Absorbent article having a shaped, flexible, and textured nonwoven fabric

Abstract

An absorbent article is provided that includes a shaped, flexible, and textured nonwoven fabric. The nonwoven fabric can be the topsheet and outer cover nonwoven fabric material of the absorbent article. A portion of the topsheet's wearer-facing surface can have a TS7 in the range of about 1 dBV2rms, from about 1 to about 4.5 dBV2rms, and a TS750 in the range of about 6 dBV2rms to about 30 dBV2rms. A portion of the outer cover nonwoven fabric material's garment-facing surface can have a TS7 in the range of about 1 dBV2rms, from about 1 to about 4.5 dBV2rms, and a TS750 in the range of about 6 dBV2rms to about 30 dBV2rms. The nonwoven fabric of the present disclosure provides a textured, flexible material.

Description

[Technical Field]

[0001] The present disclosure is directed to absorbent articles having shaped, flexible, and textured nonwovens. [Background technology]

[0002] Absorbent articles are used to contain and absorb bodily wastes (i.e., urine, feces, and menstruation) from infants, children, and adults. Absorbent articles can include, but are not limited to, diapers, pants, adult incontinence products, feminine care products, and absorbent pads. Various components of these absorbent articles contain nonwoven fabrics. Two exemplary components that contain nonwoven fabrics are the outer cover nonwoven material and the topsheet. Consumers desire these two components, which form at least a portion of the garment-facing and wearer-facing surfaces of the absorbent article, to have a certain appearance and feel while still providing superior performance. Superior performance for the topsheet can be a soft feel while also having texture for bodily waste management, breathability, and skin dryness. Superior performance for the outer cover nonwoven material can be an aesthetically pleasing texture that conveys softness and gentleness while being tactilely soft to the touch. Texture and softness are important attributes desired by consumers in these two components. However, typically, more textured nonwovens are less soft and vice versa, so nonwovens need improvement. Summary of the Invention [Means for solving the problem]

[0003] The present disclosure provides absorbent articles comprising shaped, flexible, and textured nonwovens that resolve the tradeoff between texture and softness. Typically, more textured nonwovens have less softness. Similarly, more soft nonwovens typically have very little, if any, texture. The present disclosure provides a solution to that problem by providing absorbent articles comprising nonwovens with high softness and high texture. The present disclosure further provides a solution that resolves the tradeoff between high softness and high texture while providing several improvements in fluid handling, including rapid penetration of bodily exudates and enhanced skin and topsheet dryness. Typically, the nonwovens of the present disclosure may form at least a portion of the wearer-facing surface (e.g., topsheet) and at least a portion of the garment-facing surface (e.g., outer cover nonwoven material). Softness, texture (i.e., smoothness), and / or stiffness can be measured with an Emtec Tissue Softness Analyzer according to the Emtec test herein. Tactile softness is measured as TS7. Texture / Smoothness is measured as TS750. Stiffness is measured as D. [Brief explanation of the drawings]

[0004] The above and other features and advantages of the present disclosure, as well as the manner in which they are realized, will become more apparent, and the disclosure itself will be better understood, by referring to the following description of exemplary embodiments of the present disclosure in conjunction with the accompanying drawings. [Figure 1] FIG. 1 is a photograph of an example nonwoven fabric of the present disclosure. [Figure 2] FIG. 1 is a photograph of an example nonwoven fabric of the present disclosure. [Figure 3] FIG. 1 is a photograph of an example nonwoven fabric of the present disclosure. [Figure 4] FIG. 4 is a cross-sectional view of a portion of a nonwoven fabric of the present disclosure taken around line 4-4 in FIG. 1. [Figure 5A] FIG. 1 is a schematic diagram showing the cross section of a filament made of a primary component A and a secondary component B in a side-by-side arrangement. [Figure 5B]FIG. 1 is a schematic diagram showing a cross section of a filament made with a primary component A and a secondary component B in an eccentric sheath / core arrangement. [Figure 5C] FIG. 1 is a schematic diagram showing the cross section of a filament made with a primary component A and a secondary component B in a concentric sheath / core arrangement. [Figure 6] FIG. 1 is a perspective photograph of a trilobal bicomponent fiber. [Figure 7] FIG. 1 is a schematic diagram of an example apparatus for making a nonwoven fabric of the present disclosure. [Figure 8] FIG. 8 is a detailed partial view of the apparatus of FIG. 7 for bonding a portion of a fabric of the present disclosure. [Figure 9] 9 is a further partial detail of an apparatus for bonding a portion of a nonwoven fabric of the present disclosure taken from the detail of FIG. 8 of FIG. [Figure 10] FIG. 1 is a detailed partial view of an apparatus for optionally further bonding a portion of a nonwoven fabric of the present disclosure. [Figure 11] FIG. 1 is a photograph of an example nonwoven fabric of the present disclosure. [Figure 12] FIG. 1 is a photographic representation of a portion of a forming belt useful for forming nonwoven fabrics of the present disclosure. [Figure 13] 13 is a cross-sectional view of a portion of the forming belt of FIG. 12. [Figure 14] 13 is an image of a portion of a mask utilized to create at least a portion of the forming belt of FIG. 12. FIG. [Figure 15] 17 is an image of a portion of a mask utilized to create at least a portion of the forming belt of FIG. 16. [Figure 16] FIG. 1 is a photographic representation of a portion of a forming belt useful for forming nonwoven fabrics of the present disclosure. [Figure 17] 19 is an image of a portion of a mask utilized to create at least a portion of the forming belt of FIG. 18. [Figure 18] FIG. 1 is a photographic representation of a portion of a forming belt useful for forming nonwoven fabrics of the present disclosure. [Figure 19] FIG. 1 is a photographic representation of a portion of a forming belt useful for forming nonwoven fabrics of the present disclosure. [Figure 20]20 is an image of a mask utilized to create at least a portion of the forming belt of FIG. 19. [Figure 21] FIG. 20 is a photographic representation of a nonwoven fabric of the present disclosure made on the forming belt of FIG. 19. [Figure 22] FIG. 1 is a schematic perspective view of a forming belt of the present disclosure. [Figure 23] FIG. 1 is a plan view of a nonwoven substrate comprising a nonwoven fabric of the present disclosure. [Figure 24] FIG. 1 is a plan view of a nonwoven substrate comprising a nonwoven fabric of the present disclosure. [Figure 25] FIG. 1 is a photograph of an example nonwoven fabric of the present disclosure. [Figure 26] FIG. 26 is a photograph of a cross section of the nonwoven fabric of the example of FIG. 25. [Figure 27] 1 is a perspective micro-CT image of an example nonwoven fabric of the present disclosure. [Figure 28] 1 is a perspective micro-CT image of an example nonwoven fabric of the present disclosure. [Figure 29] 29 is a micro-CT image of a cross section of the nonwoven fabric of the example of FIGS. 27 and 28. [Figure 30] 29 is a micro-CT planar image of the nonwoven fabric of the example of FIGS. 27 and 28. FIG. [Figure 31] FIG. 1 is a graphical depiction of various advantages of the nonwoven fabrics of the present disclosure. [Figure 32] FIG. 1 is a photograph of a portion of an example nonwoven fabric of the present disclosure. [Figure 33] FIG. 1 is a photograph of a portion of an example nonwoven fabric of the present disclosure. [Figure 34] FIG. 1 is a photograph of a portion of an example nonwoven fabric of the present disclosure. [Figure 35] FIG. 1 is a photograph of a portion of an example nonwoven fabric of the present disclosure. [Figure 36] FIG. 36 is a photograph of a cross section of the nonwoven fabric of the example of FIG. 35. [Figure 37] FIG. 1 is a photograph of a portion of an example nonwoven fabric of the present disclosure. [Figure 38] FIG. 1 is a photograph of a portion of an example nonwoven fabric of the present disclosure. [Figure 39] FIG. 1 is a photograph of a portion of an example nonwoven fabric of the present disclosure. [Figure 40] FIG. 1 is a photograph of a portion of an example nonwoven fabric of the present disclosure. [Figure 41] 29 is a micro-CT planar image of the nonwoven fabric of the example of FIGS. 27 and 28 after further processing. [Figure 42] FIG. 42 is a graphical depiction of various advantages of the nonwoven fabric of FIG. 41. [Figure 43] FIG. 1 is a diagram of an example page containing multiple absorbent articles. [Figure 44] FIG. 1 is a front perspective view of an absorbent article comprising one or more nonwoven fabrics. [Figure 45] FIG. 45 is a rear perspective view of the absorbent article of FIG. 44. [Figure 46] 1 is a pattern of an example of a nonwoven topsheet of the present disclosure. [Figure 47] 1 is a pattern of an example of a nonwoven topsheet of the present disclosure. [Figure 48] 1 is a pattern of an example of a nonwoven topsheet of the present disclosure. [Figure 49] 1 is a pattern for one example of an outer cover nonwoven material of the present disclosure. [Figure 50] 1 is a pattern for one example of an outer cover nonwoven material of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0005] Various non-limiting embodiments of the present disclosure will now be described to provide a comprehensive understanding of the principles of structure, function, manufacture, and use of the reversible and configurable absorbent articles disclosed herein. One or more examples of these non-limiting embodiments are shown in the accompanying drawings. Those skilled in the art will understand that the reversible and configurable absorbent articles described herein and illustrated in the accompanying drawings are non-limiting embodiments, and that the scope of the various non-limiting embodiments of the present disclosure is defined only by the claims. Features shown or described with respect to one non-limiting embodiment may be combined with features of other non-limiting embodiments. Such modifications and variations are intended to be within the scope of the present disclosure.

[0006] The present disclosure provides a molded, flexible, textured nonwoven fabric formed in a single forming process with continuous spunbond filaments directly on a shaped forming belt. The nonwoven fabric of the present disclosure can conform to the shape of the forming belt. The nonwoven fabric of the present disclosure resolves the tradeoff between softness and texture, providing high softness while also providing high texture.

[0007] Photographs of a representative example of a shaped nonwoven fabric 10 are shown in Figures 1-3. The shaped nonwoven fabric may be used, for example, as a topsheet and / or outer cover nonwoven material. The shaped nonwoven fabric may also be used as other nonwoven components of absorbent articles or in other consumer products such as, for example, cleaning and dusting products and medical gowns.

[0008] Molded nonwoven fabric 10 can be a spunbond nonwoven substrate having a first surface 12 and a second surface 14. In Figures 1-3, second surface 14 faces the viewer and is opposite first surface 12, not visible in Figures 1-3 but shown in Figure 4. The term "surface" is used broadly to refer to both sides of the web for purposes of description and is not intended to imply any necessary flatness or smoothness. Molded nonwoven fabric 10 is soft and flexible, but will be described in its flat state relative to one or more XY planes, as shown in Figures 1-3, which are parallel to the flat state and correspond to the cross-machine direction (CD) and machine direction (MD) planes, respectively, in web manufacturing technology. The length L in the MD direction and the width W in the CD direction determine the overall area A of nonwoven fabric 10. For purposes of illustration, the three-dimensional features of the shaped nonwoven fabric are described as extending outward in the Z direction from the XY plane of the first surface 16 (see FIG. 4), as shown in FIG. 4, which is a cross-section of a portion of the nonwoven fabric 10 shown in FIG. 1. The maximum dimension of a three-dimensional feature in the Z direction can define the maximum distance between the plane of the first surface 16 and the XY plane of the second surface 18, which can be measured as the average caliper AC of the nonwoven fabric 10. The average caliper can be measured by optical, non-contact means, or by an instrument that measures the caliper of a nonwoven fabric placed under a predetermined pressure between spaced flat plates. While not all three-dimensional features need have the same maximum dimension in the Z direction, multiple three-dimensional features can have substantially the same maximum dimension in the Z direction, as determined by the fiber-laying process and forming belt characteristics discussed below.

[0009] The nonwoven fabrics shown in Figures 1-4 (as well as other nonwoven fabrics disclosed herein) can be fluid permeable. The entire nonwoven fabric can be considered fluid permeable. Regions or areas (described below) can be fluid permeable. Fluid permeable, as used herein with respect to a nonwoven fabric, means that the nonwoven fabric has at least one area that allows liquids to pass through it under use conditions of the consumer product. For example, when used as a topsheet in a disposable diaper, the nonwoven fabric can have at least one area that has a level of fluid permeability that allows urine to pass through to the underlying absorbent core. Fluid permeable, as used herein with respect to a region, means that the region exhibits a porous structure that allows liquids to pass through it.

[0010] As shown in Figures 1-4, nonwoven fabric 10 can have a regularly repeating pattern of a plurality of individual, recognizably distinct three-dimensional features, including first three-dimensional feature 20, second three-dimensional feature 22, and third three-dimensional feature 24, as shown in Figures 2 and 3. For example, in Figure 1, heart-shaped first three-dimensional feature 20 is recognizably different from smaller, generally triangular second three-dimensional feature 22. The recognizable difference can be visual, such as a recognizably different size and / or shape.

[0011] The three-dimensional features of nonwoven fabric 10 can be formed by directly depositing fibers, such as by carding, air-laying, solution spinning, or melt spinning, onto a forming belt having a corresponding pattern of three-dimensional features. In a sense, nonwoven fabric 10 is molded onto a forming belt, which determines the shape of the three-dimensional features of fabric 10. Importantly, however, as described herein, the disclosed apparatus and method produces nonwoven fabric 10 such that, beyond taking the shape of the forming belt, the attributes of the forming belt and the equipment that forms the fabric impart beneficial properties to the nonwoven fabric 10 for use in absorbent articles, garments, medical products, and cleaning products. In particular, as described below, due to the nature of the forming belt and other equipment elements, the three-dimensional features of nonwoven fabric 10 have intensive properties that can vary between first and second regions within a microregion (discussed in more detail below), or from one feature to another, to impart beneficial properties to the nonwoven fabric 10 when used in personal care articles, garments, medical products, and cleaning products. For example, the first three-dimensional feature 20 may have a basis weight or density that is different from the basis weight or density of the second three-dimensional feature 22, and both may have a basis weight or density that is different from the basis weight or density of the third three-dimensional feature 24, thereby providing beneficial aesthetic and functional properties related to fluid acquisition, distribution and / or absorbency in the diaper or sanitary napkin.

[0012] The differences in intensive properties between the various three-dimensional forming elements of nonwoven fabric 10 are believed to be due to the fiber distribution and compaction resulting from the apparatus and methods described herein. The fiber distribution occurs during the fiber laying process, as opposed to a post-manufacturing process, such as an embossing process. Because the fibers are free to move during processes such as melt spinning, and their movement is determined by the nature and air permeability of the forming elements of the forming belt, as well as other processing parameters, the fibers are believed to be more stable and permanently formed within nonwoven fabric 10.

[0013] As seen in FIGS. 1-3 and understood from the description herein, the different three-dimensional features are bounded by visually distinct regions (with respect to the interior of the three-dimensional features) that may be in the form of closed figures (such as the heart shapes in FIGS. 1 and 3 and the diamond shapes in FIGS. 2 and 3). Such closed figures may be closed figures that include curves, such as the heart shapes in FIGS. 1 and 3. The bounded visually distinct regions may be regions of nonwoven fabric 10 closest to first surface 12 in the Z direction, such as region 21 shown in FIG. 4, which may lie at least partially within or on first plane 16 when in a flat state. For example, as shown in FIG. 1, first three-dimensional feature 20 is heart-shaped, and an example first three-dimensional feature 20A as shown is bounded by a closed, heart-shaped element that includes curves. A curvilinear element can be understood as a linear element having a tangent vector V at any point along its length, and a closed shape is one in which the tangent vector V has components in both the MD and CD that vary in value over more than 50% of the length of the linear element of the closed shape. Of course, a shape need not be 100% completely closed, but linear elements may have breaks that do not detract from the overall impression of a closed shape. As discussed below in connection with the forming belt, a closed heart-shaped element containing a contoured, visually distinct curvilinear shape is formed by a corresponding closed, heart-shaped raised element on the forming belt to form a closed heart shape on the fabric 10. In a repeating pattern, the individual shapes (heart shapes in the case of the first three-dimensional element of FIG. 1 ) can provide an aesthetically pleasing, flexible, pillow-like formed element over the entire area OA of the second surface 14 of the fabric 10. When nonwoven fabric 10 is envisioned for use as a topsheet in a diaper or sanitary napkin, second surface 14 of nonwoven fabric 10, as the side facing the wearer, can provide excellent aesthetic benefits as well as performance benefits related to softness, compression resistance, and fluid absorbency.

[0014] The present disclosure can utilize the process of melt spinning, which does not result in mass loss in the extrudate, and is distinguished from other spinning processes, such as wet or dry spinning from solution, which lead to mass loss as the solvent is removed by volatilization or diffusion from the extrudate.

[0015] Melt spinning can be carried out at temperatures of about 150°C to about 280°C, or about 190°C to about 230°C. The fiber spinning speed can be faster than 100 meters / minute, about 1,000 to about 10,000 meters / minute, about 2,000 to about 7,000 meters / minute, or about 2,500 to about 5,000 meters / minute. The spinning speed can affect the brittleness of the spun fiber, but generally, the higher the spinning speed, the less brittle the fiber. Continuous fibers can be produced by spunbonding or meltblown processes.

[0016] The nonwoven fabric 10 of the present disclosure can include continuous multicomponent polymer filaments comprising a primary polymer component and a secondary polymer component. The filaments can be continuous bicomponent filaments comprising a primary polymer component A and a secondary polymer component B. The bicomponent filaments have a cross-section, a length, and a peripheral surface. Components A and B can be disposed in substantially distinct zones across the cross-section of the bicomponent filament or can extend continuously along the length of the bicomponent filament. The secondary component B constitutes at least a portion of the peripheral surface of the bicomponent filament, continuously along the length of the bicomponent filament. The polymer components A and B can be melt-spun into multicomponent fibers using conventional melt-spinning equipment. The equipment is selected based on the desired configuration of the multicomponent. Commercially available melt-spinning equipment is available from Hills, Inc. (Melbourne, Florida). Spinning temperatures range from about 180°C to about 230°C. The bicomponent spunbond filaments can have an average diameter of about 6 to 40 micrometers, or about 12 to about 40 micrometers.

[0017] Components A and B can be arranged in a side-by-side configuration, as shown in FIG. 5A, or in an eccentric sheath / core configuration, as shown in FIG. 5B, to result in filaments exhibiting a natural helical crimp. Alternatively, components A and B can be arranged in a concentric sheath-core configuration, as shown in FIG. 5C. Additionally, components A and B can be arranged in a multilobal sheath-core configuration, as shown in FIG. 6. Other multicomponent fibers can be produced using the compositions and methods of the present disclosure. Bicomponent and multicomponent fibers can be in a split-pie configuration, ribbon configuration, islands-in-the-sea configuration, or any combination thereof. The sheath can be continuous or discontinuous around the core. Fibers of the present disclosure can have different geometric shapes, including round, elliptical, star, rectangular, and various other eccentric shapes.

[0018] Methods for extruding multicomponent polymer filaments into such configurations are generally known to those skilled in the art.

[0019] A wide variety of polymers are suitable for practicing the present disclosure, including polyolefins (such as polyethylene, polypropylene, and polybutylene), polyesters, polyamides, polyurethanes, elastomeric materials, etc. Examples of polymeric materials that can be spun into filaments may include natural polymers.

[0020] The primary component A and secondary component B can be selected so that the resulting bicomponent filaments provide improved nonwoven adhesion and substrate flexibility. The primary polymer component A may have a melting point lower than the melting point of the secondary polymer component B.

[0021] The primary polymer component A can include polyethylene or a random copolymer of propylene and ethylene. The secondary polymer component B can include polypropylene or a random copolymer of propylene and ethylene. Polyethylene includes linear low-density polyethylene and high-density polyethylene. Additionally, the secondary polymer component B can include additives to enhance the natural helical crimp of the filaments, reduce the bonding temperature of the filaments, and increase the abrasion resistance, strength, and flexibility of the resulting fabric.

[0022] For example, inorganic fillers such as oxides of magnesium, aluminum, silicon, and titanium may be added as inexpensive fillers or processing aids.

[0023] The filaments of the present invention may also further comprise a slip additive in an amount sufficient to impart a desirable tactile feel to the fiber. As used herein, "slip additive" or "slip agent" refers to an external lubricant. When melt-mixed with a resin, the slip agent gradually exudes or migrates to the surface during cooling or after fabrication to form a uniform, imperceptibly thin coating that provides a durable lubricating effect. The slip agent may be a fast-bloom slip agent.

[0024] During manufacture, or in post-treatment, or even both, the nonwoven fabrics of the present disclosure can be treated with surfactants or other agents to hydrophilize the web or to hydrophobize the web. For example, a nonwoven fabric used in a topsheet can be made permeable to body exudates such as urine by treating it with a hydrophilizing material or surfactant. In other absorbent articles, the topsheet can be maintained in its natural hydrophobic state or made even more hydrophobic by adding a hydrophobizing material or surfactant.

[0025] Materials suitable for preparing the multicomponent filaments of the fabrics of the present disclosure may include PP3155 polypropylene available from Exxon Mobil Corporation and PP3854 polypropylene available from Exxon Mobil Corporation.

[0026] When polyethylene is component A and a second polypropylene is component B, the side-by-side bicomponent filaments may be composed of about 5 to 95% by weight of polypropylene and about 95 to about 5% by weight of polypropylene of another composition. The filaments may be composed of about 30 to about 70% by weight of polyethylene and about 70 to about 30% by weight of each component weight.

[0027] 7, an exemplary process line 30 for preparing the fabric 10 of the present disclosure is disclosed. While the process line 30 is configured to produce a bicomponent continuous filament fabric, it should be understood that the present disclosure also encompasses nonwoven fabrics made with monocomponent or multicomponent filaments having more than two components. The bicomponent filaments may be trilobal.

[0028] Process line 30 includes a pair of extruders 32 and 34 driven by extruder drives 31 and 33, respectively, for separately extruding a primary polymer component A and a secondary polymer component B. Polymer component A is fed to corresponding extruder 32 from a first hopper 36, and polymer component B is fed to corresponding extruder 34 from a second hopper 38. Polymer components A and B can be fed from extruders 32 and 34 through respective polymer conduits 40 and 42 to filters 44 and 45 and melt pumps 46 and 47, which pump the polymers to a spin pack 48. Spinnerets for extruding bicomponent filaments are commonly known to those skilled in the art and will not be described in detail here.

[0029] Generally speaking, the spin pack 48 includes a housing containing multiple stacked plates with a predetermined pattern of openings arranged to form channels for separately directing polymer components A and B through the spinneret. The spin pack 48 has openings arranged in one or more rows. The spinneret openings form a downwardly extending curtain of filaments as the polymers are extruded from the spinneret. For purposes of this disclosure, the spinneret can be configured to form sheath / core or side-by-side bicomponent filaments as shown in FIGS. 5A, 5B, and 5C, as well as non-circular fibers such as the trilobal fiber shown in FIG. 6. Additionally, the fibers may be monocomponent, consisting of one polymer component, such as polypropylene.

[0030] The process line 30 also includes a quench blower 50 positioned adjacent to the curtain of filaments extending from the spinneret. Air from the quench blower 50 quenches the filaments extending from the spinneret. The quench air can be directed from one side of the filament curtain or from both sides of the filament curtain.

[0031] An attenuator 52 is positioned below the spinneret to receive the quenched filaments. Fiber drawing devices or aspirators used as attenuators in melt spinning polymers are generally known. Fiber drawing devices suitable for use in the process of the present disclosure may include straight fiber attenuators of the type shown in U.S. Pat. No. 3,802,817, and eductive guns of the type shown in U.S. Pat. Nos. 3,692,618 and 3,423,266.

[0032] Generally speaking, the attenuator 52 includes an elongated, vertical passage through which the filaments are drawn by aspirating air entering from the sides of the passage and flowing downward. A shaped, endless, at least partially foraminous forming belt 60 is positioned below the attenuator 52 to receive the continuous filaments from the attenuator 52 exit opening. The forming belt 60 is a belt that moves along guide rollers 62. A vacuum device 64 positioned below the portion of the forming belt 60 where the filaments are deposited draws the filaments against the forming surface. While the forming belt 60 is shown as a belt in FIG. 8, it should be understood that the forming belt may take other forms, such as a drum. Details of certain shaped forming belts are described below.

[0033] In operation of process line 30, hoppers 36 and 38 are filled with respective polymer components A and B. Polymer components A and B are melted and extruded by corresponding extruders 32 and 34 through polymer conduits 40 and 42 and spin pack 48. The temperature of the molten polymer will vary depending on the temperature of the polymer used, but when polyethylene is used as primary component A and secondary component B, respectively, the polymer temperature can range from about 190°C to about 240°C.

[0034] As the extruded filaments extend below the spinneret, airflow from a quench blower 50 at least partially quenches the filaments, inducing crystallization of the molten filaments in certain filaments. The quench air can flow in a direction substantially perpendicular to the length of the filaments at a temperature of about 0°C to about 35°C and a velocity of about 100 to about 400 feet per minute. The filaments can be quenched sufficiently prior to collection onto the forming belt 60 to allow forced air passing through the filaments and the forming surface to position the filaments. Quenching the filaments reduces their tackiness, allowing them to be moved or positioned on the forming belt during collection and web formation without adhering too closely to each other before bonding.

[0035] After quenching, the filaments are drawn by the flow of the fiber draw system into the vertical passage of the attenuator 52. The attenuator can be positioned 30 to 60 inches below the bottom of the spinneret.

[0036] The filaments may be deposited from the exit opening of attenuator 52 onto a shaped, moving forming belt 60. As the filaments contact the forming surface of forming belt 60, a vacuum device 64 draws air and the filaments against forming belt 60 to form a continuous filament nonwoven web having a shape that conforms to the shape of the forming surface. As discussed above, because the filaments are quenched, they do not become excessively tacky, and the vacuum can move or position the filaments on forming belt 60 as they are collected on forming belt 60 and formed into fabric 10.

[0037] The process line 30 includes one or more bonding devices, such as cylindrical compression rolls 70 and 72, which form a nip through which the fabric can be compressed (e.g., calendered); the compression rolls can also be heated to bond the fibers. Heating one or both of the compression rolls 70, 72 can provide enhanced properties and benefits to the nonwoven fabric 10 by bonding portions of the nonwoven fabric together. For example, it is believed that heating sufficient to create thermal bonds improves the tensile properties of the fabric 10. The compression rolls can be a pair of smooth stainless steel rolls with independent heating controls. The compression rolls can be heated by electrical elements or by circulating hot oil. The gap between the compression rolls can be hydraulically controlled to apply the desired pressure to the fabric as it passes through the compression rolls on the forming belt. By way of example, if the caliper of the forming belt is 1.4 mm and the spunbond nonwoven fabric has a basis weight of 25 gsm, the nip gap between the compaction rolls 70 and 72 can be approximately 1.4 mm.

[0038] The upper consolidation roll 70 can be heated sufficiently to melt-bond the fibers on the first surface 12 of the nonwoven fabric 10, thereby providing strength to the fabric so that it can be removed from the forming belt 60 without losing its integrity. For example, as shown in FIGS. 8 and 9 , the belt 60, bearing the spunbond fabric, enters the nip formed by rolls 70 and 72 as rolls 70 and 72 rotate in the direction indicated by the arrows. The heated roll 70 can heat the portions of the nonwoven fabric 10 (i.e., regions 21) that are pressed against the roll 70 by the raised resin elements of the belt 60, thereby forming bonded fibers 80 on at least the first surface 12 of the fabric 10. As will be understood from the description herein, the bonded regions thus formed can have the pattern of the raised elements of the forming belt 60. For example, the bonded regions thus formed can be a substantially continuous or substantially semi-continuous network on the first surface 12 of regions 21 that form the same pattern as the hearts of FIGS. 1 and 11 . By adjusting the temperature and dwell time, bonding may be limited primarily to the fibers closest to the first surface 12, or thermal bonding may be achieved to the second surface 14 as shown in Figure 11 (also showing point bonds 90, discussed more fully below) and Figures 34-38. Bonding may also be a discontinuous network, for example, as point bonds 90, discussed below.

[0039] The raised elements of the forming belt 60 can be selected to establish various network characteristics of the forming belt and the bonded areas of the nonwoven substrate 11 or nonwoven fabric 10. The network corresponds to the resin that makes up the raised elements of the forming belt 60 and can include substantially continuous, substantially semi-continuous, discontinuous, or a combination of these options. These networks can describe the raised elements of the forming belt 60 as they relate to the appearance or configuration of the network in the XY plane of the forming belt 60 or the three-dimensional features that make up the nonwoven substrate 11 or nonwoven fabric 10 of the present disclosure.

[0040] A "substantially continuous" network refers to a region in which any two points can be connected by an uninterrupted line that extends entirely within the region over the entire length of that line. That is, a substantially continuous network has substantial "continuity" in all directions parallel to the first plane and terminates only at the edges of the region. The term "substantially" in combination with "continuous" is intended to indicate that, while absolute continuity can be achieved, some deviations from absolute continuity can be tolerated as long as such deviations do not significantly affect the design and intended performance of the textile structure (or molded member).

[0041] A "substantially semi-continuous" network structure refers to a region that is "continuous" in all directions except at least one direction parallel to the first plane, such that no two points can be joined by an uninterrupted line extending entirely within the region over the entire length of that line. A semi-continuous structure may have continuity only in one direction parallel to the first plane. As with the continuous regions described above, absolute continuity in all directions except at least one direction is preferred, but some deviations from such continuity may be tolerated as long as such deviations do not significantly affect the performance of the fiber structure.

[0042] A "discontinuous" network refers to separate regions that are distinct and discontinuous in all directions parallel to a first plane.

[0043] After compression, nonwoven fabric 10 may leave forming belt 60 and be calendered through the nip formed by calender rolls 71, 73, after which fabric 10 may be wound onto reel 75. As shown in the schematic cross-section of FIG. 10, these calender rolls 71, 73 may be stainless steel rolls having an engraved pattern roll 84 and a smooth roll 86. The engraved roll may have ridges 88 that may provide additional compression and bonding to fabric 10. The ridges 88 may be a regular pattern of relatively small, spaced "pins" that form a pattern of relatively small point bonds 90 within the nip of calender rolls 71 and 73. The percentage of point bonds in nonwoven fabric 10 may be from about 3% to about 30%, or from about 7% to about 20%. The engraved pattern can be in the form of a plurality of closely spaced, regular, generally cylindrical, generally flat-topped pins, with pin heights ranging from about 0.5 mm to about 5 mm, or from about 1 mm to about 3 mm. The pin-bonded calender roll can form closely spaced, regular point bonds 90 in the nonwoven fabric 10, as shown in Figure 11. Further bonding can be achieved, for example, by hot air bonding.

[0044] As used herein, "point bonding" refers to a method of thermally bonding nonwoven fabrics, webs, or substrates. This method involves passing a web through a nip between two rolls: a heated male patterned or engraved metal roll and a smooth or patterned metal roll. The male pattern roll can have a number of raised, generally cylindrical pins that create circular point bonds. The smooth roll can be heated or unheated, depending on the application. In a nonwoven manufacturing line, the nonwoven fabric, which may be a web of unbonded fibers, is fed into a calender nip, where the fiber temperature is raised to the point where the fibers thermally fuse together at the tips of the engraved points against the smooth roll. Heating times are typically on the order of milliseconds. Fiber characteristics depend on process settings such as roll temperature, web line speed, and nip pressure, all of which can be determined by one skilled in the art to achieve the desired degree of point bonding. Another type of point bonding, commonly known as high-temperature calender bonding, can use different geometric shapes to create bonds (other than circular), such as ellipses, lines, and circles. In an example, the point bonding produces a pattern of point bonds that are 0.5 mm diameter circles with 10% of the total bonded area. Other bond geometries can have raised pins with the longest dimension across the pin's bonding surface of about 0.1 mm to 2.0 mm, with the total bonded area ranging from about 5% to about 30%.

[0045] As shown in FIG. 11 , the heated consolidation roll 70 can form a bond pattern, which may be a substantially continuous network bond pattern 80 (e.g., interconnected heart-shaped bonds), on the first surface 12 of the nonwoven fabric 10 (not shown in FIG. 11 because it faces away from the viewer), and the engraved calendar roll 73 can form relatively small point bonds 90 on the second surface 14 of the fabric 10. The point bonds 90 can secure loose fibers that would otherwise cause fraying or pilling during use of the fabric 10. The advantages of the resulting structure of the nonwoven fabric 10 are most apparent when used as a topsheet for an absorbent article, such as a diaper or sanitary napkin. When used in an absorbent article, the first surface 12 of the nonwoven fabric 10 can be relatively flat (compared to the second surface 14) and can have relatively more bonds because the heated compression roll forms bonds 80 in areas of the fabric pressed by the raised elements of the forming belt 60. This bonding provides structural integrity to the nonwoven fabric 10, but can be relatively stiff or rough against the user's skin. Thus, the first surface 12 of the nonwoven fabric 10, in a diaper or sanitary napkin, can face the interior of the article, i.e., oriented away from the side facing the wearer's body or garment. Similarly, the second surface 14 faces the wearer during use and can come into contact with the body. The relatively small point bonds 90 can be less perceptible visually or tactilely by the user, and the relatively flexible three-dimensional features can remain free of visually noticeable fuzzing and pilling while still feeling soft against the body during use. Additional bonding can be used instead of or in addition to the bonding described above.

[0046] Forming belt 60 may be made according to the methods and processes described in U.S. Patent No. 6,610,173, issued August 26, 2003 to Lindsay et al., or U.S. Patent No. 5,514,523, issued May 7, 1996 to Trokhan et al., or U.S. Patent No. 6,398,910, issued June 4, 2002 to Burazin et al., or U.S. Patent Application Publication No. 2013 / 0199741, published August 8, 2013 in the name of Stage et al., each of which incorporates the improved forming elements and patterns disclosed herein for producing spunbond nonwoven webs. While these disclosures by Lindsay, Trokhan, Burazin, and Stage describe belts representative of papermaking belts made of cured resin on fabric reinforcement members, these belts may be used in the present disclosure with modifications as described herein.

[0047] An example of a forming belt 60 of a type useful in the present disclosure, which can be made in accordance with the disclosure of U.S. Pat. No. 5,514,523, is shown in FIG. 12. As taught herein, a reinforcing member 94 (such as a woven belt of filaments 96) is completely coated with a liquid photopolymer resin to a preselected thickness. A film or negative mask incorporating repeating elements of the desired raised element pattern (e.g., FIG. 14) is juxtaposed over the liquid photopolymer. The resin is then exposed through the film to light of an appropriate wavelength (e.g., ultraviolet light for ultraviolet-curable resins). This exposure to light hardens the resin in the exposed areas (i.e., the white or unprinted portions of the mask). The uncured resin (the resin under the opaque portions of the mask) is removed from the system, leaving behind the cured resin that forms the pattern shown (e.g., cured resin elements 92 shown in FIG. 12). Other patterns may also be formed.

[0048] Figure 12 shows a portion of a forming belt 60 useful in producing the nonwoven fabric 10 shown in Figure 1. As shown, the forming belt 60 can include cured resin elements 92 on woven strength members 94. The strength members 94 can be made of filaments 96, as is commonly known in the papermaking belt art, such as resin-coated papermaking belts. The cured resin elements can have the general structure shown in Figure 12 and are made using a mask 97 having the dimensions shown in Figure 14. As shown in the schematic cross-section of FIG. 13, the cured resin elements 92 flow around the reinforcing members 94, harden, and "set" therein, and can have a width DW at the distal end of about 0.020 inches to about 0.060 inches, or about 0.025 inches to about 0.030 inches, and an overall height above the reinforcing members 94, referred to as the overburden (OB), of about 0.030 inches to about 0.120 inches, or about 0.50 inches to about 0.80 inches, or about 0.060 inches. FIG. 14 depicts a portion of a mask 97 showing the pattern and representative dimensions of one repeat unit of the repeating heart pattern of the nonwoven fabric 10 shown in FIG. 1. The white areas 98 transmit ultraviolet light, which, in the belt manufacturing process described in U.S. Pat. No. 5,514,523, allows the ultraviolet light to harden the underlying resin layer, which hardens to form the raised elements 92 on the reinforcing members 94. After the uncured resin has been washed away, the ends of the length of the belt are joined together as shown in FIG. 7, as may be determined by the design of the equipment, to obtain a formed belt 60 having a pattern of cured resin as shown in FIG. 12.

[0049] Similarly, Figure 15 shows a portion of a mask 97 showing the pattern of one repeat unit of the repeating pattern of nonwoven fabric 10 shown in Figure 2. The white portion 98 transmits ultraviolet light, which in the belt manufacturing process allows the ultraviolet light to cure the underlying resin layer, which is then cured against the reinforcing members 94. After the uncured resin is washed away, as shown in Figure 7, the ends of a length of the belt are joined together, as may be determined by the equipment design, to produce a formed belt 60 having a pattern of cured resin as shown in Figure 16.

[0050] Further, by way of example, Figure 17 shows a portion of a mask showing the pattern of one repeat unit of the repeating pattern of nonwoven fabric 10 shown in Figure 18. The white portions 98 transmit ultraviolet light, which in the belt manufacturing process allows the ultraviolet light to cure the underlying resin layer, which is then cured against the reinforcing members 94. After the uncured resin is washed away, the ends of the length of fabric 10 are seamed together to produce a formed belt 60 having the pattern of cured resin as shown in Figure 18.

[0051] Another example of a portion of a forming belt 60 of a type useful in the present disclosure is shown in FIG. 19. The portion of forming belt 60 shown in FIG. 19 is a discrete belt pattern 61 that can have a length L and a width W corresponding to the length L and width W of the overall area OA of nonwoven fabric 10. That is, forming belt 60 can have discrete belt patterns 61 (discussed more fully below with reference to FIG. 22), each having an overall area DPOA of the discrete belt pattern that corresponds to the overall area OA of nonwoven fabric 10. FIG. 20 represents a portion of a mask showing the pattern of one repeat unit of the repeating pattern of nonwoven fabric 10 shown in FIG. 21. The white areas 98 transmit ultraviolet light, which, in the belt manufacturing process, allows the ultraviolet light to cure the underlying resin layer, which is cured against reinforcing members 94. After the uncured resin is washed away, the ends of the belt length are spliced ​​together to produce forming belt 60 having the pattern of cured resin as shown in FIG. 19.

[0052] The portion of the forming belt shown in FIG. 19 illustrates another advantage of the present disclosure. The portion of the forming belt 60 shown in FIG. 19 can produce the fabric 10 shown in FIG. 21. The nonwoven fabric 10 shown in FIG. 21 can have width W and length L dimensions, as well as an overall area OA, that make the nonwoven fabric 10 suitable for use, for example, as a topsheet for a disposable diaper. The nonwoven fabric 10 produced on the forming belt 60 shown in FIG. 19 differs from the nonwoven fabric 10 shown in FIGS. 1-3 in that the pattern of three-dimensional features formed by the individual resin elements 92 on the forming belt 60 is not a regularly repeating pattern throughout the overall area. Rather, the pattern of three-dimensional raised elements within the overall area DPOA of the individual belt pattern can be described as an irregular pattern including distinct portions called zones. The difference between the zones can be visual, i.e., a visually distinguishable difference, or in the nonwoven fabric 10, the difference can result in a difference in average intensive properties, such as basis weight or density, or a combination of visual and intensive properties. A visually distinguishable difference exists when an observer under normal indoor lighting conditions (e.g., 20 / 20 vision, with sufficient lighting to read text) can visually distinguish the difference in pattern between areas such as first area 112 and second area 122.

[0053] Nonwoven fabric 10 can also have visually distinct regions corresponding to the regions of the forming belt. For example, as shown in FIG. 21 , fabric 10 can have at least two, three, or four visually distinct regions. A first region 110 having a first pattern of three-dimensional features and first average intensive properties can have a first region located approximately centrally within the overall area OA. A second region 120 having a second pattern of three-dimensional features and second average intensive properties can have a second region distributed approximately around and completely surrounding first region 110 within the overall area OA. A third region 130 having a third pattern of three-dimensional features and third average intensive properties can have a third region distributed approximately around and completely surrounding second region 120 within the overall area OA. A fourth region 140 having a fourth pattern of three-dimensional features and a fourth average intensive property can have a fourth region, such as the heart pattern shown in Figure 21, located anywhere within the overall area OA, such as the front of the topsheet. In general, there can be n regions, where n is a positive integer. Each of the n regions can have an nth pattern of three-dimensional features, an nth region, and an nth average intensive property.

[0054] Visually distinct areas, such as those shown in FIG. 21, can include visually distinct three-dimensional features. These distinct three-dimensional features can be bounded by regions of relatively higher density (relative to the interior of the three-dimensional features), which can be in the form of closed figures, such as the heart shapes of FIGS. 1 and 3 and the diamond shapes of FIGS. 2 and 3. Generally, as discussed more fully below, including in connection with microzones, the three-dimensional features can be defined by first and second regions, which are visually distinct, each associated with a common intensive property, and the first and second regions have different values ​​for the common intensive property. The three-dimensional features can be defined by first and second regions, with the first region at a higher elevation (dimension measured in the Z direction) than the second region relative to the plane of the first surface. The three-dimensional features can be defined by first and second regions, with the first region at a higher base than the second region.

[0055] As will be appreciated, the forming belt 60 of the present disclosure enables the production of nonwoven materials that, instead of having a uniform, constant repeating pattern throughout the forming belt, can have a repeating, irregular series of individual belt patterns 61, each of which is similar to the individual belt pattern shown in FIG. 19 . Each of the individual belt patterns 61 can be used to form a single nonwoven fabric 10 having an overall area OA suitable for use in disposable absorbent articles, such as diapers or sanitary napkins. The nonwoven fabric 10 can be obtained continuously (i.e., in a line) and, optionally, in multiple parallel lanes, each lane being a continuous line of nonwoven fabric 10. The continuous line of nonwoven fabric 10 can be obtained in the machine direction along an axis parallel to the machine direction. This nonwoven material can then be slit or otherwise cut to size to produce nonwoven fabrics 10 for use as topsheets in disposable absorbent articles.

[0056] The patterns within each individual belt pattern overall area DPOA may be the same or different. That is, the consecutively spaced individual belt patterns may be substantially the same, or they may differ in visual appearance and / or in the intensive properties imparted to the resulting nonwoven substrate. For example, as shown schematically in FIG. 22, the pattern of three-dimensional raised elements within the first forming zone 112 of individual belt pattern 61A may be different from the pattern of three-dimensional raised elements within the first forming zone 112 of individual belt pattern 61B. In this manner, forming belt 60 provides flexibility in the production of nonwoven webs 10 suitable for use in consumer products, including disposable absorbent articles.

[0057] Referring to FIG. 22 , a forming belt having an axis A parallel to the longitudinal direction, which is the machine direction, is shown. The forming belt 60 can have a plurality of individual belt patterns 61 arranged in at least one consecutive relationship relative to the longitudinal direction. Each individual belt pattern 61 can have an individual belt pattern overall area DPOA defined in a rectangular pattern by a length L and a width W, similar to that shown for individual belt pattern 61A. Within the overall area DPOA, each individual belt pattern can have a first forming zone 112 having a first pattern of three-dimensional raised elements extending outward from the plane of the first surface, and a second forming zone 122 having second three-dimensional raised elements extending outward from the plane of the first surface. The first forming zone can have a first air permeability value, and the second forming zone can have a second air permeability value, which can be different from the second air permeability value. The patterns within each consecutively arranged individual belt pattern overall area DPOA can be the same or different.

[0058] By way of example, and with reference to the individual belt patterns 61 of the forming belt 60 shown in FIG. 19 and the nonwoven fabric 10 shown in FIG. 21, the following properties were measured. The first region 110 of the nonwoven fabric 10 can have an average basis weight of about 5 gsm to about 30 gsm. The second region 120 can have an average basis weight of about 50 gsm to about 70 gsm, and the third region 130 can have an average basis weight of about 25 gsm to about 60 gsm. The difference in basis weight between the regions can be attributed to differences in the air permeability of the forming belt 60. Referring to the nonwoven fabric 10 of FIG. 20, in which the basis weights of regions 110, 120, and 130 are 15 gsm, 53 gsm, and 25 gsm, respectively, the air permeabilities of the respective regions 112, 122, and 132 of the forming belt 60 are 379 cfm, 805 cfm, and 625 cfm, respectively. Therefore, by varying the air permeability of each region of the forming belt 10, the intensive properties of the average basis weight and average density of each region can be enhanced across the entire area of ​​the fabric 10.

[0059] As can be understood from the description of forming belt 60 set forth in FIG. 22 and with reference to FIG. 23 , the nonwoven substrate 11 produced on belt 60 can be described as a nonwoven substrate 11 having a plurality of portions, herein described as a plurality of fabrics 10, arranged in at least one continuous relationship relative to the longitudinal direction, i.e., the machine direction, as produced on the forming belt 60. FIG. 23 is a schematic diagram of a spunbond nonwoven substrate 11 showing the continuously arranged fabrics 10, each having a different pattern within various regions. Each fabric 10 can have an overall area OA defined by a length L and a width W in a rectangular pattern. Each sequentially arranged fabric 10 can have, within its overall area OA, at least a first region 110 having a first pattern of three-dimensional features and a first average intensive property and a first region located within the overall area OA, and a second region 120 having a second pattern of three-dimensional features and a second average intensive property and a second region located within the overall area OA. Optionally, there may be additional regions, such as third region 130, having a third pattern of three-dimensional features and a third average intensive property, and having a third region within overall area OA. As shown in Figure 23, first pattern 110A of fabric 10A may be different from first pattern 110B of fabric 10B, and may be different from first pattern 110C of fabric 10C. The same is true for second regions 120A, 120B, and 120C.

[0060] In general, the continuously arranged nonwoven webs 10 of the nonwoven material 11 produced on the forming belt 60 can differ in their overall area, intensive properties, and visual appearance. A common intensive property is an intensive property possessed by more than one region (for a zoning pattern such as that shown in FIG. 21) or area (for a three-dimensional feature such as a regularly repeating pattern as shown in FIG. 1). Such intensive properties of the nonwoven web 10 can be average values ​​and can include, but are not limited to, density, volume density, basis weight, thickness, and opacity. For example, if density is a common intensive property of two different regions or areas, the density value of one region or area can be different from the density value of the other region or area. The regions (e.g., a first region and a second region) can be distinct regions that can be distinguished from one another visually and by the different intensive properties averaged within the regions.

[0061] Once obtained, the individual nonwoven fabrics 10 can be cut to size and used for their intended purpose, such as, for example, a topsheet for a disposable absorbent article. A single fabric 10 can be cut to the appropriate overall area and adhered to a diaper, for example, by means known in the art. The fabric 10 can be cut before being assembled into a diaper, or the nonwoven substrate 11 can be integrated with other components of the diaper in web form during the diaper manufacturing process and then cut to size after assembly.

[0062] As can be seen with reference to Figure 24, the nonwoven substrate 11 produced on the belt 60 can be described as a nonwoven substrate 11 having a plurality of portions, described herein as fabrics 10, arranged in at least one continuous relationship with respect to the longitudinal direction (i.e., the machine direction when produced on the forming belt 60) and at least one side-by-side relationship (i.e., the cross direction when produced on the forming belt 60). Figure 24 is a schematic diagram of a spunbond nonwoven substrate 11 showing the fabrics 10 arranged continuously in adjacent machine direction lanes 13, adjacent lanes having side-by-side fabrics 10, designated 10D, 10E, and 10F in Figure 24. Each fabric 10 can have an overall area OA defined by a length L and a width W in a rectangular pattern. Each sequentially arranged fabric 10 can have, within its overall area OA, at least a first region 110 having a first pattern of three-dimensional features and a first average intensive property and a first region located within the overall area OA, and a second region 120 having a second pattern of three-dimensional features and a second average intensive property and a second region located within the overall area OA. Optionally, there can be additional regions, such as a third region 130 having a third pattern of three-dimensional features and a third average intensive property and a third region within the overall area OA. Each fabric 10 in a side-by-side lane can be substantially identical, or each fabric 10 can differ in size, visual appearance, and / or intensive property. Once obtained, the nonwoven substrate 11 can be wound and slit into lanes and processed into consumer products, or slit and wound.

[0063] Another aspect of the present disclosure relates to commercial spunbond lines in which multiple beams are used to increase fabric laydown opacity and uniformity. In some cases, the system may include three spunbond beams (known in the art as "SSS"), which may be combined with a meltblown process (M) in a system known as an "SSMMS" spunbond line.

[0064] Calendering the nonwoven fabric 10 to provide point bonds 90 can reduce fuzzing. Fuzzing refers to the tendency of fibers to fray and separate from the fabric 10. Fraying and separation can occur due to frictional engagement with manufacturing equipment during the production of disposable absorbent articles or with another surface, such as a person's skin, that contacts the fabric 10. In some applications, such as in disposable absorbent article topsheets, fuzzing is a negative consumer phenomenon. However, bonding fibers in place can also be a negative consumer experience because it can create roughness on an otherwise soft nonwoven substrate surface. The inventors have anticipated and discovered that the nonwoven substrates and nonwoven fabrics of the present disclosure can tolerate increased bonding (and resulting reduced fuzzing) with minimal loss of softness. Bonding can be achieved by relatively closely spaced point bonds 90, the spacing being determined by the desired degree of fuzz reduction. Bonding can also be accomplished by known methods for chemically or thermally bonding fibers in nonwoven fabrics, such as heat bonding, ultrasonic bonding, pressure bonding, bonding with latex adhesives, and combinations of these methods.

[0065] Further characterization of the present disclosure can be achieved by noting the three-dimensional features within the visually distinct regions. Each region, such as regions 110, 120, and 130 discussed above, can be further described in relation to a microregion. A microregion is a portion of nonwoven fabric 10 within a region having at least two visually distinct regions, where a common intensive property difference exists between the two regions. A microregion can comprise a portion of nonwoven fabric 10 that intersects the boundary of two or more regions, where a common intensive property difference exists between the two regions, where at least two visually distinct regions exist.

[0066] The benefit of considering microregions in this disclosure is that, beyond the differences in average intensive properties within regions such as regions 110, 120, and 130, as discussed above, the present disclosure also provides fabrics having differences in actual and / or average intensive properties between regions defined by three-dimensional features within a region, with the three-dimensional features precisely positioned according to the design of the forming belt used to produce the fabric. The differences in intensive properties between regions of the three-dimensional features not only provide functional benefits but also additional visual effects. The clear visual contrast between regions can provide excellent visually distinct designs within a region and between multiple regions. Similarly, the precise positioning of regions achieved by a precisely manufactured forming belt can provide excellent and tailored flexibility, strength, and fluid handling characteristics for each region. Thus, the present disclosure provides the unexpected combination of differences in average intensive properties between regions and, at the same time, differences in intensive properties of the regions that make up the microregions.

[0067] The regions defined by the three-dimensional features can be understood with reference to Figures 25 and 26. Figure 25 shows an optical microscope image of a portion of a fabric 10 according to the present disclosure, and Figure 26 is a scanning electron micrograph (SEM) of a cross-section of the portion of the fabric shown in Figure 25. Accordingly, Figures 25 and 26 show a portion of nonwoven fabric 10 enlarged to more accurately illustrate the visually distinguishable features of the nonwoven fabric. The portion of nonwoven fabric 10 shown in Figure 25 is approximately 36 mm in the CD and exhibits at least three visually distinct zones, as discussed below.

[0068] 25 and 26, which show a portion of one pattern of nonwoven fabric 10, first region 110 (left side of FIG. 25) is characterized by generally MD rows of first regions 300 of varying width separated by MD rows of second regions 310 of varying width. The first regions are also three-dimensional features 20 that define first and second regions 300, 310. The three-dimensional features are portions of nonwoven fabric 10 formed between or around raised elements of the forming belt, herein referred to as first regions 300, with the resulting structure having a relatively large dimension in the Z direction. The adjacent second regions 310 typically share intensive properties with the first regions 300 and may have a relatively small thickness (i.e., a smaller dimension in the Z direction). The relative dimensions in the Z direction with respect to the plane of first surface 16, as discussed above, can be seen in FIG. 26. The absolute dimensions are not critical, but the dimensional difference may be visually distinguishable on the nonwoven fabric 10 without magnification.

[0069] The present disclosure allows for beneficial characteristics best described with respect to regions defined by three-dimensional features within a microregion. For example, as shown in FIG. 25, within region 110 within each three-dimensional feature 20, there is a visual distinction between first region 300 and second region 310. As noted above, visual distinctions may exist within nonwoven fabric 10 without magnification, and the magnification used herein is for purposes of clarity. Any region that extends sufficiently across the boundary between first region 300 and second region 310 such that a difference in their respective intensive properties can be considered within that region may be a microregion. Furthermore, optical microscope or micro-CT images of a structure can be used to establish the location of each region and the area of ​​the microregion.

[0070] The portion of nonwoven fabric 10 shown in Figure 25 further illustrates another beneficial feature of fabric 10 in that the difference in intensive properties between adjacent regions can be a difference across an entire region. Thus, a microregion can be identified across the region, including second region 310 of region 120 and first region 300 of region 130. Referring to nonwoven fabric 10 shown in Figures 25 and 26, it can be seen that the difference in intensive properties exhibited by regions within a microregion can be significantly different in magnitude than the difference in intensive properties exhibited by regions within a region whose region boundary is within the region.

[0071] Regardless of which zones or zone boundaries a particular microzone comprises, the three-dimensional features can be characterized by differences in the intensive properties of each region defined by the three-dimensional features. Generally, the nonwoven fabric of the present disclosure can be a spunbond nonwoven fabric having a first surface defining a first surface plane. The fabric can have a plurality of three-dimensional features, each defining a first region and a second region, each region having a common intensive property with a different value between them. The first region is at a higher elevation relative to the plane of the first surface than the second region, and thus can be distinguished as exhibiting a common thickness intensive property difference between each region. These two regions can also be distinguished as having different densities, basis weights, and volume densities. That is, the two regions can be distinguished as differing in terms of common intensive properties, including properties such as thickness, density, basis weight, and volume density, within a microzone of a spunbond nonwoven fabric. One or both regions of the microzone can be fluid permeable. The denser region of the microzone can be fluid permeable.

[0072] For example, within region 110 of the fabric portion shown in Figure 25, there may be three-dimensional features 20 that define at least two regions: a first region 300 and a second region 310. For example, the difference in caliper, basis weight, and volume density between the first region and the second region of region 110 shown in Figure 25 may be 274 micrometers, 1 gsm, and 0.437 g / cc, respectively.

[0073] Similarly, within region 130 of the fabric portion shown in Figure 25, for example, there may be three-dimensional features 20 that define at least two regions: a first region 300 and a second region 310. For example, the difference in caliper, basis weight, and volume density between the first region and the second region of region 130 shown in Figure 25 may be 2083 micrometers, 116 gsm, and 0.462 g / cc, respectively.

[0074] Additionally, within region 120 of the fabric portion shown in Figure 25, for example, there may be three-dimensional features 20 that define at least two regions: first region 300 and second region 310. For example, the difference in caliper, basis weight, and volume density between the first and second regions of the fabric portion shown in Figure 25 may be 204 micrometers, 20 gsm, and 0.53 g / cc, respectively. Region 120 forms what is visible in a non-magnified view of nonwoven fabric 10 as the sewn boundary between regions 110 and 130.

[0075] Further, for example, in the area including the boundary between areas 120 and 130 of the fabric portion shown in Figure 25, there are at least two regions: a first region 300 within area 130 and a second region 310 within area 120. For example, the differences in caliper, basis weight, and bulk density between the first and second regions of the fabric portion shown in Figure 38 can be 2027 micrometers, 58 gsm, and 0.525 g / cc, respectively.

[0076] Microregions will be discussed in more detail with reference to the data shown in Figures 27-29 and Figure 31. Figures 27-29 are micro-CT scans of a portion of nonwoven fabric 10 having a pattern similar to the portion of nonwoven fabric 10 shown in Figure 25. The micro-CT scans allow for the same features shown in Figure 25 to be described in a slightly different manner, and in a manner that allows for highly accurate measurement of intensive properties.

[0077] As shown in Figure 27, areas 110, 120, and 130 are clearly visible along with their respective three-dimensional features 20. As shown in Figures 27 and 28, the three-dimensional features are the dark portions, and the dark portions also represent first regions 300 of the three-dimensional features 20, with the adjacent light portions being second regions 310 of the three-dimensional features 20.

[0078] Micro-CT scanning allows images to be presented as "cut" cross sections, as shown by cut plane 450 in Figure 28. The cut plane can be located anywhere in the image, but for purposes of this disclosure, cut plane 450 is a cross section substantially parallel to the Z axis to obtain the cross-sectional image of Figure 29.

[0079] Micro-CT technology allows for accurate and direct measurement of intensive properties. Thickness measurements can be made directly from a magnified imaged cross-section, such as the cross-section shown in Figure 29. Furthermore, the color difference between the first and second regions represents, and is proportional to, differences in basis weight, volume density, and other intensive properties, which can also be directly measured. The micro-CT method is described below in the Test Methods section.

[0080] Figure 30 is a micro-CT scan image of the portion of nonwoven fabric 10 shown in Figures 27 and 28. Analysis can be performed using specific first and second regions, shown as numbered portions of nonwoven fabric 10. In Figure 30, specific regions were manually selected and analysis was performed to measure caliper, basis weight, and volume density, and the data is shown in Figure 31.

[0081] FIG. 31 shows data groupings of first and second region measurements taken within the three regions shown in FIG. 30. The X-axis is a region with numbers corresponding to the numbered regions in FIG. 30. First region measurements are designated as Fn (e.g., F1), and second region measurements are designated as Sn (e.g., S1). Thus, regions 1-5 are the first region F1, each within region 110. Regions 6-10 are the second region S1, also within region 110. Similarly, the first region F2 is regions 16-20 within region 120, and regions 11-15 and 21-25 are the second region S2 within region 120. Finally, regions 31-35 are the first region F3 within region 130, and regions 26-30 are the second region S2 within region 130. Each numbered region is shown identically in all three graphs of FIG. 31, although for simplicity, areas 110, 120, and 130 are shown only in the thickness map.

[0082] The graphs shown in Figure 31 graphically represent the magnitude of the difference in intensive properties between a first region and a second region within any one region, and these graphs can be used to graphically view the difference in intensive properties for each pair of regions that make up a microregion. For example, in region 110, the basis weight may be substantially the same between the two regions, but the caliper may vary from about 400 micrometers in the first region to about 40 micrometers in the second region (i.e., a difference of about 10 times). The volume density within region 110 may vary from about 0.1 g / cc to about 0.6 g / cc. Similar quantifiable differences can be seen for each of the regions shown in the figure.

[0083] 30 and 31 together, further characterization of the beneficial structure of fabric 10 of the present disclosure can be appreciated. Nonwoven fabric 10 can be described as having at least two visually distinct regions, e.g., regions 110 and 120, each of which has a pattern of three-dimensional features, each of which defines a microregion including first and second regions, e.g., regions 300 and 310, where the difference in value in at least one of the microregions within the first region is quantifiably different from the difference in value in at least one of the microregions within the second region. For example, in FIG. 30, two representative microregions 400 within region 130 are designated as region pairs shown as regions 31 and 27, and regions 33 and 26. That is, first region 31 and second region 27 form one microregion, and first region 33 and second region 26 form one microregion. Similarly, two representative micro-areas 400 within area 120 are designated as pairs of areas shown as areas 19 and 24, and areas 17 and 22. From Figure 31, Tables 4-7 can be obtained as shown below.

[0084] [Table 1]

[0085] [Table 2]

[0086] [Table 3]

[0087] [Table 4]

[0088] Four representative microzones from the two regions are shown in Tables 1-4 for illustrative purposes. However, it will be understood that each pair of first and second regions in FIG. 30 could also be quantified to further constitute an additional column in Table 1, but for purposes of brevity, this has not been done. In general, for any fabric having two or more regions, each having a pattern of three-dimensional features defining a microzone, measuring and tabulating intensive properties as shown herein with reference to FIGS. 30 and 31 allows for understanding both the difference in values ​​of the intensive properties within a region and the difference in values ​​of the intensive properties between one region in the first region and another region in the second region.

[0089] A microregion spanning two regions, such as region 110 and region 130, may have a greater difference in intensive properties compared to a microregion within a single region. For example, looking at data for a microregion spanning a first region (e.g., first region 32) in region 130 and a second region (e.g., second region 8) in region 110, the microregions exhibit significant differences in thickness, basis weight, and volume density. The thickness of first region 32 in region 130 is approximately 2100 micrometers, while the thickness of second region 8 in region 110 is approximately 29 micrometers, or a difference of 72 times, or more than 25 micrometers. Similarly, the basis weight of first region 32 in region 130 can be as high as 150 gsm, while the basis weight of second region 8 in region 110 is approximately 14 gsm, or a difference of 10 times, or more than 5 gsm. Furthermore, the volume density of the first region 32 of the area 130 may be approximately 0.069 g / cc, while the volume density of the second region 8 of the area 110 is 0.492 g / cc, or a difference of approximately 7 times or greater than approximately 0.042 g / cc.

[0090] For each of the measured intensive property parameters of different regions of a micro-region, such measurements are performed using the micro-CT method described herein, the resolution of which allows for the comparison of the differences and ratios of the regions described herein to help establish the intensive properties of the regions of the micro-region.

[0091] Further characterization of fabric 10 can be performed with reference to Figures 32-36, which are SEMs illustrating certain aspects of nonwoven fabric 10 and regions thereof in more detail. Figures 32-36 are photographs of enlarged portions of area 110 of the fabric shown in Figure 25. Nonwoven fabric 10 shown in Figure 25 was made according to the process described above with reference to Figure 7, in which the fabric was processed by passing it through a nip formed by compression rolls 70 and 72, with roll 72 in contact with first surface 12 being heated to cause partial bonding of the fibers in second region 301. Figure 32 (facing the belt) and Figure 46 (facing the heated compression roll) are SEMs of portions of second surface 14 and first surface 12, respectively, magnified 20 times. FIG. 34 (facing the belt) and FIG. 48 (facing the heated compression rolls) are photographs of a portion of second surface 14 and first surface 12, respectively, magnified 90 times, detailing the beneficial structural features of the partial fiber bonding created by compression rolls 70 and 72.

[0092] As best seen in Figures 34 and 35, as well as the cross-sectional view of Figure 36, the heated compression rolls can cause different degrees of thermal bonding of the fibers, providing beneficial effects throughout the fabric 10. As shown in the figures, fibers in contact with the heated roll (e.g., roll 70 in contact with the first surface 12 of the fabric 10) can be melt-bonded, resulting in a relatively higher degree of fiber-to-fiber bonding on the first surface 12 than on the second surface 14. The bonded fibers 80 on the first surface can be substantially completely melt-bonded, effectively forming a film skin of bonded fibers, while the fibers in the second region 310 on the second surface 14 experience little or no bonding. This feature allows a nonwoven fabric 10 used, for example, as a topsheet in a disposable absorbent article, to maintain not only its physical integrity during manufacture and use, but also its relatively high flexibility on one side, which may be the skin-contacting surface facing the wearer.

[0093] Even in the small areas with the greatest thickness differences, this "bonded skin" effect serves to maintain the integrity of the web without significantly affecting softness or other beneficial properties such as fluid handling properties. As can be seen with reference to Figures 37-40, the difference in the degree of thermal bonding of the fibers is such that the fibers on first surface 12 in second regions 310 may be complete, or substantially complete, while the degree of thermal bonding of the fibers on second surface 14 in first regions 300 may be minimal to non-existent.

[0094] FIG. 37 also shows the portion of the nonwoven fabric 10 shown in FIG. 25. FIGS. 38-40 show magnified images of one microregion, shown in FIG. 37 as first region 300 and second region 310, which visually appear as holes or openings. FIGS. 38 and 39 show the microregion as seen on the second surface 14 at 40x and 200x magnification, respectively. FIG. 40 shows the second region 310 as seen on the first side 12 at 200x magnification. The fibers in the second region 310 are completely or substantially completely bonded, while the fibers in the first region 300 are completely or substantially completely unbonded. An advantage of the structure shown in the figures is that the microregions can function as fluid-permeable openings while, at the same time, the bonded areas of the second region 310 function to maintain the physical integrity of the fabric 10.

[0095] Thus, microregions play an important role in the overall physical structure and function of the fabric 10 of the present disclosure. By producing relatively closely spaced, precisely designed, three-dimensional features, as achieved by the forming belt of the present disclosure, the fabric 10 can exhibit visually distinct regions, microregions, and three-dimensional features that not only provide superior functionality in at least the areas of softness and fluid handling, but also a visually appealing aesthetic design. The potential differences in physical properties between the first and second surfaces allow for the design of the nonwoven fabric 10 in terms of both strength and softness, both form and function.

[0096] FIG. 41 is a micro-CT scan image, similar to that shown in FIGS. 27 and 28, of a portion of nonwoven fabric 10 that has been subjected to further processing steps to form point bonds 90 within the nip of calendar rollers 71 and 73. Similar to the discussion above of FIGS. 30 and 31, the first and second regions, shown as numbered portions of nonwoven fabric 10, can be analyzed for specific point bond microzones 400, and may specifically include areas of point bonds in numbered regions 31-35. For example, adjacent regions 32 and 26 form microzones 400 within third region 130. In FIG. 41, specific regions are visually distinguished to identify areas containing added point bond areas, which were analyzed to measure thickness, basis weight, and volume density, and the data is presented in FIG. 42, quantifying and comparing the thickness, basis weight, and volume density of all areas containing point bond areas.

[0097] FIG. 42 shows data groupings of first and second region measurements taken within the three regions shown in FIG. 41. The x-axis is a region with numbers corresponding to the numbered regions in FIG. 30. First region measurements are designated as Fn (e.g., F1), and second region measurements are designated as Sn (e.g., S1). Thus, regions 1-5 are first region F1, each within region 110. Regions 6-10 are second region S1, also within region 110. Similarly, first region F2 is regions 16-20 within region 120, and regions 11-15 and 21-25 are second region S2 within region 120. Finally, regions 31-35 are second regions, but are point bonds 90, designated B1 in FIG. 55, and these point bonds 90 are distinguished in this disclosure as being formed by a point bonding process. The first region F3 within region 130 is regions 26-30 and 36-40, and regions 41-44 are the second region S2 within region 130. Each numbered region is shown identically in all three graphs of FIG. 42, but for simplicity, regions 110, 120, and 130 are shown only in the thickness map.

[0098] The graphs shown in FIG. 42 graphically represent the magnitude of the difference in intensive properties between a first region and a second region within any one region of a fabric subjected to a point-bonding process by calendering. These graphs can be used to visualize the difference in intensive properties for pairs of regions that make up a microregion. For example, in region 110, it can be seen that the basis weight between the two regions can vary within a narrower range than the thickness or volume density. For example, the thickness (caliper) can vary from about 325 micrometers in the first region of region 110 to about 29 micrometers in the second region (i.e., a difference of about 10 times). The volume density within region 110 can vary from about 0.08 g / cc to about 0.39 g / cc. Similar quantifiable differences can be seen for each of the regions shown in the figure.

[0099] In general, the microregional areas may have widely varying values ​​for basis weight, thickness, and bulk density.

[0100] 41 and 42 together, further characterization of the beneficial structure of the fabric 10 of the present disclosure can be appreciated, particularly with respect to the thermal calender point bonds 90. Focusing on region 130 for illustrative purposes, the three-dimensional features defining the microregion, including the first and second regions that are point-bonded, can be identified and the values ​​of the intensive properties quantified. For example, in FIG. 41, representative point-bonded microregions 400 within region 130 can be the pairs of regions shown as regions 26 and 32, or regions 30 and 35. That is, first region 26 and second region 32 form one point-bonded microregion 400, and first region 30 and second region 35 form one point-bonded microregion 400.

[0101] The differences in certain intensive properties of point-bonded microzones can be seen in Figure 42. For example, taking the two point-bonded microzones 400 described above (e.g., the two point-bonded microzones 400 in regions 26 and 32 and regions 30 and 35, respectively), it can be seen that while there is a small difference in basis weight between the first and second regions, ranging from about 55 to about 60 gsm, the same regions exhibit a large difference in thickness, from about 430 micrometers to about 460 micrometers to about 125 micrometers, and a large difference in bulk density, from about 0.13-0.14 g / cc to about 0.41-0.48 g / cc. Other differences in intensive properties can be observed by referring to Figure 42.

[0102] Point bonds 90 can play an important role in the overall physical structure and function of fabric 10 of the present disclosure. By adding point bonds 90 to fabric 10, which includes relatively closely spaced, precisely designed three-dimensional features achieved by the forming belt of the present disclosure, fabric 10 can be further improved to exhibit unexpected combinations of visually distinct zones, micro-zones, and three-dimensional features that not only provide superior functionality in the high-performance combination of softness, strength, low fuzz, and fluid handling, but also provide a visually appealing aesthetic design. With point bonds, nonwoven fabric 10 is designed to provide the highest performance combination of strength, softness, liquid handling, and visual aesthetics, especially when both form and function are considered.

[0103] package The absorbent articles of the present disclosure may be placed in a package. The package may include a polymeric film and / or other materials. Graphics and / or indicia relating to the characteristics of the absorbent article may be formed, printed, positioned, and / or disposed on an exterior portion of the package. Each package may include multiple absorbent articles. The absorbent articles may be packaged under compression to reduce the package size while providing a sufficient amount of absorbent articles per package. Packaging the absorbent articles under compression allows caregivers to easily handle and store the package and may also result in reduced distribution costs for manufacturers due to the size of the package.

[0104] Thus, a package of absorbent articles of the present disclosure may have an in-bag stacking height based on the in-bag stacking height test described herein of less than about 110 mm, less than about 105 mm, less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, less than about 80 mm, less than about 78 mm, less than about 76 mm, less than about 74 mm, less than about 72 mm, or less than about 70 mm, specifically recited are all values ​​in 0.1 mm increments within the specified ranges, and all ranges therein or formed thereby. Alternatively, a package of absorbent articles of the present disclosure may have an in-bag stack height according to the In-Bag Stack Height Test described herein of about 70 mm to about 110 mm, about 70 mm to about 105 mm, about 70 mm to about 100 mm, about 70 mm to about 95 mm, about 70 mm to about 90 mm, about 70 mm to about 85 mm, about 72 mm to about 80 mm, or about 74 mm to about 78 mm, specifically recited in 0.1 mm increments within the specified range, and all ranges therein or formed thereby.

[0105] 43 shows an exemplary package 1000 containing a plurality of absorbent articles 1004. The package 1000 defines an interior space 1002 into which the plurality of absorbent articles 1004 are placed. The plurality of absorbent articles 1004 are arranged in one or more stacks 1006.

[0106] absorbent articles The nonwoven fabrics of the present disclosure can form a portion of an absorbent article. The absorbent article may include a tape diaper, pants, an adult incontinence diaper or pad, a sanitary napkin, a panty liner, and / or other suitable absorbent articles. The nonwoven fabrics may also be useful in other consumer products. In the context of absorbent articles, the nonwoven fabrics may form an outer cover nonwoven material, a topsheet, an acquisition layer, a distribution layer, a portion of a core bag, an ear nonwoven material, a secondary topsheet, a waist belt laminate, and / or other suitable nonwoven absorbent article components. The nonwoven fabrics may also form a portion of these components.

[0107] Figures 44 and 45 show exemplary absorbent articles in the form of pants, although tape-type diapers are also within the scope of this disclosure. The pants may include a nonwoven fabric of the present disclosure, for example, as the topsheet and / or outer cover nonwoven material, or as part of the topsheet and / or outer cover nonwoven material. Figure 44 is a front perspective view of an absorbent article including one or more nonwoven fabrics of the present disclosure. Figure 45 is a rear perspective view of the absorbent article of Figure 44.

[0108] Referring again to Figures 44-45, an exemplary absorbent article 710 in the form of belt pants is shown. The absorbent article 710 may include a front region 712, a crotch region 714, and a back region 716. The absorbent article may include a central chassis 726 extending at least partially between the front region 712 and the back region 716. The absorbent article 710 may define leg openings 760 and may include a front waist belt 754 and a back waist belt 756. The front and back belts 754, 756 may include a first extensible material and a second extensible material. An elastic member, such as an elastic film or a plurality of elastic strands, may be disposed intermediate the first and second extensible materials. The first waist belt 754 and the second waist belt 756 may be attached to each other along their lateral edges to form side seams 758. The side seams may include butt seams or overlap seams.

[0109] The central chassis 752 may include a topsheet 760, a backsheet 761, and an absorbent core at least partially disposed intermediate the topsheet and backsheet. The topsheet 760 may form a portion of the garment-facing surface of the absorbent article 710 and may include one or more nonwovens disclosed herein. The central chassis 752 may include an outer cover nonwoven material 762 that forms a portion of the garment-facing surface of the absorbent article and is in a facing relationship with the backsheet film. The outer cover nonwoven material 762 may include one or more nonwovens disclosed herein. The central chassis may include one or more acquisition layers and / or one or more distribution layers at least partially intermediate the topsheet and the absorbent core. The nonwovens may include crimped fibers.

[0110] Emtec The present disclosure provides a solution to the problems discussed in the Background section by providing absorbent articles comprising nonwoven fabrics with improved softness while maintaining high texture. The present disclosure further resolves the tradeoff between high softness and high texture while providing several improvements in fluid handling, including rapid penetration of bodily exudates and enhanced skin and topsheet dryness. Typically, nonwoven fabrics of the present disclosure may form at least a portion of the wearer-facing surface (e.g., topsheet) and at least a portion of the garment-facing surface (e.g., outer cover nonwoven material). In accordance with the Emtec test herein, softness, texture (i.e., smoothness), and / or stiffness can be measured with an Emtec Tissue Softness Analyzer. Tactile softness is measured as TS7. Texture / smoothness is measured as TS750. Stiffness is measured as D.

[0111] All of the following Examples 1-10 are side-by-side bicomponent spunbond nonwovens made by spinning a 30:70 blend of polypropylene (PP3155, obtained from Exxon Mobil Corporation) and a 25:75 blend of polypropylene (PP3155 and PP3854, obtained from Exxon Mobil Corporation). Approximately 1% titanium dioxide and 1% erucamide were added to the polymer to improve whiteness and softness. In the topsheet of Example 2, 0.25% by weight of the nonwoven of a blue pigment melt additive was added to enhance the visual perception of three-dimensionality. All of the nonwovens were spun on a forming belt with a three-dimensional pattern, as generally described with reference to Figure 16, although the patterns varied. The belt traveled at a line speed of approximately 28 meters / min to form a 25 gsm nonwoven. The belt was operated at a slower line speed for the higher basis weight nonwoven outer cover materials of Examples 7-10. The fibers of the nonwoven fabrics of Examples 1 to 10 were compressed by heated compression rolls 70, 72 and further bonded by an 8% dot pattern calender roll at a temperature of about 140°C.

[0112] [Table 5] * All values ​​in Table 5 are measured according to the Emtec test herein.

[0113] A portion or all of the wearer-facing surface of the topsheet of the present disclosure has a thermal conductivity of about 1 dBV 2 rms~about 4.5dBV 2 rms, about 2dBV 2 rms~about 4.5dBV 2 rms, or approximately 2 dBV 2 rms ~ approx. 4.0dBV 2 A portion or all of the wearer-facing surface of the topsheet of the present disclosure may also have a TS7 value in the range of about 4 dBV rms. 2 rms~about 30dBV 2 rms, approximately 6 dBV 2 rms~about 30dBV 2 rms, approximately 6 dBV 2rms~about 20dBV 2 rms, approximately 6 dBV 2 rms~about 15dBV 2 rms, approximately 6 dBV 2 rms~about 12dBV 2 rms, or approximately 6.5 dBV 2 rms ~ approx. 10dBV 2 The TS750 value may be in the range of rms. Portions or all of the wearer-facing surface of the topsheet of the present disclosure may also have a D value in the range of about 1 mm / N to about 10 mm / N, about 3 mm / N to about 8 mm / N, about 2 mm / N to about 6 mm / N, about 2 mm / N to about 4 mm / N, or about 3 mm / N to about 4 mm / N. All values ​​are measured according to the Emtec test herein. The TS7 value is tactile softness, so a low number is desired (the lower the number, the softer the material). The TS750 value is texture, so a high number is desired (the higher the number, the more textured the material). Having a low TS7 value and a high texture value is a contradiction in that the nonwoven typically has more texture and is less soft. Without wishing to be bound by theory, applicants have discovered the unexpected result of a highly textured nonwoven fabric that is still very soft, by providing a range of selections for the areas of Region 1 and Region 2 of the nonwoven fabric, as discussed below.

[0114] [Table 6] * All values ​​in Table 6 are measured according to the Emtec test herein.

[0115] A portion of the garment-facing surface of the outer cover nonwoven material of the present disclosure has a thermal conductivity of about 1 dBV 2 rms~about 4.5dBV 2 rms, about 2dBV 2 rms~about 4.5dBV 2 rms, or approximately 2 dBV 2 rms ~ approx. 4.0dBV 2A portion of the garment-facing surface of the outer cover nonwoven material of the present disclosure may also have a TS7 value in the range of about 4 dBV rms. 2 rms~about 30dBV 2 rms, approximately 6 dBV 2 rms~about 30dBV 2 rms, approximately 6 dBV 2 rms~about 20dBV 2 rms, approximately 6 dBV 2 rms~about 15dBV 2 rms, approximately 6 dBV 2 rms~about 12dBV 2 rms, or approximately 6.5 dBV 2 rms ~ approx. 10dBV 2 The outer cover nonwoven material of the present disclosure may have a TS750 value in the range of rms. Portions or all of the garment-facing surface of the outer cover nonwoven material may also have a D value in the range of about 1 mm / N to about 10 mm / N, about 3 mm / N to about 8 mm / N, about 2 mm / N to about 6 mm / N, about 2 mm / N to about 4 mm / N, or about 3 mm / N to about 4 mm / N. All values ​​are measured according to the Emtec test described herein. Having a low TS7 value and a high texture value is typically a contradiction in that the nonwoven will have more texture and less softness. While not wishing to be bound by theory, applicants have discovered the unexpected result of a highly textured nonwoven that is still very soft by providing a range of selections for the areas of Region 1 and Region 2 of the nonwoven, as discussed below.

[0116] It may be desirable to have the specific TS7 and TS750 properties discussed above in both the outer cover nonwoven material and the topsheet, which provides a soft texture on both sides (i.e., wearer-facing and garment-facing) of the absorbent article.

[0117] The absorbent article may include a nonwoven topsheet, a backsheet, an absorbent core at least partially disposed intermediate the topsheet and the backsheet, and a nonwoven outer cover joined to the backsheet, wherein a first portion of the nonwoven topsheet on a wearer-facing side and a second portion of the nonwoven outer cover on a garment-facing side each have a nonwoven outer cover that is less than about 1 dBV according to the Emtec test. 2 rms~about 4.5dBV 2 The second portion of the nonwoven outer cover on the garment-facing side may have a TS750 value in the range of about 1.2 to about 4 times, about 1.3 to about 3 times, or about 1.5 to about 2 times greater than the TS750 value of the first portion of the nonwoven topsheet on the wearer-facing side.

[0118] Area 1 and Area 2 Area% To achieve the desired results of the present disclosure of improved softness with increasing texture of nonwovens such as outer cover nonwoven materials and topsheets, it may be desirable to have a portion of the nonwoven (corresponding to the resin pattern on the belt) have a total Area 1 region (e.g., a low basis weight region) ranging from about 5% to about 25%, about 5 to about 20%, or 10% to 20% of the total area of ​​the nonwoven, while the remainder of the nonwoven has a total Area 2 region (e.g., a high basis weight region) (e.g., corresponding to the region on the belt that does not contain resin). Higher basis weight regions are typically softer than lower basis weight regions because they contain more fibers. Nonwovens having low basis weight regions ranging from about 5% to about 20% of the total nonwoven typically achieve good dryness and good softness. Low basis weight regions less than 5% typically achieve high softness but typically do not provide good dryness. Low basis weight regions greater than 25% typically achieve good dryness but typically do not provide good softness.

[0119] In addition to the above advantages, another advantage of the shaped, flexible, textured nonwoven fabric of the present disclosure is the ability to provide a nonwoven fabric with microzones comprising one or more hydrophobic regions and one or more distinct hydrophilic regions. The hydrophilicity and / or hydrophobicity of a specific region of a microzone can be determined by wicking time measurements using the Wick Time Test Method described herein and / or contact angle measurements using the Contact Angle Test Method described herein. When used herein with respect to a specific region of a microzone, the term "hydrophilic" means that the wicking time of that specific region is less than 10 seconds when tested using the Wick Time Test Method. When used herein with respect to a specific region of a microzone, the term "hydrophobic" means that the contact angle of that specific region is 90° or greater when tested using the Contact Angle Test Method.

[0120] Table 7 below details the contact angle and wick time measurements for the molded, flexible, and textured nonwoven fabrics detailed herein. In both Examples 11 and 12 below, the nonwoven fabrics were made on the belt illustrated in Figure 16, and the nonwoven fabrics had an appearance similar to that shown in Figure 2.

[0121] [Table 7]

[0122] Example 11: A bicomponent spunbond nonwoven fabric was obtained by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A obtained from Dow Chemical Company) and polypropylene core (PH-835 obtained from LyondellBasell) into a trilobal fiber configuration. The nonwoven fabric was spun onto a forming belt having a repeating pattern as described in FIG. 16, moving at a linear speed of approximately 25 meters / min, to form fabric 10 having an average basis weight of 25 grams per square meter and a diamond repeating pattern as shown in FIG. 2. The fabric fibers were compressed by compression rolls 70 and 72, but were not calendered. Further bonding was achieved by a through-air bonding unit at a temperature of 145°C.

[0123] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylate and PEG diester) supplied by Pulcra Chemicals, was then placed on the backside of the nonwoven fabric (i.e., the flat surface opposite the side on which the relatively pillow-like three-dimensional features were placed) through a kiss coating process. The coating process was carried out using a Reicofil Kiss Roll and Omega drying process, both of which are commonly known in the art. The surfactant used in the kiss roll process was a 6% surfactant concentration in water at a temperature of 40°C. The kiss roll contact angle was set at 250°, and the drying temperature was 80°C. The nonwoven fabric was then contacted with a kiss roll operating at a speed of 13 rpm, and 0.45 wt% of surfactant was applied to the nonwoven fabric (surfactant % = 1 m 2 The weight of surfactant added per 1m 2 (The weight of the nonwoven fabric is calculated by dividing the weight by the weight of the nonwoven fabric.)

[0124] Example 12 A bicomponent spunbond nonwoven fabric was obtained by spinning a 50:50 ratio of polyethylene sheath (Aspun-6850-A obtained from Dow Chemical Company) and polypropylene core (PH-835 obtained from LyondellBasell) into a trilobal fiber configuration. The nonwoven fabric was spun onto a forming belt having a repeating pattern as described in FIG. 16, moving at a linear speed of approximately 25 meters / min, to form fabric 10 having an average basis weight of 25 grams per square meter and a diamond repeating pattern as shown in FIG. 2. The fabric fibers were compressed by compression rolls 70 and 72, but were not calendered. Further bonding was achieved by a through-air bonding unit at a temperature of 145°C.

[0125] Next, a surfactant, Stantex S 6327 (a combination of castor oil ethoxylate and PEG diester) supplied by Pulcra Chemicals, was applied to the front side of the nonwoven fabric (i.e., the side with the relatively pillow-like three-dimensional features located on top) via an inkjet printing process. The inkjet printing process was performed using a Dimatix DMP 2831 inkjet printer equipped with cartridge model #DMC-11610 / PM 700-10702-01 (10 pL). The print head temperature was 40°C. The surfactant used in the inkjet printing process consisted of 75% w / w Stantex S 6327 and 25% w / w ethanol. The nonwoven fabric sample was oriented so that the second region of the microzones in the first row was aligned with the print head direction, and the surfactant was printed in the second region of the microzones of the nonwoven fabric by printing a first series of straight lines with the droplet spacing adjusted to 170 μm. The nonwoven fabric sample was then rotated by an angle such that the second region of the second row of microzones was aligned with the print head, printing a second series of straight lines at 170 μm. The basis weight of the fibers in the second region was approximately 16.0 gsm. The basis weight of the surfactant inkjet-printed on the second region was approximately 0.25 gsm. Therefore, the amount of surfactant locally printed on the second region was determined to be approximately 1.6 wt.% surfactant (0.25 gsm / 16.0 gsm). Overall, the amount of surfactant printed on the nonwoven fabric sample was determined to be approximately 0.2 wt.% surfactant, based on the ratio of the printed line width to the line spacing.

[0126] In addition to Stantex S 6327, the use of other surfactants (by any method of application) to render the first and / or second regions of a particular microregion hydrophilic and / or hydrophobic is considered within the scope of the present disclosure.

[0127] The nonwoven fabrics detailed above have microzones with regions of differences in intensive properties, such as basis weight, density, or thickness. These same nonwoven fabrics can also simultaneously contain such regions of microzones that are hydrophobic and / or hydrophilic, specifically and separately. Any of the example nonwoven fabrics detailed herein (e.g., samples including regions and / or microzones with regions of differences in thickness, basis weight, and / or volume density, and / or surfaces with the various TS7, TS750, and D values ​​disclosed herein) can further have regions of microzones with differences in hydrophilicity, as detailed herein. Hydrophilicity can be provided by targeted application(s) of surfactant(s) onto specific regions of the microzones of the nonwoven fabric. For example, a second region of a microzone can have a surfactant disposed thereon, while a first region of the same microzone may not have a surfactant disposed thereon. Furthermore, a first region of a microzone can have a surfactant disposed thereon, while a second region of the same microzone may not have a surfactant disposed thereon. For example, in one microzone, the first or second region may have any concentric range of surfactant within the ranges of about 0.01% to about 5.0%, about 0.05% to about 4.0%, about 1.0% to about 3.0%, and about 0.01% to about 5.0%, while the other region has no surfactant (i.e., no surfactant). As an example, in one microzone, the second region may have any concentric range of surfactant within the ranges of about 0.01% to about 5.0%, about 0.05% to about 4.0%, about 1.0% to about 3.0%, and about 0.01% to about 5.0%, while the first region has no surfactant (i.e., no surfactant). Thus, some nonwoven fabrics disclosed herein have microzones having at least one of the first and second regions having surfactant, wherein the ratio of the surfactant % in the first region to the surfactant % in the second region is less than 1. Additionally, some nonwoven fabrics disclosed herein have microzones that include at least a second region of the microzone having surfactant, wherein the ratio of the % surfactant in the first region to the % surfactant in the second region is less than 1.

[0128] As another example, a second region of a microzone can have a particular amount or percentage of surfactant disposed thereon, while a first region of the same microzone can have a different amount or percentage of surfactant disposed thereon. For example, within a single microzone, the first region can have any concentric range of surfactant within the ranges of about 0.01% to about 2.0%, about 0.05% to about 1.5%, about 0.1% to about 1.0%, and about 0.01% to about 2.0%, while the second region can have a different amount. Furthermore, within a single microzone, the second region can have any concentric range of surfactant within the ranges of about 0.01% to about 5.0%, about 0.05% to about 4.0%, about 1.0% to about 3.0%, and about 0.01% to about 5.0%, while the first region can have a different amount. The surfactant % of a particular area of ​​a microzone can be determined by taking the grams per square meter of surfactant disposed in the particular area and dividing it by the basis weight of the fibers of the molded nonwoven contained within the same area. The grams per square meter of surfactant disposed in the particular area can be determined using any method currently known in the art (e.g., gravimetric measurements, etc.). The basis weight of the fibers of the nonwoven contained within the particular area of ​​a microzone can also be determined using any method currently known in the art (e.g., gravimetric measurements, microCT, etc.).

[0129] The surfactant can be deposited on the nonwoven fabric by any method known in the art. Specific examples include kiss coating, inkjet printing, gravure printing, offset gravure printing, surfactant flexographic printing, and surfactant registration printing. Any such method can deposit the surfactant on either the first and / or second surface of the nonwoven fabric. The surfactant can be added to the molded nonwoven fabric in any concentric range within the following ranges, relative to the total molded nonwoven fabric (considering all individual areas and microareas on the fabric): about 0.01% to about 2.0%, about 0.05% to about 1.5%, about 0.1% to about 1.0%, and about 0.01% to about 2.0%. To calculate the surfactant percentage in the total molded nonwoven fabric, the grams per square meter of surfactant in the total molded nonwoven fabric is divided by the basis weight of the total molded nonwoven fabric. The grams per square meter of surfactant deposited in the total molded nonwoven fabric can be determined using any method currently known in the art, such as gravimetric measurements. The basis weight of the entire molded nonwoven may also be determined using any method currently known in the art (eg, gravimetric methods, micro-CT methods, etc.).

[0130] Referring again to FIGS. 25 and 26, which illustrate a portion of one pattern of nonwoven fabric 10, first region 110 (left side of FIG. 25) is characterized by generally MD rows of first regions 300 of varying width separated by MD rows of second regions 310 of varying width (the first and second regions are within a microregion). The first regions are also three-dimensional features 20 that define first and second regions 300, 310. The three-dimensional features are portions of nonwoven fabric 10 formed between or around raised elements of the forming belt, referred to in this description as first regions 300, with the resulting structure having a relatively larger dimension in the Z direction, a relatively higher basis weight, and a lower bulk density compared to second regions 310. Furthermore, first regions 300 may be hydrophobic, and second regions 310 may be hydrophilic. Targeted addition of surfactant to the second region 310 of the microzone can render the second region hydrophilic. Accordingly, the first region 300 of the microzone can have a contact angle greater than about 90°, or between about 90° and about 140°, or between about 110° and about 135°, or between about 125° and about 135°, or any concentric range contained within about 90° and about 140°, when tested according to the Contact Angle Test Method detailed herein. The second region 310 of the microzone can have a contact angle less than 90° when tested according to the Contact Angle Test Method detailed herein. The first region 300 of the microzone can have a wick time value greater than about 10 seconds, or between about 10 seconds and 60 seconds, when measured according to the Wick Time Test Method detailed herein. The second region 310 of the microzone may have a wicking time value, as measured by the Wick Time Test Method detailed herein, of less than about 10 seconds, less than about 5 seconds, or less than about 2.5 seconds, or less than about 1.0 seconds, or less than about 0.5 seconds, or in a range of about 0.5 seconds to about 10 seconds, or about 0.5 seconds to about 5 seconds. Nonwoven fabrics contemplated herein include any of the detailed parameter ranges above for the first region and / or second region in combination with contact angle and / or wicking time measurements, any of the other intensive properties / property differences disclosed herein, the same or different regions within the same or different microzones on the molded nonwoven fabric.

[0131] For example, shaped nonwoven fabrics having the detailed microregions described above having regions of differential basis weight, density, or thickness, while simultaneously having such regions of specific microregions that are separately hydrophobic and / or hydrophilic, can provide many useful applications, such as topsheet materials for absorbent articles, as well as for use in medical pads, wipes, and cleaning pads.

[0132] Test Method: Local basis weight The local basis weight of a nonwoven fabric can be measured by several available methods, but one simple and representative method is to measure the 2 A die having an area of ​​0.01 mm is used to cut a sample piece of the web from a selected area of ​​the total area of ​​the nonwoven. The sample piece is then weighed and divided by its area to obtain the local basis weight of the nonwoven in grams per square meter. Results are reported as the average of two samples per selected area.

[0133] Bag stacking height test The stack height of a package of absorbent articles within a bag is measured as follows.

[0134] device A thickness tester is used that includes a flat, rigid horizontal sliding plate. The thickness tester is configured so that the horizontal sliding plate is free to move vertically while always maintaining a horizontal orientation directly above a flat, rigid horizontal base plate. The thickness tester includes a device suitable for measuring the gap between the horizontal sliding plate and the horizontal base plate to within ±0.5 mm. The horizontal sliding plate and the horizontal base plate are larger than the surface of the absorbent article package that contacts each plate (i.e., each plate extends beyond the contact surface of the absorbent article package in all directions). The horizontal sliding plate applies a downward force of 850±1 grams-force (8.34 N) to the absorbent article package, which can be achieved by placing a suitable weight in the center of the top surface of the horizontal sliding plate that does not contact the package, so that the total mass of the sliding plate plus the additional weight equals 850±1 grams.

[0135] Test Procedure The absorbent article package is equilibrated at 23±2° C. and 50±5% relative humidity prior to measurement.

[0136] Raise the horizontal sliding plate and center the absorbent article package under it with the absorbent articles in the package oriented horizontally (see Figure 43). Any handles or other packaging features on the surface of the package that would contact any of the plates should be folded flat against the surface of the package to minimize their effect on the measurement. Slowly lower the horizontal sliding plate until it contacts the top surface of the package, then release it. 10 seconds after releasing the horizontal sliding plate, measure the gap between the horizontal plates to within ±0.5 mm. Five identical packages (same size package and same number of absorbent articles) are measured and the arithmetic mean is reported as the package width. Calculate "in-bag stack height" = (package width / number of absorbent articles per stack) x 10 and report within ±0.5 mm.

[0137] Measurement method of intensive properties using micro-CT This micro-CT intensive property measurement method measures basis weight, thickness, and volume density values ​​within visually distinct regions of a substrate sample. The method is based on the analysis of 3D X-ray sample images acquired with a micro-CT instrument (a suitable instrument is the Scanco μCT 50, available from Scanco Medical AG, Switzerland, or an equivalent instrument). The micro-CT instrument is a cone-beam microtomograph equipped with a shielded cabinet. A maintenance-free X-ray tube is used as the source, with an adjustable focal spot diameter. The X-ray beam passes through the sample, and a portion of the X-rays is attenuated by the sample. The degree of attenuation correlates with the mass of material through which the X-rays must pass. The transmitted X-rays are then incident on a digital detector array, generating 2D projection images of the sample. A 3D image of the sample is generated by collecting multiple individual projection images of the rotated sample and then reconstructing these projection images into a single 3D image. The instrument is interfaced with software running on a computer to control image acquisition and store the raw data. The 3D image is then analyzed using image analysis software (suitable image analysis software is MATLAB or equivalent software available from The Mathworks, Inc., Natick, MA) to measure the intensive properties of basis weight, thickness, and volume density of regions within the sample.

[0138] Sample preparation: To obtain the sample for measurement, one layer of dry substrate material is laid flat and a circular piece 30 mm in diameter is punched out.

[0139] If the substrate material is a layer of an absorbent article, such as a topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer, the absorbent article is taped to a firm, flat surface in a planar configuration. Individual substrate layers are carefully separated from the absorbent article. If necessary, a scalpel and / or cryospray (Cyto-Freeze, Control Company, Houston, TX) can be used to remove the substrate layer from any underlying layers, preventing longitudinal and lateral stretching of the material. Once the substrate layer is removed from the article, samples are punched out as described above.

[0140] If the substrate material is in the form of a wet wipe, open a new package of wet wipes and remove the entire stack from the package. Remove one wipe from the middle of the stack, lay it flat and allow it to dry completely before die-cutting a sample for analysis.

[0141] Samples can be cut from any location that contains a visually distinct area for analysis. Within a region, the area for analysis is an area associated with a three-dimensional feature that defines a microregion. A microregion contains at least two visually distinct areas. Regions, three-dimensional features, or microregions can be visually distinct due to variations in texture, height, or thickness. Regions within different samples taken from the same substrate material may be analyzed and compared to each other. Care should be taken when selecting sample locations to avoid folds, wrinkles, or tears.

[0142] Image acquisition: The micro-CT instrument is prepared and calibrated according to the manufacturer's specifications. The sample is placed between two rings of low-density material with an inner diameter of 25 mm in a suitable holder. This allows the central portion of the sample to be horizontally positioned and scanned without any other material directly adjacent to its top or bottom surfaces. Measurements must be taken in this area. The 3D image field of view is approximately 35 mm on each side in the XY plane, has a resolution of approximately 5000 x 5000 pixels, and a sufficient number of 7-micrometer-thick slices are collected to completely encompass the Z direction of the sample. The reconstructed 3D image resolution contains 7-micrometer isotropic voxels. Images are acquired using a 45 kVp and 133 μA power supply without additional low-energy filtering. These current and voltage settings can be optimized to allow sufficient x-rays to penetrate the sample to maximize contrast in the projection data, but once optimized, they are kept constant for all substantially similar samples. A total of 1500 projection images are acquired with an integration time of 1000 ms and three averages. These projection images are reconstructed into 3D images and saved in 16-bit RAW format to preserve the complete detector output signal for analysis.

[0143] Image Processing: Load the 3D image into image analysis software. Threshold the 3D image to isolate and remove background signal due to air, while preserving the signal from the sample fibers within the substrate.

[0144] Three 2D intensive property images are generated from the thresholded 3D image. The first is a basis weight image. To generate this image, the value of each voxel in a slice in the XY plane is summed with the values ​​of all of the corresponding voxels in other Z slices that contain signal from the sample. This generates a 2D image in which each pixel has a value equal to the cumulative signal throughout the sample.

[0145] A basis weight calibration curve is generated to convert the raw data values ​​in the basis weight image to actual values. A substrate having a substantially similar composition to the sample being analyzed and a uniform basis weight is obtained. At least 10 replicate samples of the calibration curve substrate are obtained according to the procedure described above. The basis weight of each single-layer calibration sample is accurately measured by measuring the mass to the nearest 0.0001 g, dividing by the sample area, and converting to grams per square meter (gsm), and the average is calculated to the nearest 0.01 gsm. A micro-CT image of the single-layer calibration sample substrate is acquired according to the procedure described above. The micro-CT image is processed according to the procedure described above to generate a basis weight image containing raw data values. The actual basis weight value of this sample is the average basis weight value measured for the calibration sample. Two layers of the calibration substrate sample are then stacked on top of each other, and a micro-CT image of the two-layer calibration substrate is acquired. A raw data image of the combined basis weight of both layers is generated. The actual basis weight value is equal to twice the average basis weight value measured for the calibration sample. Single-layer calibration substrates are stacked, micro-CT images of all layers are acquired, and raw data basis weight images of all layers are generated, with the actual basis weight equal to the number of layers multiplied by the average basis weight measured on the calibration samples. This procedure is repeated, resulting in a total of at least four different basis weight calibration images. To ensure accurate calibration, the basis weight values ​​of the calibration samples must include values ​​above and below the basis weight of the original sample being analyzed. A calibration curve is generated by performing a linear regression of the raw data against the actual basis weight values ​​for the four calibration samples. This linear regression must have an R2 value of at least 0.95; if not, the entire calibration procedure is repeated. This calibration curve is then used to convert the raw data values ​​to actual basis weights.

[0146] The second intensive property 2D image is the thickness image. To generate this image, the top and bottom surfaces of the sample are identified and the distance between these surfaces is calculated to obtain the sample thickness. The top surface of the sample is identified by identifying the Z voxel location for every pixel location in the XY plane where sample signal was first detected, starting with the top Z slice and progressing through the sample, evaluating each slice. To identify the bottom surface of the sample, the same procedure is followed, except that every Z voxel located is the location in the XY plane where sample signal was last detected. Once the top and bottom surfaces are identified, they are smoothed with a 15 x 15 median filter to remove signal from stray fibers. The 2D thickness image is then generated by counting the number of voxels between the top and bottom surfaces for each pixel location in the XY plane. This raw thickness value is then converted to an actual distance in micrometers by multiplying the voxel count by the 7 μm slice thickness resolution.

[0147] The third intensive property 2D image is the volume density image. This image is generated by dividing each XY-plane pixel value in the basis weight image in gsm by the corresponding pixel in the thickness image in micrometers. The volume density image has units of grams per cubic centimeter (g / cc).

[0148] Intensive properties of basis weight, thickness, and volume density by micro-CT: The analysis begins by identifying the area to be analyzed. The area to be analyzed is an area associated with a three-dimensional feature that defines a microregion. A microregion includes at least two visually distinct regions. A region, three-dimensional feature, or microregion may be visually distinct due to variations in texture, height, or thickness. Next, the boundary of the area to be analyzed is identified. The boundary of the area is identified by visually distinguishing differences in intensive properties compared to other areas within the sample. For example, the boundary of the area can be identified based on visually distinguishing differences in thickness compared to another area of ​​the sample. Any intensive property can be used to distinguish the boundary of an area within the physical sample itself, either in an image of the intensive property from micro-CT. Once the boundary of the area is identified, an oval or circular "region of interest (ROI)" is drawn within the area. The ROI must be at least 0.1 mm. 2 The area having an area of ​​0.01 gsm, the thickness of the ROI, and the volume density of the ROI should be selected to measure. From each of the three intensive property images, calculate the average basis weight, thickness, and volume density within the ROI. Record these values ​​for the area to the nearest 0.01 gsm for the basis weight, 0.1 micrometer for the thickness, and 0.0001 g / cc for the volume density.

[0149] Emtec Test The Emtec test is performed on a target portion of the outer cover nonwoven material or topsheet. In this test, TS7, TS750, and D values ​​are measured using an Emtec Tissue Softness Analyzer ("Emtec TSA") (Emtec Electronic GmbH, Leipzig, Germany) connected to a computer running Emtec TSA software (version 3.19 or equivalent). The Emtec TSA includes a rotor with a vertical blade that rotates on the test specimen at a specified, calibrated rotation speed (set by the manufacturer) and a contact force of 100 mN. Contact between the vertical blade and the test specimen generates vibrations in both the blade and the specimen, and the resulting sound is recorded by a microphone within the instrument. The recorded sound file is then analyzed by the Emtec TSA software to determine the TS7 and TS750 values. The D value is a measure of the specimen's stiffness and is increased from 100 mN to 600 mN based on the vertical distance required for the blade's contact force on the test specimen. Sample preparation, instrumentation, and testing procedures are performed according to the instrument manufacturer's specifications.

[0150] Sample preparation Test samples are prepared by cutting a square or circular section of interest from the outer cover nonwoven material or topsheet of the absorbent article. Freezing spray is not used to remove the portion of the outer cover nonwoven material or topsheet to be analyzed, but freezing spray can be used on distal areas to help initiate layer separation. Test samples are cut to lengths and widths (diameters for circular samples) of approximately 90 mm to 120 mm to allow the sample to be properly clamped within the TSA device. (If the absorbent article does not contain a sufficiently large area of ​​the substrate of interest to extract a sample of the size specified above, equivalent material can be sampled from roll stock.) Test samples are selected to ensure there are no perforations, wrinkles, or folds within the test area. Six substantially identical replicate samples are prepared for testing.

[0151] Prior to conducting the TSA test, all samples are equilibrated for at least 2 hours at TAPPI's standard temperature and relative humidity conditions (23°C ± 2°C and 50% ± 2%), and the TSA test is also conducted under TAPPI conditions.

[0152] Test Procedure The instrument is calibrated according to Emtec's instructions using a one-point calibration method using appropriate reference standards available from Emtec (so-called "ref. 2 samples" or equivalent).

[0153] The test specimen is mounted in the fixture with the target surface facing upwards and the test is performed according to the manufacturer's instructions. The software displays the TS7, TS750, and D values ​​upon completion of the automated fixture test routine. TS7 and TS750 are each 0.01 dBV. 2 The force is recorded in rms units, and D is recorded to the nearest 0.01 mm / N. The test sample is then removed from the fixture and disposed of. This test procedure is performed separately on the corresponding target surface of each of the six replicate samples (the garment-facing surface of the topsheet sample and the garment-facing surface of the outer cover nonwoven material sample).

[0154] The values ​​of TS7, TS750, and D are each averaged over six sample replicates (arithmetic mean). The mean values ​​of TS7 and TS750 are within 0.01 dBV. 2 Reported in rms units. Average values ​​of D are reported in 0.01 mm / N.

[0155] Contact Angle and Wick Time Test Method Contact angle and wicking time measurements are determined using a sessile drop experiment. A specific amount of Type II reagent distilled water (as defined in ASTM D1193) is applied to the surface of the test sample using an automated liquid delivery system. A high-speed video camera captures time-stamped images of the droplet over a 60-second period at a rate of 900 frames per second. The contact angle between the droplet and the surface of the test sample is determined for each captured image by image analysis software. The wicking time is determined as the time it takes for the contact angle of a droplet absorbed into the test sample to decrease to a contact angle of <10°. All measurements are performed at a constant temperature (23°C ± 2°C) and relative humidity (50% ± 2%).

[0156] To perform this test, an automated contact angle tester is required. The system includes a light source, a video camera, a horizontal sample stage, a liquid delivery system with a pump and microsyringe, and a computer with suitable software for video image capture, image analysis, and reporting of contact angle data. A suitable instrument is the Optical Contact Angle Measurement System OCA 20 (DataPhysics Instruments, Filderstadt, Germany) or equivalent. The system must be capable of delivering an 8.2 microliter droplet and capturing images at a rate of 900 frames per second. Unless otherwise specified in this test procedure, the system is calibrated and operated according to the manufacturer's instructions.

[0157] To obtain the test sample for measurement, lay a single layer of dry substrate material flat and cut out a rectangular test sample 15 mm wide and approximately 70 mm long. The width of the sample can be reduced as needed to ensure that the test area of ​​interest is not obscured by surrounding features during testing. Care must be taken with narrow sample pieces to ensure that droplets do not reach the edge of the test sample during testing; otherwise, the test must be repeated. Precondition the sample for 2 hours at 23°C ± 2°C and 50% ± 2% relative humidity before testing.

[0158] Sample preparation Test samples can be cut from any location that contains a visually distinct area for analysis. Within a region, the area for analysis is an area associated with a three-dimensional feature that defines a microregion. A microregion includes at least two visually distinct areas. A region, three-dimensional feature, or microregion can be visually distinct due to variations in texture, height, or thickness. Regions within different test samples taken from the same substrate material can be analyzed and compared to each other. When selecting the location for sample collection, care must be taken to avoid folds, wrinkles, or tears.

[0159] If the substrate material is a layer of an absorbent article, such as a topsheet or outer cover nonwoven material, acquisition layer, distribution layer, or other component layer, tape the absorbent article to a firm, flat surface in a planar configuration. Carefully separate the individual substrate layers from the absorbent article. If necessary, a scalpel and / or a cold spray (Cyto-Freeze, Control Company, Houston, TX) can be used to remove the substrate layer from any underlying layers, thereby preventing longitudinal and lateral stretching of the material. Once the substrate layer is removed from the article, proceed to cut the test samples. If the substrate material is in the form of wet wipes, open a new package of wet wipes and remove the entire stack from the package. Remove one wipe from the middle of the stack, lay it flat, and allow it to dry completely before cutting out a sample for analysis.

[0160] Test Procedure The test sample is placed on a horizontal sample stage with the test surface facing up and the test area within the camera's field of view below the needle of the liquid delivery system. The test sample is held flat but not taut, and all interaction between the droplet and the underlying surface is avoided to prevent excessive capillary forces. A 27-gauge blunt-tip stainless steel needle (ID 0.23 mm, OD 0.41 mm) is positioned above the test sample so that at least 2 mm of the needle tip is within the camera's field of view. The sample stage is adjusted so that there is a distance of approximately 3 mm between the tip of the needle and the surface of the test sample. 8.2 microliter droplets of reagent distilled water are formed at a rate of 1 microliter / second and allowed to free-fall onto the surface of the test sample. Video image capture is initiated before the droplet contacts the surface of the test sample, and a continuous series of images is then collected 60 seconds after the droplet contacts the surface of the test sample. This procedure is repeated for a total of five substantially similar replicate test areas. Use a new test sample or ensure that the wetted area of ​​the previous drop is avoided during subsequent measurements.

[0161] On each of the images captured by the video camera, the test sample surface and the outline of the droplet are identified and used by image analysis software to calculate the contact angle for each droplet image, reported to the nearest 0.1 degrees. The contact angle is the angle formed by the surface of the test sample and is tangent to the surface of the droplet in contact with the test sample. For each series of images from the test, time zero is the time the droplet contacts the surface of the test sample. The contact angle of the droplet image corresponding to zero plus 5 seconds is measured and recorded. The contact angle at 5 seconds is reported as 0° if the droplet is completely absorbed by the test sample within 5 seconds. This procedure is repeated for five replicate test areas. The arithmetic mean of the contact angles at zero plus 5 seconds for the five replicate test areas is calculated, and this value is reported as the contact angle to the nearest 0.1 degrees.

[0162] Wick time is defined as the time it takes for the contact angle of a droplet absorbed into the test sample to decrease to a contact angle of <10°. Wick time is measured by identifying the first image in a given series in which the contact angle decreases to a contact angle of <10°, and then calculating and reporting the amount of time elapsed from time zero based on that image. If a contact angle of <10° is not reached within 60 seconds, the wick time is reported as 60 seconds. This procedure is repeated for five replicate test areas. The arithmetic mean of the wick times for the five replicate test areas is calculated and this value is reported to the nearest 0.1 millisecond.

[0163] Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "approximately 40 mm."

[0164] All documents cited in this application, including all cross-referenced or related patents or patent applications, and any patent application or patent to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest, or disclose such invention, either alone or in combination with any other reference(s). Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0165] While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the disclosure. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this disclosure.

Claims

1. An absorbent article comprising: a topsheet comprising a nonwoven fabric, the nonwoven fabric comprising a surface facing a wearer; A backsheet film; an absorbent core positioned at least partially intermediate the topsheet and the backsheet film; first and second visually distinguishable areas on the wearer-facing surface, each of the first and second visually distinguishable areas having a pattern of three-dimensional features; each of the three-dimensional features defines a microregion including a first region and a second region; the first and second regions have a difference in value of the intensive property; the intensive properties are thickness, basis weight and / or bulk density; first and second visually distinguishable regions, wherein the difference in value of the intensive property of at least one of the micro-regions of the first region is different from the difference in value of the intensive property of at least one of the micro-regions of the second region; a portion of the wearer-facing surface overlaps with an area having a pattern of three-dimensional features; the portion of the wearer-facing surface has a Total Area 1 area that is a low basis weight area that is 5% to 25% of the total area of ​​the portion of the wearer-facing surface, and the remainder of the portion of the wearer-facing surface is a Total Area 2 area that is a high basis weight area, and ２ rms~3.8dBV ２ having TS7 values ​​in the range of rms, 7 dBV according to Emtec testing. ２ rms~9.6dBV ２ having TS750 values ​​in the range of rms, An absorbent article wherein said portion of said wearer-facing surface has a D-value in the range of 3.16 mm / N to 3.95 mm / N according to the Emtec test.

2. The absorbent article of claim 1 , wherein the nonwoven fabric is a spunbond nonwoven fabric.

3. an outer cover nonwoven in facing relationship with at least a portion of the backsheet film, the outer cover nonwoven including a second nonwoven having a garment-facing surface; third and fourth visually distinct areas on the garment-facing surface of the outer cover nonwoven material, each of the third and fourth regions having a pattern of three-dimensional features; each of the three-dimensional features defines a microregion including a third region and a fourth region; the third and fourth regions have a difference in value of the intensive property; third and fourth visually distinguishable regions, wherein the difference in value of the intensive property of at least one of the micro-regions of the third region is different from the difference in value of the intensive property of at least one of the micro-regions of the fourth region; a portion of the garment-facing surface of the outer cover nonwoven material overlaps with an area having a pattern of three-dimensional features; the portion of the garment-facing surface of the outer cover nonwoven material has a thermal conductivity of 2.69 dBV according to Emtec testing; ２ rms~3.04dBV ２ having TS7 values ​​in the range of rms, the portion of the garment-facing surface of the outer cover nonwoven material has a thermal conductivity of 5.87 dBV according to Emtec testing; ２ rms~20.5dBV ２ having TS750 values ​​in the range of rms, The absorbent article of claim 1 or 2, wherein said portion of the garment-facing surface of said outer cover material has a D-value in the range of 3.53 mm / N to 4.67 mm / N according to the Emtec test.

4. 4. The absorbent article of claim 3, wherein the nonwoven of the topsheet and / or the second nonwoven of the outer cover nonwoven material comprises crimped fibers.

5. 5. The absorbent article of claim 1, wherein the intensive property is thickness, and the difference in thickness between the first and second regions of at least one of the micro-zones is greater than 25 micrometers according to a micro-CT intensive property measurement method.

6. 6. The absorbent article according to any one of claims 1 to 5, wherein said intensive property is basis weight, and said difference in basis weight between said first and second regions of at least one of said micro-zones is greater than 5 gsm according to a micro-CT intensive property measurement method.

7. The absorbent article according to any one of claims 1 to 6, wherein the intensive property is volume density, and the difference in volume density between the first and second regions of at least one of the micro-zones is greater than 0.042 g / cc according to a micro-CT intensive property measurement method.

8. 8. The absorbent article of any one of claims 1 to 7, wherein in at least one of said microzones, said first region of said at least one microzone is hydrophobic and said second region of said at least one microzone is hydrophilic.

9. 9. The absorbent article of any one of claims 1 to 8, wherein in at least one of said microzones, said second region of said at least one microzone comprises a surfactant and said first region of said at least one microzone does not comprise a surfactant.

10. 10. The absorbent article of any one of claims 1 to 9, wherein in at least one of said microzones, said first region of said at least one microzone exhibits a contact angle of greater than 90 degrees according to a contact angle test method.

11. The portion of the surface facing the garment is 6 dBV or less according to Emtec testing. ２ rms ~ 15dBV ２ 5. The absorbent article of claim 3 or 4, having a TS750 value in the rms range.

12. The absorbent article of claim 3 , wherein the outer cover nonwoven material is hydrophobic.

Images