape of the absorbent core 14, particularly in the unbonded zones 31, can remain substantially unchanged as the elastic members 21 of the chassis 17 are stretched, elongated, or relaxed, such that gathers of the core 18 can be reduced or eliminated when the elastic members 21 of the chassis 17 are relaxed, and flattening of the core 18 can be reduced or eliminated when the elastic members 21 of the chassis 17 are stretched. Thus, during use of at least some embodiments, the shape and surface topology of the core 18 can be said to remain generally unchanged. The shape and surface topology of the chassis 17 can change dynamically during use, while the shape and surface topology of the core 18 can be said to be static or substantially static during use.

[0060] In some embodiments, additional elastic or stretchable components (e.g., elastic member 21e) may be incorporated into and / or coupled to absorbent core 14 to impart a desired shape to the absorbent core. In such embodiments, the stretchability of such additional elastic or stretchable components may be independent or substantially independent of the stretchability of chassis 17 (e.g., independent or substantially independent of the elastic or stretchable components of chassis 17).

[0061] In some embodiments, the underside of the core 18 and / or absorbent core 14 may have an embossed pattern. In such embodiments, the embossed pattern may create or aid in the formation of channels (e.g., narrow capillary channels or wide channels) disposed between the core 18 and / or absorbent core 14 and the underlying structure (i.e., the chassis 17 or a component thereof). For example, without limitation, FIG. 16A illustrates an embodiment of an absorbent core 14 having an embossed pattern 40. FIG. 16B illustrates an embodiment of an absorbent core 14 in which the embossed pattern 40 is bonded to the chassis 17, forming channels 50.

[0062] In some embodiments, the material underlying the core 18 (i.e., the chassis 17 or portions of the chassis) may have modified wetting properties, thereby forming a wettable surface. For example, the chassis 17 or portions thereof (e.g., the inner backsheet layer 12 and / or the outer backsheet layer 11) can be modified to become more hydrophilic or more hydrophobic, for example, by treating it with a surfactant, corona treatment, or other surface treatment. Modifying the wettability of the chassis 17 can promote fluid flow between the core 18 and the chassis 17. Hydrophobic treatment of the chassis 17 in certain zones can slow or block fluid flow, for example, at the sides or ends of the core 18. As used herein, the term "wettable surface" refers to a surface that can have liquid barrier properties, for example, a material that has been modified by corona or plasma treatment of the surface to allow fluid distribution over the surface.

[0063] void space

[0064] In some aspects, the unbonded zone of the floating absorbent core 14 has a degree of "free width," a degree of "free length," and a degree of "free area" that allows it to move freely perpendicularly (i.e., along axis 950 as shown in FIG. 21A), laterally, or longitudinally relative to the position of the underlying layer (i.e., the stretchable chassis 17) of the absorbent article 10. Such an unbonded zone of the floating absorbent core 14 is referred to as "floating." For purposes of explanation, and not limitation, the terms "free width," "free length," and "free area" are described with reference to the figures.

[0065] 10A and 10B, core 14 has an average length (longitudinal extent) indicated by reference numeral 1000. However, only a small portion of length 1000, specifically unbonded length 2, is unbonded from chassis 17. Unbonded length 2 may be, for example, but not limited to, approximately 80% or less of length 1000. That is, if length 1000 is 10 inches (25.4 cm), unbonded length 2 is 8 inches (20.32 cm). Two portions at each end of core 14 are bonded to each other via bonded zones 19a and 19b and are shown as bonded length 3. Along bonded length 3, core 14 may be 100% or nearly 100% restrained from vertical movement relative to chassis 17. However, along unbonded length 2, core 14 may be approximately 95% or more unconstrained relative to chassis 17, allowing it to move freely vertically relative to chassis 17. Thus, along about 80% of the length of core 14, the core has a free width of about 95% or more, allowing the core in this region to move freely relative to chassis 17, and along about 20% of the length of core 14, the core has a free width of about 0%. As is evident from Figure 10A, the lateral widths of core 14 coincident with bond zones 19a, 19b have a free width and free length of about 0%, while the lateral widths of core 14 not coincident with bond zones 19a, 19b have a free length of about 95% or more (e.g., there is some adhesion of the core to the topsheet and chassis 17 along the edges of the core, as shown in Figure 7).

[0066] 17A and 17B, core 14 has an average width (lateral extent) designated by reference numeral 2000. However, only two portions of width 2000, specifically unbonded widths 7, are unbonded from chassis 17. Unbonded widths 7, taken together, are, for example, about 85% of width 2000, such that each unbonded width 7 is about 42.5% of width 2000, but are not limited thereto. That is, if width 2000 is 10 inches (25.4 cm), each unbonded width 7 is 4.25 inches (10.80 cm). A central portion of core 14 is bonded via bonded zone 19, designated bonded width 5. Along bonded width 5, core 14 may be 100% or nearly 100% restrained from vertical movement relative to chassis 17. However, along the unbound width 7, the core 14 may be about 95% unconstrained relative to the chassis 17, allowing it to move freely perpendicular to the chassis 17. Thus, along 100% of the length of the core 14, the free or unbound width is at least 85% of the width of the core 14.

[0067] Thus, each portion of the "free width" of core 14 is the percentage of the overall width of core 14 that is free to move vertically relative to the underlying stretchable chassis 17. Each portion of the free width can be free of bonded zones across its entire extent. As will be appreciated by those skilled in the art, similar calculations and / or approximations regarding the amount of unbonded length and / or width of each embodiment of core 14 (e.g., the embodiments shown in FIGS. 3A, 4A, 5A, and 6A) can be performed to define the length and width extent of core 14 that is free to move vertically relative to the underlying stretchable chassis 17 to determine each core's partial free length. In some aspects, core 14 has an unbonded free width that is at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 95% of the overall core width along a core length that is about 50%, about 60%, about 70%, about 80%, about 90%, or about 95% or more of the core's overall length. In some aspects, core 14 has an unbonded free width that ranges from 50% to 95% of the overall core width along a core length that ranges from 50% to 95% of the overall core length.

[0068] Referring to FIG. 3A , at the three bond zones 19a-19c, the free width is 80% or less of the core width. Between bond zones 19a-19c, the free width is greater than 95% of the core width. The longitudinal length of each bond zone 19a-19c accounts for approximately 3% of the core length. Thus, core 14 may be described as having a free width of 80% or less for the first 3% of the core length, greater than 95% for the next 45.5% of the core length, again less than 80% for the next 3% of the core length, greater than 95% for the next 45.5% of the core length, and finally, less than 80% for the last 3% of the core length. Alternatively, core 14 may also be described as having a free width greater than 80% or some average free width (80%-95%, possibly greater than 90%) for 100% of the core length.

[0069] 4A, one bonding zone 19, centered on core 14, has a length that is approximately 10% of the core length. Core 14 may be described as having a free width of greater than 95% along 45% of the core length on each side of bonding zone 19. Conversely, core 14 may be described as having a free length of 90% or less along 100% of the core width.

[0070] 6A, core 14 is bonded at three pairs of bond zones 19a-19c, each having a width of about 10% of the core width. Each bond zone 19a-19c has a length equal to about 5% of the core length. Thus, core 14 may be described as having a free length of up to 80% for 5% of the core length and greater than 95% for 42.5% of core 14.

[0071] Referring to FIG. 4A , the absorbent core 14 may have at least one “free region” that allows free movement relative to the underlying chassis 17. As shown in FIG. 3A , the core 14 has two free regions 3000. However, as will be understood by those skilled in the art, the core 14 may have more than two or fewer free regions. For example, FIG. 1A shows a core 14 with only one free region. Each free region coincides with an unbonded zone of the core 14. Within the perimeter of each free region 3000, there is no bonded zone that restricts movement of the core 14 relative to the chassis 17. Within the perimeter of the free region 3000, the core 14 is not uniformly or extensively bonded to the chassis 17. In some aspects, the core 14 has an unbonded free region that is greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95% of the total surface area of ​​the bottom surface 114 of the core 14. For example, 50 square inches (322.58 cm 2 A core having a total basal surface area of ​​25 square inches (161.30 cm) and an unbonded free area that is 50% of the total area of ​​the core would have an area of ​​25 square inches (161.30 cm). 2 ) has a non-bonded free surface area of

[0072] In some aspects, a void space is formed between the unattached, floating portion of the absorbent core 14 of the absorbent article 10 and the chassis 17. Such a void space will correspond to the free area, free width, and / or free length of the core 14. The void space 500 is shown in Figures 8, 9A, and 9B.

[0073] 9A and 9B, a void space 500 is formed between two layers of the absorbent article 10, specifically between the absorbent core 14 and the impermeable layer 13. The void space 500 is not limited to being positioned between the absorbent core 14 and the impermeable layer 13; the void space 500 may be positioned between other adjacent layers of the absorbent article 10, such as between the impermeable layer 13 and a layer of the chassis 17, such as the inner backsheet layer 12, as shown in and described in detail below with reference to FIGS. 17A and 17B. The void space 500 may be positioned on the side opposite the main body side 300 of the absorbent article 10. As used herein, the main body side 300 of the absorbent article 10 is the side of the absorbent article 10 that faces the crotch region of the user's body when the absorbent article 10 is worn by a user. In some aspects, no layer is positioned between the bottom surface 114 of the floating absorbent core 14 and the void space 500. In other respects, the impermeable layer 13 is the only layer positioned between the bottom surface 114 of the floating absorbent core 14 and the void space 500 .

[0074] The configuration and arrangement of the void space 500, including its shape, size, and volume, is determined, at least in part, by the location and arrangement of the bonds between the layers of the absorbent article 10 (e.g., the location and arrangement of the bond zones 19). The absorbent article 10 can have a single void space or multiple void spaces located in any of a variety of locations between the layers of the absorbent article 10. Figures 9A and 9B show an absorbent article 10 having a single, generally centrally located void space 500. Figure 8 shows an absorbent article 10 having two void spaces 500, each spaced generally from the center of the absorbent article 10 and located along the longitudinal edges 25a, 25b of the absorbent core 14. In some aspects of absorbent articles having multiple void spaces, at least some of the multiple void spaces are in direct fluid communication with others of the multiple void spaces. In another aspect of an absorbent article having multiple void spaces, each of the multiple void spaces is fluidly isolated (i.e., not in fluid communication with) others of the multiple void spaces. For example, bond regions 19 can seal each of the multiple void spaces from others of the multiple void spaces.

[0075] Void Space - Fluid Distribution and Ventilation

[0076] In some such aspects, the void space 500 provides a fluid distribution for liquid, gas, or both liquid and gas within the absorbent article 10. Fluid (liquid or gas) can enter the void space 500 from the absorbent core 14 and travel within the void space 500 to other portions of the absorbent article 10. For example, liquid can exit a saturated portion of the absorbent core 14, flow within the void space 500 to a less saturated portion of the absorbent core 14, and be reabsorbed into the absorbent core 14 at that less saturated portion.

[0077] In some aspects, the void space 500 has a configuration (e.g., shape) that directs liquid within the void space to and / or toward a desired location within the absorbent article 10. For example, the void space 500 can extend longitudinally, laterally, or a combination thereof to direct liquid flow therein longitudinally, laterally, or both. The void space 500 shown in Figure 8 can direct fluid flow toward the longitudinal edges of the absorbent article 10, whereas the void space formed by the absorbent article 10 of Figures 4A and 4B can direct fluid flow toward the side edges of the absorbent article 10.

[0078] 8, 9A, and 9B, in some aspects, fluid channels 200 are formed within the void space 500. The fluid channels 200 may be formed by elastic forces acting on the chassis 17 (i.e., by crinkling and / or gathering of the upper backsheet 12, lower backsheet 11, and impermeable layer 13). As a result of such crinkling and / or gathering, peaks 201 and valleys may be formed in the layers forming the chassis 17, where the valleys are fluid channels 200. Such fluid channels 200 may function to direct the flow of fluid within the void space 500 to desired locations within the absorbent article 10.

[0079] Thus, the void space 500 can function to aid in the distribution of fluid throughout the absorbent article 10. The void space 500 can also serve as a fluid retention zone in the absorbent article 10. For example, when the absorbent core 14 becomes saturated, the void space 500, in some respects, provides additional volume capacity for the retention of fluid within the void space 500.

[0080] The void space 500 may also provide for ventilation of gases from and through the absorbent article 10. Such ventilation of gases from and / or through the absorbent article 10 may facilitate drying of the absorbent article 10, or at least the absorbent core 14.

[0081] In some respects, the contour of the void space 500 can define or at least influence the contour of the absorbent core 14 positioned thereover. Thus, the contour of the void space 500 can define and / or influence the fluid retention and / or fluid distribution capabilities of the absorbent core 14.

[0082] Void space - improved fit

[0083] In some aspects, the provision of the void space 500 within the absorbent article 10 provides the absorbent article with an improved fit against a user's body when worn, as compared to an otherwise identical absorbent article without such a void space. For example, an absorbent article with a floating absorbent core and associated void space as described herein may result in a generally flatter absorbent core and topsheet of the absorbent article positioned against a user's body, as compared to an otherwise identical absorbent article without a floating absorbent core and associated void space.

[0084] Void space - below the impermeable layer

[0085] 17A and 17B, an absorbent article 10 is shown in which a bond zone 19 is positioned below the impermeable layer 13 and between the impermeable layer 13 and the outer chassis 17, more specifically between the impermeable layer 13 and the upper backsheet 12. In this regard, the impermeable layer 13 is floating and resiliently isolated from the chassis 17 in the same manner as described herein with respect to the floating and resiliently isolated absorbent core 14.

[0086] In some such aspects, the impermeable layer 13 blocks and / or impedes the passage of liquid into the void space 500, resulting in reduced and / or eliminated passage of liquid through the impermeable layer 13 into the void space 500. Thus, in some such aspects, with the void space 500 positioned between the impermeable layer 13 and the upper backsheet 12, the void space 500 either provides reduced fluid retention and / or fluid distribution properties compared to aspects having the void space 500 positioned between the absorbent core 14 and the impermeable layer 13, or provides a void space 500 with no fluid retention and / or fluid distribution properties.

[0087] In some such aspects, with the void space 500 positioned between the impermeable layer 13 and the upper backsheet 12, the void space 500 provides improved fit, gas ventilation and associated dryness of the absorbent article 10 or at least the absorbent core 14, or a combination thereof, as described elsewhere herein.

[0088] In some aspects, with the void space 500 positioned between the impermeable layer 13 and the outer chassis 17, the impermeable layer 13 is not rendered stretchable and / or elastically isolated from the chassis 17. Thus, in some such aspects, the impermeable layer 13 is not wrinkled, contracted, or gathered when the elastic members 21 of the chassis 17 are contracted, or at least is wrinkled, contracted, or gathered to a lesser extent when the elastic members 21 of the chassis 17 are contracted, compared to an otherwise identical absorbent article except that the void space is positioned between the absorbent core 14 and the impermeable layer 13 and the impermeable layer 13 is not rendered stretchable and / or elastically isolated from the chassis 17.

[0089] With the void space 500 positioned between the impermeable layer 13 and the outer chassis 17, the absorbent core 14 may be smoother and / or less prone to wrinkling and more comfortable to wear than an otherwise identical absorbent article except that the void space 500 is positioned between the absorbent core 14 and the impermeable layer 13.

[0090] Furthermore, in some such aspects, resistance between the impermeable layer 13 and the nonwoven layer or other layer of the outer chassis 17 (e.g., the upper backsheet 12) is reduced, thereby allowing the absorbent core 14 to more easily "float" above the chassis 17 and / or providing the absorbent core 14 with increased freedom of movement than would be the case in an otherwise identical absorbent article, except that no void space is positioned between the impermeable layer 13 and the chassis 17.

[0091] Aspects having a "floating" impermeable layer 13 exhibit minimized shrinkage and / or wrinkling of the impermeable layer 13 caused by its connection with the elastic of the outer chassis 17. Additionally, in some such aspects, all layers connected above the impermeable layer 13 (e.g., the topsheet 15 and the absorbent core 14) also exhibit reduced or eliminated shrinkage and / or wrinkling and / or gathering. As a result of such reduced or eliminated shrinkage, wrinkling, and / or gathering, the absorbent core 14 has a generally flat body-facing surface (flat appearance) when worn against the user's body and the topsheet 15 has a generally flat appearance when worn against the user's body.

[0092] In such an embodiment, the stretchable outer chassis 17 is free to contract and conform to the wearer's anatomy while the surfaces of the absorbent article 10 (topsheet 15 and core 14) remain unaffected or only minimally affected by the stretchability of the outer chassis 17, so that the topsheet 15 and core 14 remain generally flat against the wearer's body.

[0093] Void Space - Dynamic Properties

[0094] In some aspects, the void space 500 exhibits dynamic properties, including, but not limited to, dynamic volume, dynamic shape, dynamic fluid distribution properties, dynamic fluid retention properties, dynamic ventilation and absorbent core dryness properties, or combinations thereof. As used herein, the term "dynamic properties" refers to properties that change dynamically. For example, such dynamic properties can change with the interaction of the void space 500 configuration with the user's body movements and forces acting on the absorbent article 10. Furthermore, the void space 500 and absorbent core 14 dynamically respond to body movements and external forces, including torsional, compressive, and elastic forces.

[0095] 18A-19B, various body movements are shown that can impart forces that affect the void space 500 and the absorbent core 14. FIG. 18A shows the wearer 400 in a first position with the wearer's legs generally extended downward and generally aligned with the wearer's torso. In the first position, a stretching force 600 is exerted on the front portion of the absorbent article 10, and a compressive force 700 is exerted on the rear portion of the absorbent article 10. Such forces resulting from the wearer's body movements will be exerted on the elastics of the chassis of the absorbent article 10. However, because the absorbent article has a floating absorbent core, the transmission of such forces to the floating absorbent core is reduced or eliminated compared to an otherwise identical absorbent article except that the absorbent core was not "floating." FIG. 18B shows the wearer 400 in a second position with the wearer's legs extended outward toward the front of the wearer's body relative to the first position. In this second position, a compressive force 700 is exerted on the front portion of the absorbent article 10, and a stretching force 600 is exerted on the rear portion of the absorbent article 10. Figure 18C shows the wearer 400 in a third position with the wearer's legs extended further outward toward the front of the wearer's body relative to the second position. In the third position, a compressive force 700 is exerted on the front portion of the absorbent article 10, and a stretching force 600 is exerted on the rear portion of the absorbent article 10. Figure 19A shows the wearer 400 in a fourth position with the wearer's legs extended downward and generally aligned with the extent of the wearer's torso. In the fourth position, a compressive force 700 is exerted generally on the front crotch region of the absorbent article 10. Figure 19B shows the wearer 400 in a fifth position with the wearer's legs extended outward from the wearer's body and generally angled relative to the extent of the wearer's torso relative to Figure 19A. In the fifth position, the stretching force 600 is exerted entirely on the front crotch region of the absorbent article 10 .

[0096] When the region of the absorbent article 10 containing the floating section of the floating absorbent core 14 is stretched, the void space 500 closes or at least contracts in volume. When the region of the absorbent article 10 containing the floating section of the floating absorbent core 14 is compressed and the elastic members 21 are relaxed, the void space 500 opens or at least expands in volume. In some aspects, the void space 500 is never fully open or fully closed. While worn by a wearer, the configuration of the void space 500 can vary through a continuum of configurations located between a fully open state and a fully closed state, depending on the amount of stretch and / or compression applied to any particular portion of the floating absorbent core 14.

[0097] Figure 20A shows the absorbent article 10 in a relaxed, compressed (i.e., contracted) state, and Figure 20B shows the absorbent article 10 of Figure 20A but in a stretched, elongated state. With reference to Figures 20A and 20B, exemplary effects of various forces acting on the absorbent article 10 are shown. The configuration of the void space 500 may be determined or influenced at least in part by the elastic state (e.g., stretched or contracted state) of the elastic members 21 when they impart potential energy to portions of the absorbent article 10, and thus the void space 500 dynamically changes with the wearer's movements (i.e., greater stretch results in greater tensile forces being applied to the elastic, thereby causing a decrease in the volume of the void space). In the relaxed compressed state, the void space 500 is generally in an open configuration, with the absorbent core 14 floating above the outer chassis (which in this case includes the impermeable layer 13, the upper backsheet 12, and the lower backsheet 11) forming the void space 500. In contrast, in the stretched state, the absorbent core 14 is positioned closer to the outer chassis, such that the void space 500 is generally in a closed configuration, with the volume and / or size of the void space 500 reduced or eliminated. Thus, the volume of the void space 500 in the stretched state is reduced relative to the volume of the void space 500 in the relaxed compressed state. In some aspects, the volume of the void space 500 is completely eliminated in the stretched state, such that the void space 500 no longer exists in the stretched state. Additionally, the width 800 of the absorbent article 10 in the stretched, elongated state is greater overall than the width in the relaxed, compressed state because each of its layers is stretched.

[0098] The fluid channels 200 are also modified in the stretched state relative to the relaxed, compressed state. As the elastic members 21 are stretched and elongated, the remainder of the outer chassis is also stretched and elongated. With the elastic members 21 in a relaxed, compressed (i.e., contracted) state, the remainder of the outer chassis becomes gathered and / or wrinkled because these portions of the outer chassis are attached (e.g., attached) to the elastic members 21, and therefore the elastic forces (both compressive and elongated) of the elastic members 21 act on the outer chassis. As described elsewhere herein, such gathering and / or gathering results in the formation of, in some respects, peaks 201 and valleys (fluid channels 200). As a result of the stretching and elongation of the outer chassis via the stretching and elongation of the elastic members 21, the depth of the valleys forming the fluid channels 200 decreases. In some aspects, the elastic members 21 and outer chassis may be stretched sufficiently to eliminate such peaks 201 and valleys, such that the fluid channels 200 do not exist in the stretched, elongated state, as shown in FIG. 20B. When the valleys are flattened, they exert a force on any liquid present in the fluid channels 200, causing the liquid to be directed along the fluid channels 200 to another location within the absorbent article (e.g., into the void spaces 500 or reabsorbed into the absorbent core 14). The fluid channels 200 may be oriented laterally, longitudinally, at an angle relative to both the lateral and longitudinal extent of the floating absorbent core 14, or a combination thereof. The direction of the extent of the fluid channels 200 and / or void spaces 500 may be designed to direct the flow of fluid within the fluid channels 200 and / or void spaces 500 to a desired location.

[0099] When the upper portion of the absorbent article 10 (in this case including the topsheet 15 attached to the absorbent core 14) is only partially attached (e.g., not glued) to the outer chassis of the absorbent article 10, the elastic force of the elastic member 21 is not transmitted to the topsheet 15 and absorbent core 14, or is transmitted to at least the topsheet 15 and absorbent core 14 to a lesser extent than when such elastic force is transmitted to the outer chassis, and is transmitted to the topsheet 15 and absorbent core 14 to a lesser extent than in an otherwise identical absorbent article except that the absorbent core 14 is not floating.

[0100] As the absorbent article moves from a relatively relaxed, compressed state (FIG. 20A) to a relatively elongated, stretched state (FIG. 20B) in which fluid (liquid and / or gas) is present within the void space 500, the relative movement of the absorbent core 14 toward the outer chassis at least partially closes the void space 500 and applies a force (a void-closing force) to the fluid within the void space 500. In some such aspects, the liquid is directed by such force to flow within the void space 500 to another location within the void space 500, or to be absorbed into the absorbent core 14, or a combination thereof.

[0101] Changing the void space 500 from a relatively closed configuration to a relatively open configuration can facilitate ventilation and / or drying of the absorbent article 10. In some such aspects, gas present within the void space 500 is directed by such forces to another location within the void space 500 for absorption into the absorbent core 14, for ventilation to the exterior of the absorbent article 10, or a combination thereof. When the void space 500 moves from a relatively closed configuration to a relatively open configuration, such opening of the void space 500 can create a vacuum force that draws air (e.g., from the exterior of the absorbent article 10), thereby facilitating ventilation and / or drying of portions of the absorbent article 10 (e.g., the absorbent core 14).

[0102] In some aspects, the absorbent article 10 cycles between a relatively elongated, expanded configuration and a relatively relaxed, compressed configuration when various forces, such as forces resulting from various movements of the wearer's body, are applied to the absorbent article 10. In such aspects, the void space 500 cycles between a relatively closed configuration and a relatively open configuration in response to various forces, such as forces resulting from various movements of the wearer's body, being applied to the absorbent article 10. This cycling of the void space 500 between open and closed configurations facilitates the continuation of cyclical ventilation, fluid distribution, fluid retention, or a combination thereof, throughout the period that the absorbent article 10 is worn by the wearer.

[0103] Figure 21A shows the absorbent article 10 in a relaxed, compressed (i.e., contracted) state, with the direction of the compressive (contraction) force 700 applied to the absorbent article indicated, and fluid flow lines 203 indicating the direction of fluid flow within the void space 500. As the elastic members 21 are stretched and elongated, the floating absorbent core 14 is compressed toward the outer chassis of the absorbent article 10, causing fluid to flow within the void space 500, for example, along the fluid flow lines 203. Figure 21B shows the absorbent article 10 of Figure 21A, but in a stretched, elongated state.

[0104] Thus, the void space 500 may be created through active stretch either from the floating absorbent core 14 or by interaction with the floating absorbent core 14 coupled (at a separate location) to the stretchable chassis 17 as various forces cause the void space 500 to open (i.e., open) or close (i.e., close). Such active stretch can create a void space that repeatedly cycles between a low-volume (flattened / stressed) and a high-volume (pillow-like / unstressed) configuration. This repeated cycling of the void space 500 between open and closed or low-volume and high-volume configurations acts as an active "pump" that pushes fluid along and into the void space 500, thereby creating a bellows effect that results in increased liquid distribution and gas ventilation. This bellows effect created as the wearer moves about causes the void space 500 to open and close, thereby allowing ventilation or even pumping of air through and around the chassis 17 of the absorbent article. Increased ventilation within the void space 500 results in a lower relative humidity in the microclimate at and around the wearer's skin, thereby resulting in lower skin hydration. Thus, increased ventilation can increase comfort for the wearer of the absorbent article. The bellows effect can direct fluid away from the bond points between the floating absorbent core 14 and the chassis 17. In configurations where the bond zone 19 is in the center of the floating absorbent core 14 (FIG. 8), fluid is directed toward the sides and longitudinally. In configurations with bond zones 19 positioned at the sides of the floating absorbent core 14, fluid may be directed toward the center and longitudinally of the floating absorbent core 14.

[0105] Mechanisms for dynamic changes (e.g., changes in volume, shape, contour) within the void space 500 include, but are not necessarily limited to, loads (e.g., compression) applied to the absorbent article 10 due to the relative position and movement of the wearer's body. Such movement causes changes in the void space 500, at least in part because such movement applies forces to the elastic members 21 of the stretchable chassis 17, which in turn apply stretching and pulling forces to the elastic members 21, which in turn cause the floating absorbent core 14 to flatten or pillow.

[0106] Void spaces - formed under an impermeable layer

[0107] 22, in some aspects, a void space is formed below the impermeable layer 13. The impermeable layer 13 may be attached (e.g., glued or otherwise laminated) to the bottom surface of the floating absorbent core 14 such that the impermeable layer 13 floats with the floating absorbent core 14 positioned above the stretchable chassis 17, forming a void space 500 between the impermeable layer 13 and the bottom surface of the floating absorbent core 14. In some such aspects, the impermeable layer 13 is attached to the floating absorbent core 14 in a side-by-side relationship.

[0108] The void space 500 formed under the impermeable layer 13 can serve as a conduit for moist air that has exited the impermeable layer 13 (e.g., a breathable barrier film), facilitating the exit of the absorbent article 10. Such ventilation in the skin microclimate promotes dryness and reduces skin hydration for better skin health. In addition, the separation between the impermeable layer 13 and the outer nonwoven fabric of the stretchable chassis (i.e., the upper backsheet 12) can reduce the damp and clammy feeling on the outer surface of the absorbent article 10 caused by vapor condensation.

[0109] Void Space-Connecting Pattern

[0110] In some aspects, the dynamic properties (i.e., responsiveness to forces and cycling through configurations) of the floating absorbent core 14 and associated void space 500 can be modified and / or improved by configuring the bond pattern (i.e., by designing the spacing, placement, and / or alignment of bond zones 19) between the floating absorbent core 14 and the outer chassis underlying the absorbent article 10. Such configuration of the bond pattern between the floating absorbent core 14 and the outer chassis underlying the absorbent article 10 can be used to change the shape, volume, relative placement, size of the floating absorbent core 14 and void space 500 within the absorbent article 10, responsiveness to forces (e.g., elastic and other forces exerted by body movement), or a combination thereof.

[0111] Increasing the degree of bonding of the absorbent core 14 to the outer chassis underlying the absorbent article 10 (i.e., more and / or wider bond zones 19) reduces the level of "float" of the absorbent core 14, resulting in the absorbent core 14 being more elastically bonded to the elastic members 21 (compared to a lower degree of bonding). The bonding pattern of the floating absorbent core 14 to the stretchable chassis 17 will, at least in part, define the void space 500 and the floating absorbent core 14. The bonded areas of the floating absorbent core 14 will be wrinkled by contraction of the elastic members 21 of the stretchable chassis 17, whereas the unbonded areas of the floating absorbent core 14 will not be wrinkled or will wrinkle to a lesser extent than the bonded areas. In some aspects, increasing the degree of bonding of the floating absorbent core 14 to the stretchable chassis 17 can create a bond pattern that exists between the absorbent core 14 and the outer chassis underlying the absorbent article 10 and is configured to promote fluid retention, fluid distribution, breathability, or a combination thereof. For example, the bond pattern between the absorbent core 14 and the outer chassis underlying the absorbent article 10 can be configured to direct fluid flow within the void space 500 to specific locations within the absorbent article 10. The bond pattern between the absorbent core 14 and the outer chassis underlying the absorbent article 10 can be designed and / or configured to create fluid retention zones within the void space 500. Thus, by configuring the bond pattern between the absorbent core 14 and the outer chassis underlying the absorbent article 10, the design of the absorbent article 10 can be optimized to advantageously combine the features and benefits of the floating absorbent core 14 with the features and benefits of the void space 500 defined by the particular bond pattern (e.g., enhanced fluid retention and / or fluid distribution and / or breathability characteristics).

[0112] The bond pattern between the absorbent core 14 and the outer chassis underlying the absorbent article 10 may be designed and / or configured to form pillows of the floating absorbent core 14. As used herein, the term "pillow" refers to a floating absorbent core having a void space formed beneath the floating absorbent core and defined by one or more bond zones. For example, the floating absorbent core 14 in Figures 9A and 9B is a single pillow-type floating core, while the floating absorbent core 14 in Figure 8 is a double pillow-type floating core that defines two void spaces, each defined by bond zones 19.

[0113] In some aspects, the floating absorbent core 14 provides cushioning, such as with pillows, to the wearer of the absorbent article 10. As forces are exerted on the topsheet 15 and absorbent core 14 through the wearer's body, the topsheet 15 and absorbent core 14 respond by moving relatively toward the outer chassis of the absorbent article 10. The compression of the pillow-shaped structure cushions the interaction between the wearer's body and the absorbent article 10. Thus, the floating absorbent core 14 provides improved fit and comfort to the wearer.

[0114] In some aspects, the bond (e.g., bond line) between the floating absorbent core 14 and the stretchable chassis 17 extends laterally, longitudinally, at an angle relative to both the lateral and longitudinal extent of the floating absorbent core 14, or a combination thereof. In some aspects, the bond line between the floating absorbent core 14 and the chassis 17 is linear, non-linear (e.g., curved), or a combination thereof.

[0115] In some aspects, the bond between the floating absorbent core 14 and the stretchable chassis 17 may be configured to provide a longitudinally oriented and longitudinally extending void space 500. A longitudinally oriented and longitudinally extending void space 500 allows fluid to flow longitudinally within the void space, thereby allowing for more complete utilization of the absorbent core 14 compared to a laterally oriented and laterally extending void space, which may result in fluid leakage along the sides of the void space 500 of the absorbent article 10.

[0116] In some aspects, the bond between the floating absorbent core 14 and the stretchable chassis 17 may be configured to provide a non-linear void space that can direct liquid to specific areas within the floating absorbent core 14, such as the distal ends (e.g., toward the waist), thereby achieving full utilization of the absorbent core 14.

[0117] As will be apparent to one skilled in the art, the void spaces 500 disclosed herein provide a mechanism for moving liquid and / or air within the absorbent article 10 .

[0118] Void Spaces - Treatment and Retrofitting

[0119] In some aspects, one or more treatments or modifications of the void space 500 can provide desired improvements to the void space. For example, but not by way of limitation, a wettable surface can be formed within the void space 500, thereby allowing for rapid and efficient fluid movement within the void space. The wettable surface can be formed on one or more of the surfaces forming the interior walls of the void space 500.

[0120] For example, in FIG. 9A , the top or body-facing surface of the impermeable layer 13, where the ridges 201 and fluid channels 200 are formed, can be a wettable surface. In such configurations having a void space 500 formed between the floating absorbent core 14 and the impermeable layer 13 (e.g., a polyethylene barrier film), fluid distribution characteristics can be improved by modifying the impermeable layer 13 to make it wettable. In some such aspects, all or at least a portion of the inner surface area of ​​the impermeable layer 13, which constitutes a portion of the interior wall of the void space 500, can be modified to be wettable. As will be appreciated by those skilled in the art, various techniques can be used to impart wettable properties to materials, including, but not limited to, adding surfactants to the surface and corona or plasma treating the surface. In the case of microporous films, such as filled PE films, treatment conditions can be optimized to minimize any reduction in liquid barrier properties. In some aspects, the impermeable layer 13 is formed of a material (e.g., an integral barrier film) that is inherently breathable and wettable. For example, certain grades of polyethylene block amide (PEBA) function as a wettable, breathable liquid barrier, and such PEBA can be used in place of a microporous polyethylene (PE) film. The use of such a wettable, impermeable layer 13 within the void space 500 provides additional fluid distribution characteristics to the void space 500.

[0121] Method for manufacturing absorbent articles

[0122] The absorbent article 10 can be manufactured by methods known to those skilled in the art, such as those disclosed in U.S. Pat. Nos. 7,462,172, 7,361,246, and 8,148,598, and U.S. Patent Application Publication Nos. 2012 / 0071852, 2014 / 0303582(A1), and 2014 / 0276508, each of which is incorporated by reference in its entirety.

[0123] In some aspects, a method of manufacturing an absorbent article disclosed herein includes attaching (e.g., bonding) an absorbent core to a stretchable chassis by one or more separate bond zones so that at least a portion of the absorbent core floats above the underlying stretchable chassis, with a void space disposed between the absorbent core and the stretchable chassis. The method may include configuring the separate bond zones (size, shape, and location) to provide a void space having a desired shape, size, volume, contour, and fluid distribution, retention, and breathability characteristics, as described above. The method may include elasticizing the chassis of the absorbent article and at least partially isolating the floating absorbent core from the stretchable chassis. In some aspects, the method includes forming the absorbent article as a three-piece diaper.

[0124] The method may include the step of designing the configuration of the void space and / or floating absorbent core so that the configuration of the void space and / or floating absorbent core responds to movement by a wearer of the absorbent article. In some such aspects, the void space and / or floating absorbent core is designed and / or configured to cycle the void space between open and closed configurations or between low-volume and high-volume configurations.

[0125] The absorbent article formed by this method may be any of the absorbent articles disclosed herein and may have any or all of the structural and / or functional characteristics described herein, including, but not limited to, the structural and / or functional characteristics of the absorbent articles shown in any of Figures 1A-22.

[0126] While the present embodiments and advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made to such embodiments without departing from the spirit and scope of the present invention as set forth in the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the processes, machines, manufacture, compositions of matter, means, methods, and steps described in the specification. Those skilled in the art will be readily able to utilize, in accordance with the present disclosure, existing or later-developed processes, machines, manufacture, compositions of matter, means, methods, or steps that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein. Accordingly, the present invention as set forth in the appended claims is intended to include within its scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims

1. An absorbent article comprising: an absorbent core composite including an absorbent core and a stretchable chassis, wherein the absorbent core is joined to the stretchable chassis by at least one separate bonded zone that joins the absorbent core to the stretchable chassis and imparts elasticity to the absorbent core; the absorbent core includes at least one unbonded zone that is not joined to the stretchable chassis, the bonded zone including a surface area of ​​a bottom side of the absorbent core that is joined to the stretchable chassis, the unbonded zone including a surface area of ​​the bottom side of the absorbent core that is not joined to the stretchable chassis; multiple void spaces are formed between the surface area of ​​the bottom side of the absorbent core and the stretchable chassis, each of the multiple void spaces being sealed along its longitudinal edge such that each void space is isolated from the other void spaces of the multiple void spaces along its longitudinal edge; and the multiple void spaces are positioned to receive liquid from the absorbent core and direct liquid flow within the absorbent article.

2. The absorbent article of claim 1 , wherein the surface area of ​​the bottom surface of the absorbent core that is not connected to the elastic chassis is not restrained by the elastic chassis and can move relative to the elastic chassis.

3. The absorbent article of claim 1, wherein the surface area of ​​the bottom surface of the absorbent core that is not bonded to the elastic chassis has an unbonded free width ranging from 50% to 95% of the width of the absorbent core for a core length that is greater than 50% of the total length of the absorbent core.

4. The absorbent article of claim 1, wherein the surface area of ​​the bottom surface of the absorbent core that is not bonded to the elastic chassis has an unbonded free area equal to more than 50% of the surface area of ​​the bottom surface of the absorbent core.

5. 2. The absorbent article of claim 1, wherein the surface area of ​​the bottom surface of the absorbent core that is not bonded to the elastic chassis has an unbonded free width ranging from 70% to 95% of the total width of the absorbent core for a core length ranging from 60% to 95% of the total length of the absorbent core.

6. The absorbent article of claim 1 , wherein the stretchable chassis has a plurality of laterally stretched elastics.

7. 7. The absorbent article of claim 6, wherein said bond zones bond said absorbent core to said stretchable chassis at areas of said stretchable chassis that do not include said plurality of laterally stretched elastics.

8. The absorbent article of claim 1 , wherein the absorbent core incorporates one or more elastic members.

9. The absorbent article of claim 8 , wherein the elastic members of the absorbent core are separated from the elastic members of the stretchable chassis.

10. The absorbent article of claim 1 , wherein the lower surface of the absorbent core includes an embossed pattern that forms a channel between the absorbent core and the stretchable chassis.

11. 2. The absorbent article of claim 1, wherein when the elastic body of the stretchable chassis is in a contracted state, one of the multiple void spaces is positioned between the absorbent core and the stretchable chassis, and the void space coincides with the non-bonded zone of the absorbent core.

12. 2. The absorbent article of claim 1, further comprising an impermeable layer positioned between the stretchable chassis and the plurality of void spaces, wherein each of the plurality of void spaces is isolated from the other void spaces of the plurality of void spaces.

13. 12. The absorbent article of claim 11, wherein when the elastic of the stretchable chassis is in the contracted state, the stretchable chassis is wrinkled or pleated such that peaks and valleys are formed in the stretchable chassis, and the valleys form fluid channels within the void spaces of the multiple void spaces.

14. The absorbent article of claim 11 , wherein said void spaces of said multiple void spaces comprise at least one fluid retention zone.

15. 12. The absorbent article of claim 11, wherein the void spaces of the multiple void spaces have dynamic properties including dynamic volume, dynamic shape, dynamic fluid distribution characteristics, dynamic fluid retention characteristics, dynamic ventilation and drying characteristics, or combinations thereof, which dynamic properties change dynamically in response to stretching and contraction of the elastic body of the stretchable chassis.

16. The absorbent article of claim 11 , wherein the bond pattern of the bond zones at least partially defines the contours of the void space and the absorbent core.

17. An absorbent article comprising: an absorbent core; a stretchable chassis that imparts elasticity to the absorbent core at one or more bond zones; an absorbent article comprising: a plurality of void spaces formed between the stretchable chassis and a bottom surface of the absorbent core, the void spaces coinciding with unbonded zones of the absorbent core where the absorbent core is not bonded to the stretchable chassis; each of the plurality of void spaces being sealed along its longitudinal edges such that each void space is isolated from the other void spaces of the plurality of void spaces along its longitudinal edges; and the plurality of void spaces being positioned to receive liquid from the absorbent core and direct liquid flow within the absorbent article.

18. 1. A method of manufacturing an absorbent article, comprising: bonding an absorbent core to a stretchable chassis at one or more separate bond zones, such that the absorbent core is unbonded from the stretchable chassis at one or more unbonded zones that are not bonded to the stretchable chassis; a surface area of ​​the bottom surface of the absorbent core in the bonded zone is bonded to the stretchable chassis, and a surface area of ​​the bottom surface of the absorbent core in the non-bonded zone is not bonded to the stretchable chassis; a plurality of void spaces are formed between the absorbent core and the stretchable chassis, each of the plurality of void spaces being sealed along its longitudinal edges such that each void space is isolated from the other void spaces of the plurality of void spaces along its longitudinal edges, the plurality of void spaces being positioned to receive liquid from the absorbent core and direct liquid flow within the absorbent article.

19. 2. The absorbent article of claim 1, wherein the bonded zone occupies 5% to 40% of the surface area of ​​the bottom surface of the absorbent core that is bonded to the stretchable chassis, and the non-bonded zone occupies 60% to 95% of the surface area of ​​the absorbent core that is not bonded to the stretchable chassis.

20. 19. The method of claim 18, wherein between 5% and 40% of the surface area of ​​the bottom surface of the absorbent core is bonded to the stretchable chassis, and between 60% and 95% of the surface area of ​​the bottom surface of the absorbent core is not bonded to the stretchable chassis.

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