Absorbent article having a laminated bonding pattern

Abstract

The absorbent article includes a first waist region and a second waist region, and a crotch region disposed between the first waist region and the second waist region. The absorbent article includes a chassis having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. At least one elastic ear including a laminate is joined to the chassis. The laminate is an ultrasonic bonded laminate of an elastomer layer and a nonwoven layer. The bonding pattern includes a plurality of separate primary ultrasonic bonds and a plurality of secondary ultrasonic bonds. The primary bonds permanently attach the layers of the laminate, and the secondary bonds releasably attach the layers of the laminate. The secondary bonds release when the laminate is stretched in the longitudinal direction.

Description

[Technical Field]

[0001] This disclosure relates to an absorbent article having a stretchable laminate having a bonding pattern. More specifically, this disclosure relates to a stretchable laminate including one or more permanent bonding portions and one or more releasable bonding portions. [Background technology]

[0002] Elastomer laminates are used in a variety of products, including absorbent articles (e.g., diapers, incontinence products, feminine hygiene pads). Such laminates typically include an elastomer layer that provides stretchability to the laminate, and an outer layer that is less stretchable but suitable for providing durability and desirable tactile properties. In this way, the laminate allows the components of the article to adhere closely to the wearer and be in comfortable contact with them, while providing desirable appearance quality.

[0003] Layers of elastomer laminates can be joined by various means, including thermal bonding in gathered laminate configurations where corrugations exist in one or more layers. When joining layers, manufacturers must balance considerations of strength, ductility, and comfort. However, these considerations often cancel each other out. For example, more bonding may provide greater laminate strength, but it may impair ductility. Similarly, a more elastic material may provide greater tear resistance, but it will have less flexibility or breathability. [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] Therefore, there is a continuing need to balance the strength, comfort, and stretchability of stretchable laminates. Furthermore, there is a need to provide bonding patterns that maximize desired laminate properties while minimizing undesirable characteristics. Additionally, there is a need to ensure that the bonding patterns contribute to the resulting laminate properties. [Means for solving the problem]

[0005] An absorbent article comprising a top sheet, a back sheet, and an absorbent core disposed between the top sheet and the back sheet. The absorbent core includes at least one elastic tab having a laminate. The laminate includes an elastomer layer and a nonwoven fabric layer. The laminate may include a plurality of separate primary ultrasonic bondings and a plurality of secondary ultrasonic bondings. The elastomer layer and the nonwoven fabric layer are permanently bonded by the primary ultrasonic bondings and remain releasably bonded by the secondary ultrasonic bondings. The secondary ultrasonic bondings are released when the laminate is stretched by more than about 5 mm in the stretch direction.

[0006] An absorbent article comprising a top sheet, a back sheet, and an absorbent core disposed between the top sheet and the back sheet. The absorbent core includes at least one elastic tab having a laminate. The laminate includes an elastomer layer and a nonwoven fabric layer. The laminate may include a plurality of separate primary ultrasonic bondings and a plurality of secondary ultrasonic bondings. The elastomer layer and the nonwoven fabric layer are permanently bonded by the primary ultrasonic bondings and remain releasably bonded by the secondary ultrasonic bondings. The secondary ultrasonic bondings are released when the laminate is stretched in the stretching direction with a force of at least 0.5 N / in.

[0007] An absorbent article comprising a top sheet, a back sheet, and an absorbent core disposed between the top sheet and the back sheet. The absorbent core comprises at least one component having a laminate. The laminate comprises an elastomer layer and a nonwoven fabric layer. The laminate may comprise a plurality of separate primary ultrasonic bondings and a plurality of secondary ultrasonic bondings. The elastomer layer and the nonwoven fabric layer are permanently bonded by the primary ultrasonic bondings and remain releasably bonded by the secondary ultrasonic bondings. The secondary ultrasonic bondings are released when the laminate is stretched by more than about 5 mm in the stretch direction. [Brief explanation of the drawing]

[0008] The above and other features and advantageous aspects of the present disclosure, as well as the manner in which they are realized, will become more apparent by referring to the following description of exemplary forms of the present disclosure in conjunction with the accompanying drawings, and the understanding of the present disclosure itself will be deepened. [Figure 1] FIG. 3 is an exploded perspective view of an exemplary laminate according to a non-limiting embodiment of the present disclosure. [Figure 2A] FIG. 6 is a plan view of an exemplary laminate according to a non-limiting embodiment of the present disclosure. [Figure 2B] FIG. 9 is a plan view of an exemplary laminate according to a non-limiting embodiment of the present disclosure. [Figure 2C] FIG. 12 is a plan view of an exemplary laminate according to a non-limiting embodiment of the present disclosure. [Figure 2D] FIG. 15 is a schematic view of a stretchable laminate subjected to a lateral tensile force. [Figure 2E] FIG. 18 is a schematic view of a stretchable laminate having various types of releasable coupling sites after being subjected to a lateral tensile force. [Figure 2F] FIG. 21 is a schematic view of a stretchable laminate having various types of releasable coupling sites after being subjected to a lateral tensile force. [Figure 2G] FIG. 24 is a schematic view of a stretchable laminate having various types of releasable coupling sites after being subjected to a lateral tensile force. [Figure 3A] FIG. 27 is a schematic representation of an exemplary pattern of a laminate according to a non-limiting embodiment of the present disclosure. [Figure 3B] FIG. 30 is a schematic representation of an exemplary pattern of a laminate according to a non-limiting embodiment of the present disclosure. [Figure 3C] FIG. 33 is a schematic representation of an exemplary pattern of a laminate according to a non-limiting embodiment of the present disclosure. [Figure 4A] FIG. 36 is a schematic representation of an exemplary pattern of a laminate according to a non-limiting embodiment of the present disclosure. [Figure 4B] FIG. 39 is a schematic representation of an exemplary pattern of a laminate according to a non-limiting embodiment of the present disclosure. [Figure 4C] FIG. 42 is a schematic representation of an exemplary pattern of a laminate according to a non-limiting embodiment of the present disclosure. [Figure 4D] Schematic representation of an exemplary pattern of a laminate according to a non - limiting embodiment of the present disclosure. [Figure 5A] Schematic representation of an exemplary pattern according to a non - limiting embodiment of the present disclosure. [Figure 5B] Schematic representation of an exemplary pattern according to a non - limiting embodiment of the present disclosure. [Figure 6] Cross - sectional view of a laminate according to a non - limiting embodiment of the present disclosure. [Figure 7] Plan view of the outer surface of a laminate according to a non - limiting embodiment of the present disclosure. [Figure 8] Plan view of an exemplary laminate according to a non - limiting embodiment of the present disclosure. [Figure 9] Plan view of another exemplary laminate according to a non - limiting embodiment of the present disclosure. [Figure 10] Schematic plan view of an exemplary absorbent article according to one non - limiting embodiment of the present disclosure. The absorbent article is shown in a flat, non - shrunken state. [Figure 11A] Schematic perspective view of an exemplary embodiment of absorbent pants. [Figure 11B] Schematic plan view of an exemplary embodiment of the front - body structure of absorbent pants before joining the front and rear sections of the belt. [Figure 12] Schematic perspective view of a package according to an embodiment of the present disclosure. [Figure 13] Illustration of a bonding pattern according to an embodiment of the present disclosure. [Figure 14] Illustration of a corrugated laminate on a rigid surface according to an embodiment of the present disclosure.

Best Mode for Carrying Out the Invention

[0009] Definitions "Absorbent articles" refer to devices that absorb and contain bodily waste, and more specifically, to devices that are in contact with or near the wearer's body and absorb and contain various types of bodily waste discharged from the body. Examples of absorbent articles include diapers, training pants, pull-on diapers (i.e., diapers with pre-formed waist and leg openings as illustrated in U.S. Patent No. 6,120,487), refastened diapers or diaper pants, incontinence briefs and underwear, diaper holders and liners, women's hygiene clothing such as panty liners, and absorbent inserts.

[0010] "Elasticity," "elastomerity," and "elastic stretchability" mean the ability of a material or part of a material to stretch or contract by at least 50% under a given load without rupture or breakage in one of the directions determined by the hysteresis tests described herein, and to recover at least 70% (i.e., have less than 30% permanent strain) upon release of the load. Stretchability, sometimes referred to as strain, strain percentage, engineering strain, draw ratio, or elongation, may be measured by the hysteresis tests described in more detail below, as well as recovery and permanent strain. Materials that are not elastic are referred to as inelastic. As used herein, a laminate is elastic if at least 20% of its area satisfies the definition of elasticity as defined herein. In this situation, the percentage of the laminate's area is determined when the laminate is fully stretched or contracted.

[0011] "Stretchability" means the ability to stretch or elongate by at least 50% without rupture or breakage, as determined by step 5(a) of the hysteresis test specified herein. As used herein, a laminate is stretchable if at least 20% of the area of ​​the laminate satisfies the definition of stretchability specified herein. In this situation, the percentage of the area of ​​the laminate is determined when the laminate is fully stretched. A laminate is a stretchable laminate if it does not satisfy the definition of elasticity above but satisfies the definition of stretchability presented in this paragraph.

[0012] In relation to laminates, "fully stretched" means (1) in the case of corrugated laminates, the laminate is fully stretched when the corrugation is substantially flattened by stretching the laminate while ensuring that the inelastic substrate of the laminate is not plastically deformed, and (2) in the case of non-corrugated laminates, the laminate is considered to be fully stretched without any such stretching (i.e., non-corrugated laminates are fully stretched in their relaxed state). "Relaxed" for a laminate means that it is at rest with substantially no external forces acting on it other than gravity.

[0013] A "unit" is the smallest building block of a pattern, whose geometric arrangement defines the characteristic image of the pattern, and whose repetition in space is necessary to reconstruct the pattern. A pattern can be formed from one or more units. A "repeating unit" is a unit that appears multiple times within a pattern, and such unit can be reoriented by rotation, reflection, or other means.

[0014] A “closed-cell unit” means an identifiable unit that has a perimeter, which is formed by at least five bonds that substantially surround a region that does not contain permanent bonds. The perimeter may be formed by discontinuous bonds. For example, separate bonds that are small enough and / or close together may cause an observer to see a shape substantially surrounded by a perimeter. Closed-cell units can share bonding sites with one another to form closed cells.

[0015] The term "releasable joints" in relation to a laminate means that when the laminate is stretched from a relaxed state in the stretch direction during use, the joints will release. Release includes at least partial separation of the joints. For example, one or more fibers in the nonwoven portion of the laminate may remain bound at the joint when the laminate is stretched. However, even though these one or more fibers remain bound, the joint is considered to have released.

[0016] A "permanent joint" in a laminate means that when the laminate is stretched or compressed by at least 15 mm in the transverse direction from its relaxed state, according to the laminate stretching test method, the joint remains in its original state.

[0017] "Joined" refers to a configuration in which one element is directly attached to another element by directly adhering it to that element, and a configuration in which one element is indirectly attached to another element by adhering it to an intermediate member, and that intermediate member being further attached to another element.

[0018] overview As shown in Figure 1, the laminate 10 includes a first cover material layer 12 and an elastomer layer 14. The laminate may include a second cover material layer 16, and the elastomer layer 14 may be sandwiched between the first and second cover material layers. The cover material layer material may be inelastic. Additional layers may be included. The layers may be nonwoven fabrics, inelastic materials, elastic or stretchable materials. The laminate may be stretchable. In certain embodiments, the laminate is elastomerous. Two or more laminate layers may be joined by a plurality of connectors 30, as shown in Figure 2A. The connectors may be ultrasonic connectors 31 that can join nonwoven fabric layers through the elastomer layer. Ultrasonic bonded laminates may be formed by any preferred process, including but not limited to those described in U.S. Patents No. 10,568,775, No. 10,568,776, and No. 10,575,993 by the same applicant. The joint can be any preferred shape or size such that two or more laminate layers are joined together.

[0019] As illustrated in Figures 2A to 2C, the laminate may include a plurality of bonding portions 30, which may be ultrasonic bonding portions 31. The plurality of bonding portions may be arranged within a bonding pattern. The bonding pattern may include a plurality of bonding portions arranged in a grid configuration or molded configuration such that the group of bonding forms one or more shapes. For example, as illustrated in Figure 2A, the laminate includes a first bonding pattern 200. The first bonding pattern 200 includes closed-cell units 204. The laminate may include one or more bonding patterns, and these bonding patterns may be different.

[0020] The joints of the bonding pattern may include a bonding separation distance of about 0.1 mm to about 15 mm, or about 1.2 mm to about 10 mm, or about 1.5 mm to about 5 mm, or less than about 5 mm, according to the bonding measurement test method herein. Each of the permanent and releasable joints may have a joint size of 0.5 mm to 10 mm or about 0.7 mm to 3 mm in one or more directions, according to the bonding dimension test method. The permanent joints may be larger in size than the releasable joints. The permanent and releasable joints may have any shape, such as rectangular, circular, hexagonal, elliptical, diamond-shaped, or any other shape that allows the laminates to be bonded together.

[0021] Referring to Figure 2B, the bonding pattern 200 may be a plurality of bonding points 30 arranged in a grid configuration. As illustrated in Figure 2C, the bonding pattern 200 may also be a plurality of bonding points 30 arranged in an offset configuration such that a row of bonding points is offset from an adjacent row of bonding points. It should be understood that the bonding pattern may be irregular, and the density of bonding points within the bonding pattern may vary in various regions of the laminate. Furthermore, the plurality of bonding points may not be from the bonding pattern, but rather may be unevenly spaced on the laminate.

[0022] In addition to the above, the bonding pattern 200 may include a plurality of separate primary bonding portions 30, also referred to herein as permanent bonding portions, and a plurality of secondary bonding portions 32, also referred to herein as releasable bonding portions. The primary ultrasonic bonding portions may be such that the laminate 10 is permanently attached in the region of the primary bonding portion 30. The secondary bonding portions 32 may be such that when the laminate is stretched in the stretch direction, these bonding portions are released, allowing two or more layers of the laminate to separate. The primary bonding portions 30 may be permanent bonding portions 34, and the secondary bonding portions may be releasable bonding portions 36. The releasable bonding portions 36 are configured to bond two or more layers of the laminate 10 together before the bonding portion is released. When the releasable bonding portions 36 are released, two or more layers of the laminate separate partially or completely. The releasable bonding portions 36 may be configured to release when the laminate is stretched in one or more directions. For example, the laminate may have elastic tabs. Before the elastic lugs are stretched, the releasable connectors hold each layer of the elastic lugs together. When the elastic lugs are stretched, the releasable connectors 36 are released, allowing two or more layers of the elastic lug laminate to separate. The releasable connectors 36 allow the laminate to be in a relatively flat state before stretching, and then, when stretched and the releasable connectors are released, it can become relatively tall and pillow-shaped. The permanent connectors 34 prevent the laminate from separating when the laminate is stretched. Both the permanent connectors and the releasable connectors may be ultrasonic connectors. The permanent connectors and the releasable connectors may be different types of connectors.

[0023] These and other features will be described in detail below. The ear portions 130 and / or waistband 180 and / or leg cuffs of the absorbent article may include the laminates described herein.

[0024] Laminate As described above, the laminate 10 comprises one or more cover material layers 12, 16 and an elastomer layer 14. The cover material layer material may be selected from nonwoven fabrics, films, and / or any other type of web-based material. In various embodiments, one or more cover material layers include nonwoven fabrics. Any suitable nonwoven fabric may be used in the laminate 10. Suitable nonwoven fabrics may have a basis weight of at least about 8 gsm, or at least about 10 gsm, or at least about 15 gsm, or at least about 40 gsm, or about 30 gsm or less, or about 22 gsm or less, or about 17 gsm or less, or about 10 gsm to about 22 gsm. Suitable nonwovens include, but are not limited to, spunbond, spunlaid, meltblown, spunmelt, solvent spinning, electrospinning, carding, film fibrillation, melt-film fibrillation, air lamination, dry lamination, wet lamination, water entanglement, spunlace, air-through bonding, and other nonwoven web materials formed partially or entirely of polymer fibers, as known in the art. In an unspecified example, the nonwoven includes a meltblown layer. Additionally or alternatively, the nonwoven may include a spunbond layer. In an unspecified example, the nonwoven may include two or more spunbond layers. In a further unspecified example, one or more nonwovens may have an SMS (spunbond-meltblown-spunbond) configuration. In a further unspecified example, one or more nonwovens may have an SPS (spunbond-pulp-spunbond) configuration. Alternatively, one or more of the nonwovens in the selvage of an absorbent article may not contain a meltblown layer. While meltblown layers have been shown to enhance bonding in selvages where adhesion is required (given that they inhibit the diffusion of adhesion through the porous nonwoven structure), meltblown layers often lack strength. In some embodiments, the nonwoven essentially consists of a spunbond layer. In some non-limiting examples, both the first and second nonwovens include at least two spunbond layers, or three or more spunbond layers. The fibers of the nonwoven can be joined by multiple thermal bonding, as is known in the art.In non-limiting examples, nonwoven fabrics may contain approximately 20% or less of the bonding area (with respect to their thermal bonding).

[0025] The nonwoven web may be formed primarily of polymer fibers. In some examples, suitable nonwoven fiber materials may include, but are not limited to, polyolefins, polyesters, polyamides, nylons, or polymer materials such as polypropylene (PP), polyethylene (PE), polylactic acid (PLA), polyethylene terephthalate (PET), and / or blends thereof. In some examples, the fibers may be formed from a PP / PE blend, such as that described in U.S. Patent No. 5,266,392. The nonwoven fibers may be formed from components such as aliphatic polyesters, thermoplastic polysaccharides, or other biopolymers, or may contain these components as additives or modifiers. Further useful nonwoven fabrics, fiber compositions, fibers, and methods for forming nonwoven fabrics, and related methods are described in U.S. Patent Nos. 6,645,569, 6,863,933, and 7,112,621, and U.S. Patent Applications Nos. 10 / 338,603, 10 / 338,610, and 13 / 005,237. Individual fibers in a nonwoven fabric layer may be single-component or multi-component (including two-component). Multi-component fibers may be two-component, for example, comprising various polymer components in a core and sheath arrangement or parallel arrangement. Individual components may include polyolefins such as polypropylene or polyethylene, or copolymers thereof, or polyester, thermoplastic polysaccharides, or other biopolymers, or recycled or regenerated polymer resins. Furthermore, the nonwoven fabric may include, for example, a blend of different fibers selected from the types of polymer fibers described above.

[0026] The individual fibers of the nonwoven fabric may also include natural fibers. These natural fibers may be derived from plant or natural sources such as plants and / or wood. Suitable sources for this application include wood pulp, cotton, rice, wheat, bamboo, and seaweed. The fiber web may contain fibers, fiber components (linters, seed hairs, trichomes, straw), or spun fibers, or a combination thereof, from any of these natural sources. The most common and suitable spun fibers for this application are made from spun wood pulp and bamboo.

[0027] Nonwoven fabrics may include a combination of plant-based fibers and non-plant-based synthetic fibers. For example, nonwoven fabrics may include both polypropylene fibers and cotton fibers; see, for example, U.S. Patent Application Publication 2017 / 0203542. The cotton content may range from about 3% by weight, 5% by weight, 10% by weight, or 15% to about 50% by weight of the nonwoven fabric. When synthetic fibers such as polypropylene are used, the polypropylene is preferably phthalate-free polypropylene fiber.

[0028] In some examples, at least a portion of these fibers may exhibit spiral crimp having a helical shape. For example, these fibers may include two-component fibers, each comprising different materials, typically a first polymer material and a second polymer material. The use of parallel two-component fibers is considered beneficial for imparting spiral crimp to these fibers. Examples of potentially suitable crimped or "shrunk" two-component fibers and nonwovens formed therefrom are described in U.S. Patents 5,382,400, 5,418,045, 5,707,468, 6,454,989, 6,632,386, 5,622,772, and 7,291,239. For the purposes of this specification, the use of nonwoven fabrics formed from two- or multiple-component crimped fibers, such as those described in the patents and / or patent applications cited immediately prior to this specification, may be desirable as one or both nonwoven layers, for the reason that they can feel particularly soft to the touch (comfortable on the inside for the wearer and aesthetically pleasing on the outside) and are generally quite flexible. In other non-limiting examples, the nonwoven fabrics may not have crimped fibers.

[0029] If the laminate 10 contains more than one nonwoven fabric, the nonwoven fabrics may have the same basis weight or different basis weights. Similarly, the nonwoven fabrics may have the same layer configuration (e.g., SSS) or different layer configurations (e.g., SMS, SPS).

[0030] The elastomer layer 14 comprises one or more elastomeric materials that provide elasticity to at least a portion of the layer 14. Non-limiting examples of the elastomeric material include films (e.g., polyurethane films, films derived from rubber and / or other polymer materials), elastomeric coatings applied to another substrate (e.g., hot-melt elastomers, elastomeric adhesives, printed elastomers, or elastomers co-extruded onto another substrate), elastomeric nonwovens, scrims, strands (including one or more strands), and the like. The elastomeric material may be formed from an elastomeric polymer containing any suitable known elastomer, including but not limited to styrene derivatives (e.g., styrene-based block copolymer materials), polyesters, polyurethanes, polyetheramides, polyolefins, combinations thereof, or co-extruded VISTAMAXX®. Exemplary elastomers and / or elastomeric materials are disclosed in U.S. Patent Nos. 8,618,350, 6,410,129, 7,819,853, 8,795,809, 7,806,883, 6,677,258, and U.S. Patent Publication 2009 / 0258210.Commercially available elastomeric materials include KRATON (styrene-based block copolymer; available from Kraton Chemical Company (Houston, TX)), SEPTON (styrene-based block copolymer; available from Kuraray America, Inc. (New York, NY)), VECTOR (styrene-based block copolymer; available from TSRC Dexco Chemical Company (Houston, TX)), ESTANE (polyurethane; available from Lubrizol, Inc. (Ohio)), PEBAX (polyether-based block amide; available from Arkema Chemicals (Philadelphia, PA)), HYTREL (polyester; available from DuPont (Wilmington, DE)), VISTAMAXX (homopolyolefin and random copolymer, and blends of random copolymers; available from EXXON Mobile (Spring, TX)), VERSIFY (homopolyolefin and random copolymer, and blends of random copolymers; available from Dow Chemical Company (Midland, Michigan)), and INFUSE (Dow Chemical Examples include block copolymers available from the Company.

[0031] In a non-limiting example, the elastomer layer 14 includes a film 15. The film may be a single layer or multiple layers. The film may be stretchable or elastic in the transverse and / or longitudinal directions. The film may be pre-processed, for example, pre-activated, as disclosed in U.S. Patent No. 9,533,067. Additionally or alternatively, the elastomer layer 14 may be perforated.

[0032] The elastomer layer may be shorter than the laminate itself in one or more dimensions of the laminate. For example, as illustrated in Figures 2A-2C, the elastomer layer may include the maximum dimension Y in the stretch direction, and the laminate may include the maximum dimension W in the stretch direction. In various embodiments, the stretch direction is transverse. The maximum dimension is measured when the laminate is in a relaxed state. In an unrealistic example, Y may be at least about 10 mm smaller than W. In certain embodiments, Y is at least about 20% of W, or about 25% to about 100%, or about 35% to about 85%, or about 80% or less. In various embodiments, the stretch direction is transverse. Additionally or alternatively, the elastomer layer may have dimensions equal to one or more dimensions of the laminate. For example, the elastomer layer may include substantially the same longitudinal length of the laminate across the entire transverse width of the laminate. In some embodiments, the elastomer layer may have a basis weight of about 5 to about 150 gsm, or about 10 to about 100 gsm, or less than about 150 gsm.

[0033] Looking at Figures 2A to 2C, the laminate 10 may include a primary region 18 defined by the periphery of the elastomeric material 14, and one or more inelastic regions 20, 22. The primary region 18 includes an elastic region 26 and one or more non-stretchable zones 28. In the elastic region 26, the laminate 10 is elastically stretchable. In the non-stretchable zones 28, the laminate 10 may not be elastic despite the presence of the elastomer layer. In some embodiments, the area of ​​the primary region 18 includes at least about 20%, or about 30% to about 100%, or about 80% or less, of the total area of ​​the laminate. The laminate 10 may include one or more inelastic regions 20, 22. In certain embodiments, the laminate 10 includes a first inelastic region 20 which extends laterally outward from the first laminate edge 9 of the laminate and is adjacent to the elastic region 18 at the first elastomeric material edge 17. The laminate may further include a second inelastic region 22, which may extend laterally inward from the second laminate edge 11 and may be adjacent to the elastic region 18 at the second elastomeric material edge 19. The first and second inelastic regions may be made of the same material or different materials.

[0034] In certain embodiments, the laminate 10 includes a gathered laminate 24, where one of the layers deforms at a larger angle than the remaining layers during lamination. Thus, the low-stretch layers, for example, the cover material layers 12, 16, will form gathers when the gathered laminate 24 is in a relaxed state. In some embodiments, at least a portion of the elastomer layer deforms during lamination while the cover material layer (including one or more nonwoven fabrics) is in a relaxed state. The elastomer layer can be stretched or contracted in one or more directions. Then, when the subsequently formed laminate 24 is in a relaxed state, a waveform is formed within the nonwoven fabric layer. The laminate may have a waveform regularity of more than about 50%, such that when measured perpendicular to a flat surface of the laminate, about 50% of the waveforms have substantially the same amplitude, as illustrated in Figure 14. The laminate may have a waveform regularity of more than about 75%, such that when measured perpendicular to a flat surface of the laminate, about 75% of the waveforms have substantially the same amplitude, as illustrated in Figure 14. When manufacturing a gathered laminate, the elastomer layer is stretched in the direction of expansion and contraction (i.e., the intended direction of expansion and contraction in the final product). The direction of expansion and contraction may also be transverse. In a non-limiting example, the elastomer layer is stretched in a direction corresponding to the transverse direction of the article. In other words, when the laminate is joined to the chassis after lamination, the laminate will be oriented so that it is expandable and contractible in the transverse direction of the article (i.e., the laminate is transversely stretchable).

[0035] For example, as illustrated in Figure 2A, the layers of the laminate are joined by one or more joints 30. The joints may be of any preferred shape, and multiple shapes may be used within the laminate. In various embodiments, the joints may be ultrasonic joints 31. The joints may be located within one or more patterns 200. Each pattern may contain one or more closed-cell units 204. Repeating closed-cell units form one or more repeating units 202. Repeating units are the same or substantially the same closed-cell units repeated in the joining pattern. Thus, a first repeating unit contains first closed-cell units having substantially the same shape, and a second repeating unit contains second closed-cell units having substantially the same shape, but different in shape from the first and second closed-cell units. It should be understood that the closed-cell units of different repeating units may differ in at least one of their shape and size. The joining pattern may contain closed-cell units in which each closed-cell unit is the same or substantially the same shape and / or size. The bonding pattern may include closed-cell units that are different, for example, different shapes and / or sizes. Certain closed-cell units may be the same as, or substantially the same as, certain other closed-cell units in the bonding pattern, while certain other closed-cell units may be different. For example, the bonding pattern may include closed-cell units that have only a hexagonal shape, or the bonding pattern may include some closed-cell units that have a hexagonal shape and some closed-cell units that have a triangular shape. The laminate may include a first bonding pattern 200a having one or more repeatable closed-cell units 204. The first bonding pattern may at least partially overlap the primary region 18.

[0036] Furthermore, the bonding pattern 200 may include permanent bonding portions 34. The permanent bonding portions 34 allow the laminate to remain bonded in the region of the permanent bonding portion 34 while the laminate is stretched or contracted. The bonding pattern 200 may also include releasable bonding portions 36. The permanent bonding portion 34 may be referred to as a primary bonding portion 29, and the releasable bonding portion 36 may be referred to as a secondary bonding portion 32. Releasable bonding portions refer to ultrasonic bonding portions that are breakable (or releasable) when stretched or contracted. Figure 2D is a schematic diagram of a stretchable laminate 10 including an elastomer film layer 14 sandwiched between a first cover layer 12 and a second cover layer 16. The layers are held together by a plurality of ultrasonic bonding portions 31. The stretchable laminate 10 may be subjected to lateral tensile forces in the direction of stretching or contracting. Figures 2E to 2G are schematic diagrams of the stretchable laminate 10 of Figure 2D having various types of releasable bonding portions 36 after being subjected to lateral tensile forces. In Figure 2E, the releaseable bonding site 36 separates from both the first cover layer 12 and the second cover layer 14 in the separation region 702. In Figure 2F, the releaseable bonding site 36 separates from either the first cover layer 12 or the second cover layer 14 in the separation region 702. In Figure 2G, the releaseable bonding site 36 separates only partially from either the first cover layer 12 or the second cover layer 14 in the separation region 702.

[0037] The releasable joints 36 may be located within and / or outside closed-cell units, as illustrated in Figure 2A. The releasable joints 36 are releasable when the laminate is stretched in the expansion and contraction direction by more than about 5 mm, according to a laminate stretching test method. For example, the joint is released when at least one of the bonded layers within the region of the releasable joint is separated from one or more other layers, or at least partially separated from one or more layers within the region of the releasable joint. In some embodiments, the releasable joint is released when the laminate is stretched from about 5 mm to about 12 mm, or from about 5 mm to about 10 mm, or from about 5 mm to about 8 mm, according to a laminate stretching test method. The permanent joint remains bonded when the laminate is stretched to 15 mm.

[0038] According to the peel force test method, the secondary releaseable joints can be released when the laminate peel force (the peel force applied to the laminate) is 0.3 N / cm or greater. In another embodiment, the permanent joints may remain connected, but according to the peel force test method, the releaseable joints will be released when the individual joints are subjected to a force of 0.06 N / joint or less. In another embodiment, the permanent joints may remain connected, but according to the laminate stretch test method, the releaseable joints will be released when the laminate is stretched in the stretching direction by a force of 0.5 N / in or greater. In some embodiments, the releaseable joints of the laminate can be released when the laminate is stretched by a force of about 0.4 N / in to about 0.7 N / in, or about 0.4 N / in to about 0.5 N / in, according to the laminate stretch test method.

[0039] It should be understood that one or more of the releasable joints may be released before the laminate is stretched 5 mm in the stretching direction. For example, a second or releasable joint may be configured such that one or more of the releasable joints are released when the laminate is stretched by a first stretch of less than 5 mm in the stretching direction, and a second set of releasable joints are released when the laminate is stretched by a second stretch of 5 mm or more in the stretching direction. For example, a laminate stretched by a first stretch of about 5 mm in the stretching direction results in either partial or complete release of the first portion of the releasable joints, and a laminate stretched by a second stretch of about 10 mm in the stretching direction results in either partial or complete release of the remaining or second portion of the releasable joints. Similarly, one or more releasable joints may be released before the laminate is stretched with a force of 0.5 N / in in the stretching direction, but additional joints do not need to be released until the laminate is stretched with a force of 0.5 N / in or more in the stretching direction. It should also be understood that, according to the peel force test method, if an individual releasable joint receives a peel force of 0.06 N / joint or less, one or more of the releasable joints do not necessarily have to be released. Therefore, if more force is applied to the releasable joints, additional releasable joints may be released. For example, all releasable joints are released when an individual releasable joint receives a force of 1.2 N / joint or less. In a preferred embodiment, substantially all releasable joints are configured to be released when an individual releasable joint receives a force of about 0.06 N / joint or less, which is an approximate force applied by the user when applying an absorbent article containing a laminate, as disclosed herein.

[0040] Releasing a releasable joint allows the bonded area to change from a relatively compressed area to a more pillow-like area. For example, a releasable joint or secondary joint may be present in the ear portion of a disposable absorbent article, and the secondary joint or releasable joint may be released when the absorbent article is first applied to the wearer. Releasing a releasable joint may allow the ear portion to have a relatively more pillow-like feel, higher breathability, and / or increased airflow when the absorbent article is in use or placed on the wearer. Furthermore, releasing a releasable joint may result in changes in opacity, graphic visibility, and / or color intensity. Releasing a releasable joint may also result in an increase in the thickness of the laminate.

[0041] To achieve a more pillow-like region, the number of primary bonds 29 is greater than the number of secondary bonds 32. In other words, the number of permanent bonds 34 may be greater than the number of releasable bonds. The permanent bonds 34 and releasable bonds 36 may have a bond ratio. The bond ratio is the ratio of the permanent bonds 34 to the releasable bonds 36. The number of permanent bonds and releasable bonds can be determined by a bond ratio test method. The laminate has a bond ratio of 1, or greater than about 1, or greater than about 1.1, or greater than about 1.3, or greater than about 1.5, or greater than about 1.7, or greater than about 2, or greater than about 5, or greater than about 8, or greater than about 10, according to the bond ratio test method. Having a bond ratio greater than 1 allows the laminate to remain sufficiently attached for use and the releasable bonds to separate during use. Furthermore, the bonding ratio allows the laminate to be sufficiently compressed before use, such as while in the package, and after stretching, to become relatively pillow-like while maintaining a sufficient amount of interlayer bonding during use.

[0042] As illustrated in Figure 2A, the releasable joint 36 may be located within a closed-cell unit composed of permanent joints 34. The releasable joint 36 may allow the closed-cell unit to maintain a more compressed state before use or expansion of the laminate. When the releasable joint 36 is released, the laminate in the region of the releasable joint 36 may be released, separating the laminate in the region of the releasable joint 36 so that the releasable joint 36 no longer connects the laminate, or only partially connects the laminate so that one or more fibers remain connected. When the releasable joint is released, the permanent joint remains recognizable by the user.

[0043] The releasable joint 36 may be part of a bond pattern that does not include closed-cell bonding, as illustrated in Figures 2B and 2C. The secondary joints or releasable joints may be distributed uniformly or non-uniformly across the laminate. As illustrated in Figures 2A, 2B, and 2C, the releasable joints may form a secondary bond pattern across the laminate. It should be understood that the first bond pattern formed by the permanent joints may not be fully recognizable to the user until the second bond pattern formed by the releasable joints is released. Furthermore, the first bond pattern formed by the permanent joints and the second bond pattern formed by the releasable joints may form a cooperative bond pattern before the release of the releasable joints, and the first bond pattern may become visible when the second bond pattern is released.

[0044] Each of the primary and secondary joints (sometimes referred to herein as welds) may be formed by one or more methods, including ultrasonic bonding, adhesive bonding, mechanical bonding such as heat and pressure or a combination of heat and pressure, and electrostatic bonding. The primary joint may be formed by a first bonding method, and the secondary joint may be formed by a second bonding method. The first bonding method may be different from the second bonding method. In some embodiments, the primary and secondary joints may be formed by the same bonding method but may have different bond strengths. For example, to vary the bond strength, the joints may be of different sizes, contain different materials, and have different shapes. Furthermore, the joints may be formed by the same method but may have different bond strengths due to different structures of the nonwoven fibers, such as the cross-sectional area of ​​the fibers, and / or due to elastic film properties or coatings.

[0045] As previously discussed, the permanent and releasable joints may form one or more bond patterns. These bond patterns may include uniformly or non-uniformly distributed bonds. These bond patterns may also form one or more closed-cell units. Furthermore, the permanent joint may form a first bond pattern, and the releasable joint may form a second bond pattern. When the releasable joint is released, the second bond pattern may be removed from the laminate, while the first bond pattern remains. Even further, the permanent joint may form a first bond pattern, and the releasable joint may form a second bond pattern. When the releasable joint is released, the second bond pattern may be removed from the laminate, and the permanent joint may form a third bond pattern different from the first bond pattern.

[0046] Figures 3A to 5B provide examples of bond patterns having permanent and releasable bonds. For example, Figures 3A to 3C illustrate bond patterns having closed-cell units including a perimeter 206 formed by one or more permanent bonds 34 and releasable bonds 36. For example, Figures 3A and 3B illustrate a plurality of closed-cell units 204 forming a first bond pattern 200 and a second bond pattern 201. The first bond pattern 200 and the second bond pattern 201 may be formed by one or more permanent bonds 34 and one or more releasable bonds 36. Figure 3B illustrates a portion of the bond pattern illustrated in Figure 3A and the perimeter 206 formed by each of the closed-cell units. The perimeter 206 is shown as a dashed line for illustrative purposes and to better understand the disclosure, although the dashed line does not form part of the bond pattern. The perimeter 206 is formed by connecting adjacent individual bonds. It should be understood that the periphery of the first closed-cell unit may form part of the periphery of the second closed-cell unit. Furthermore, the periphery 206 may be formed by connecting one or more permanent and detachable joints.

[0047] Referring to Figure 3C, when the laminate is stretched in the expansion and contraction direction, the releasable joints 36 release, leaving the permanent joints 34. The permanent joints 34 remaining after the release of the releasable joints 36 reveal a third bonding pattern distinct from both the first and second bonding patterns. Furthermore, the release of the releasable joints 36 provides a larger area of ​​the laminate that is not limited by the bonding, resulting in a more pillow-like or cushion-like appearance of the laminate.

[0048] A closed-cell unit can be any shape that can be identified as having a perimeter that substantially encloses a region. For example, closed-cell units can be various shapes, including polygons, heart shapes, circles, ellipses, and combinations thereof. A bonding pattern may include closed-cell units, each having the same shape. A bonding pattern may include closed-cell units having different shapes. Some bonding patterns may include two or more closed-cell units having different shapes. For example, as illustrated in Figures 3A and 3B, a bonding pattern may include a first closed-cell unit 204a and a second closed-cell unit 204b. The first closed-cell unit 204a may be a hexagonal closed-cell unit, and the second closed-cell unit 204b may be a triangular closed-cell unit. It should also be understood that various closed-cell units can be substantially the same shape but can be different in size. Closed-cell units can form patterns as previously discussed.

[0049] Bonding patterns with closed-cell units, as discussed herein, allow relatively large areas of nonwoven fabric to come together without the risk of having, for example, an uncontrolled area of ​​unbonded regions that could tear when the laminate is in a contracted state. Furthermore, these bonding patterns with closed-cell units allow for a more cushioned feel against the wearer's skin and will likely result in less pressure and skin marking for the wearer. The bonding patterns discussed herein may also allow for relatively greater breathability.

[0050] Figures 4A to 4D illustrate another bonding pattern of the laminate. The bonding pattern includes both permanent bonding sections 34 and releasable bonding sections 36. Figures 4A and 4B illustrate a laminate before stretching in the stretch direction, including both permanent bonding sections 34 and releasable bonding sections 36 that bond two or more layers of the laminate. The permanent bonding sections 34 and releasable bonding sections 36 may be positioned to form closed-cell units. Furthermore, the permanent bonding sections 24 and releasable bonding sections 36 may be positioned to form a first bonding pattern 200 that forms a hexagonal region and a second bonding pattern 201 that forms a triangle. When the laminate is stretched in the stretch direction, the releasable bonding sections 36 are released, allowing two or more layers of the laminate to separate from each other. As illustrated in Figures 4C and 4D, the release of the releasable bonding sections results in the presence of additional closed-cell units in the laminate. The laminate includes a first closed-cell unit of a hexagon of a first size and a second closed-cell unit of a hexagon of a second size different from the first size. It should be understood that in some embodiments, the shapes of the first closed-cell unit and the second closed-cell unit may be the same size. In other words, the shapes of the patterns formed by the joints may be the same shape or of different sizes.

[0051] Furthermore, the first bonding pattern is intended to include the area of ​​closed-cell units and unenclosed bonding patterns. For example, as illustrated in Figure 5A, the bonding pattern may include separate closed-cell units 204. Each of the separate closed-cell units has a perimeter that does not share the perimeter of another closed-cell unit. Referring to Figure 5A, for example, the bonding pattern may include closed-cell units and individual linearly arranged bonding parts. It should also be understood that the bonding pattern may include the area of ​​one or more closed-cell units that share a perimeter with each other and unenclosed bonding patterns. Closed-cell units may be formed by permanent bonding. Individual linear bonding parts may be formed by releaseable bonding parts 36. Thus, as illustrated in Figure 5B, when the releaseable bonding parts are released, the closed-cell units are independent of each other such that the bonding parts from the first closed-cell unit do not share those bonding parts with another closed-cell unit.

[0052] In some embodiments, the laminate may have a first cover material layer 12 including a first outer surface 210 and a second cover material layer 16 including a second outer surface 212, as illustrated in Figure 6. The first and second cover material layers may be made from different materials and have different basis weights, layer configurations, and stretchability. For example, the first cover material layer may include a nonwoven fabric and the second cover material layer may include a nonwoven fabric. Alternatively, the first cover material layer may include a first nonwoven fabric and the second cover material layer may include a second nonwoven fabric, resulting in the first and second nonwoven fabrics differing in at least one of basis weight, layer configuration (e.g., SS, SMS, SPS, etc.), and stretchability. In another non-limiting example, the first and second cover material layers may have the same constituent material, but one of the two layers includes a surface treatment or coating that causes a change in material properties such as stretchability, tensile strength, flexibility, or a combination thereof. In different embodiments, the same bonding pattern 200 may result in different appearances and / or different bonding strengths for the first and second cover material layers. As illustrated in Figure 7, for example, the bonding area may appear relatively darker and more visually prominent on the second outer surface 212 than on the first outer surface 210.

[0053] Regions of the laminate containing the bonding pattern may have a 50% unloading force of about 0.2 N / in or more, or about 0.3 N / in or more, or about 0.35 to about 1 N / in, according to the hysteresis test method herein, and these ranges are listed herein in increments of 0.01 N / in.

[0054] The laminate may include a first bonding pattern 200a and a second bonding pattern 200b, as illustrated, for example, in Figures 8 and 9. The second bonding pattern differs from the first bonding pattern in at least one of the following: the shape of the bonds, the number of bonds, the number of closed-cell units (or the absence of closed-cell units), the shape of the repeating units, the enclosing area of ​​the closed-cell units, the bond density, the bond area, and combinations thereof. The second bonding pattern may be positioned outside the first bonding pattern, resulting in a non-overlapping relationship between the two patterns. As illustrated, for example, in Figures 8 and 9, the second bonding pattern may be positioned along one or more edges of the laminate. In this way, the second bonding pattern may enclose or frame at least a portion of the first bonding pattern or the entire first bonding pattern at least partially. The second bonding pattern may at least partially overlap with the non-stretchable region 34, the inelastic region 20, the fastening system 148, and / or the reinforcing layer 160 (e.g., the folded substrate, or an additional substrate added to the laminate to enhance integrity).

[0055] The first and second bonding patterns may overlap in the transition zone. The overlap between the first and second bonding patterns in the transition zone may be less than approximately 5 mm, less than approximately 3 mm, or less than approximately 1 mm.

[0056] The bonding pattern may include one or more releasable bonds and one or more permanent bonds. As illustrated in Figures 8 and 9, the first bonding pattern 200a includes releasable bonds 36 and permanent bonds 34. The releasable bonds 34 may be located within closed-cell units of the first bonding pattern 200a. The second bonding pattern 200b may also include at least one of the permanent bonds 34 and releasable bonds 36 of a grid pattern.

[0057] The second bonding pattern 200b may not contain closed-cell units. Alternatively, the second bonding pattern may contain one or more closed-cell units having any of the features described herein.

[0058] In certain embodiments, the laminate has an air permeability value of at least about 1 m 3 / m 2 / min, or about 1 m 3 / m 2 / min to about 125 m 3 / m 2 / min, or about 2 m 3 / m 2 / min to about 50 m 3 / m 2 / min.

[0059] The bonding pattern of the laminate can be coordinated with other parts of the absorbent article. For example, the bonding pattern of the laminate can be coordinated with the bonding pattern on the chassis such as the topsheet and / or backsheet, ears, fasteners, and / or waist features. The coordination pattern can be a pattern formed by mechanically changing the structure of the material or by adding material to form a pattern such as by printing. The bonding pattern of the laminate may be coordinated with the bonding pattern included in another part of the absorbent article such that the bonding patterns are the same, or the bonding patterns may be different in terms of size, for example, one bonding pattern is larger or smaller than the other bonding pattern. The bonding patterns may be coordinated such that the bonding patterns have the same geometric shape.

[0060] The laminate can include additional materials such as inks, discoloring indicators, and skin compositions such as humectants, fragrances, lubricants, antibacterial substances, insect repellents, and UV protecting substances. The additional materials may be disposed on one or more layers of the laminate. The additional materials may be disposed on the surface of one or more layers of the laminate. For example, ink may be applied to the laminate by printing. The ink can provide the user with a visual signal such as the position of a releasable joint or a bonding pattern or graphic.

[0061] As previously described, laminates can be manufactured using various methods. For example, a method for manufacturing an elastic laminate may include the following steps: A first substrate and a second substrate may be provided. The first substrate and the second substrate may be any of the previously considered materials, such as a nonwoven fabric. Each of the first substrate and the second substrate may include a first surface and an opposing second surface, defining a width in the transverse direction. The first surface of the first substrate may be wrapped around the outer surface of an anvil. The elastic film or other elastomer substrate may be advanced in the machine direction.

[0062] The elastic film may be pre-activated in the machine direction, in the transverse direction substantially perpendicular to the machine direction, or both. Regarding the pre-activation process, the elastomer film may be guided through a system of interlocking rollers, each roller containing a disc packet having multiple interlocking discs arranged on an axis. This process is commonly referred to as a ring-rolling process. In this case, the elastomer film is stretched transversely by the interlocking disc packets.

[0063] The expansion and contraction may be uniform or vary across the width of the film. The pre-activation process may be performed with varying pitch and / or varying engagement depth. The pre-activation process may be performed in the mechanical direction or any other direction. Pre-activation by ring rolling creates visible lines on the film due to localized mechanical deformation caused by the engaging discs, and these lines are also known as activation stripes. Activation stripes formed on the elastic film are visible to the naked eye.

[0064] Pre-activation of elastomer films has a positive effect on the stretch force profile, thereby helping to facilitate the stretching motion of stretchable laminates fabricated over large stretch areas. Furthermore, the recovery of stretchable laminates can also be improved by pre-activating the elastomer film. Recovery is the ability of a stretchable laminate to return to its original dimensions after being stretched to its stretch limit. The improved recovery of elastomer films after the pre-activation process is due to the removal of the amount of permanent strain in the film. Pre-activation of elastomer films is disclosed in U.S. Patent No. 11135100, which is incorporated by reference.

[0065] The elastomer film further comprises at least one coating disposed on an elastically stretchable material, the coating forming at least one of the film surfaces. Such a coating is a stretchable material and provides the outer surface of the elastomer film, which is less tacky than the underlying elastically stretchable material. In some embodiments, the coating may also qualify as an elastically stretchable material, but will be less stretchable than the underlying elastically stretchable material. Therefore, compared to the elastically stretchable material, the coating will recover less from the same amount of stretch. In other words, compared to the elastically stretchable material, the coating will have a greater percentage of permanent strain from the same percentage of strain. The coating can assist the processability of the elastomer film and its thickness is about 1 μm to about 10 μm, or about 3 μm to about 7 μm, or in some embodiments, about 5 μm. In certain embodiments, the coating overlapping the elastically stretchable material in the elastomer film is a polyolefin. Non-limiting examples of useful coating materials include metallocene polyethylene, low-density polyethylene, high-density polyethylene, linear low-density polyethylene, ultra-low-density polyethylene, polypropylene homopolymer, plastic random polypropylene / olefin copolymer, syndiotactic polypropylene, metallocene polypropylene, polybutene, impact copolymer, polyolefin wax, and combinations thereof. Exemplary elastomer films useful for the stretchable 5-laminated structures detailed herein (i.e., elastically stretchable materials having at least one coating disposed on the surface of an elastically stretchable material) include the M18-1117 and M18-1361 elastomer films commercially available from Clopay Corporation in Cincinnati, Ohio; the K11-815 and CEX-826 10 elastomer films commercially available from Tredegar Film Products in Richmond, Va.; and elastomer films commercially available from Mondi Gronau GmbH in Gronau, Germany. These exemplary elastomer films include a single layer of elastically stretchable material with a 15 μm coating placed on both surfaces of the material.

[0066] A film suitable for this application comprises a coating that provides a first surface and a second coating that provides a second surface. During pre-activation, the coating and the elastically stretchable material are stretched and contracted similarly (i.e., subjected to similar strains). However, after stretching and contraction, the coating and the elastically stretchable material will shrink and recover differently (i.e., have different permanent strain values). Because the coating has lower elasticity compared to the elastically stretchable material, it recovers less after stretching and contraction, i.e., has a larger permanent strain value. Also, because the coating is much thinner than the elastically stretchable material, when the thicker elastically stretchable material shrinks and recovers after pre-activation stretching and contraction, it forces the attached coating to shrink along with it. However, because the coating cannot recover as well as the elastically stretchable material, the coating bends and wrinkles. Without pre-activation, the outer surface of the coating, and therefore the elastomer film, is substantially smooth in cross-section. As disclosed in U.S. Patent No. 10,485,713, pre-activation causes the outer surface of the coating, and therefore the elastomer film, to be substantially wrinkled in a cross-sectional view.

[0067] A pre-activated elastic film may be advanced into a spreader mechanism including an engagement portion. The elastic film may be stretched or compressed in the spreader mechanism to a first elongation in the transverse or mechanical direction. Next, the elastic film is advanced from the spreader mechanism to an anvil. The anvil may include an activated vacuum zone having its maximum width in the transverse direction. The elastic film is positioned in contact with the second surface of the first substrate on the anvil, and the second substrate is advanced to a position where the first surface of the second substrate is in contact with the elastic film and the second surface of the first substrate on the anvil. With the elastic material positioned between the first and second substrates, the first substrate is ultrasonically bonded together with the second substrate. A sonotrode may be used to ultrasonically bond the laminate. Ultrasonic bonding of the laminate imparts one or more bonding patterns as previously discussed herein. Methods for manufacturing the laminates are disclosed in U.S. Patent Nos. 10,561,537, 10,568,776, U.S. Patent Publication No. 2021 / 0401638, and U.S. Patent Application No. 17 / 493,098, filed on 4 October 2021, which are jointly owned publications incorporated herein by reference.

[0068] The releasable joint may be fabricated by various means, including reducing the joint size, reducing the joint pressure, reducing the joint nub height, and reducing energy transfer through the nub shape or geometry. Changes in the joint nub height can be achieved by laser metal deposition, as disclosed in U.S. Patent Publication No. 2020 / 0180025.

[0069] Articles containing laminates Referring to Figure 10, the laminate 10 of this disclosure may be incorporated into an absorbent article 100, such as a disposable absorbent article. The laminate may be attached to one or more layers of a chassis 120 by a chassis mounting connector 102. The chassis mounting connector may include an ultrasonic connector, an adhesive connector, a mechanical connector, or a combination thereof.

[0070] Figure 10 is a plan view of an exemplary and non-limiting embodiment of an absorbent article 100 in a flat, non-shrinking state. The body-facing surface 115 of the absorbent article 100 is directed towards the observer. The absorbent article 100 includes a longitudinal centerline 105 and a transverse centerline 110.

[0071] The absorbent article 100 includes a chassis 120. The absorbent article 100 and chassis 120 are shown having a first lumbar region 114, a second lumbar region 118 opposite the first lumbar region 114, and a crotch region 116 located between the first lumbar region 114 and the second lumbar region 118. The lumbar region 114 and lumbar region 118 generally include those portions of the absorbent article that surround the wearer's waist when worn. The lumbar region 114 and lumbar region 118 may include elastic members 155 that gather around the wearer's waist to improve fit and containment. The crotch region 116 is the portion of the absorbent article that is generally located between the wearer's legs when the absorbent article is worn.

[0072] The outer periphery of the chassis 120 is defined by longitudinal edges 112 and waist edges (a first waist edge 113 in the first waist region 114 and a second waist edge 119 in the second waist region 118). The chassis 120 may have opposing longitudinal edges 112 that are generally oriented parallel to the longitudinal centerline 105. However, for a better fit, the longitudinal edges 112 may be curved or angled so that, for example, an article with an hourglass shape when viewed in plan view, as shown in Figure 10, is produced. The chassis 120 may have opposing lateral edges 113, 119 (i.e., a first waist edge 113 and a second waist edge 119) that are generally oriented parallel to the lateral centerline 110.

[0073] The chassis 120 may include a liquid-permeable top sheet 124, a back sheet 126, and an absorbent core 128 between the top sheet 124 and the back sheet 126. The top sheet 124 may be bonded to the core 128 and / or the back sheet 126. The back sheet 126 may be bonded to the core 128 and / or the top sheet 124. It should be noted that other structures, elements, or substrates may be positioned between the core 128 and the top sheet 124 and / or the back sheet 126. In some embodiments, a capture and distribution system 127 is positioned between the top sheet 126 and the absorbent core 128.

[0074] In certain embodiments, the chassis 120 includes the main structure of the absorbent article 100, along with other features added to form a composite absorbent article structure. The top sheet 124, back sheet 126, and absorbent core 128 may be assembled in various well-known configurations, but the configurations of absorbent articles are generally described in U.S. Patents 3,860,003, 5,151,092, 5,221,274, 5,554,145, 5,569,234, 5,580,411, and 6,004,306.

[0075] The components of disposable absorbent articles may include, at least partially, biosource content, as described in U.S. Patent Publications 2007 / 0219521(A1), 2011 / 0139658(A1), 2011 / 0139657(A1), 2011 / 0152812(A1), and 2011 / 0139659(A1). These components include, but are not limited to, top sheets, backsheet films, backsheet nonwovens, selvage / selvage laminates, leg gasket systems, superabsorbents, trapping layers, core wrap materials, adhesives, fastening systems, and landing zones. In at least one embodiment, the components of a disposable absorbent article contain biobase content values ​​ranging from about 10% to about 100%, or about 25% to about 75%, or about 50% to about 60%, using Method B of ASTM D6866-10. To determine the biobase content of any component by applying the methodology of ASTM D6866-10, a representative sample of the component must be obtained for testing. In at least one embodiment, the components of a disposable absorbent article may be ground to fine particles of less than about 20 mesh using a known grinding method (e.g., a Wiley® mill), and a representative sample of a suitable mass may be taken from the randomly mixed particles.

[0076] The laminate 10 of this disclosure may form one or more components of an article, or may be a part thereof, including but not limited to ear portions, waist features, belts, and combinations thereof.

[0077] Top sheet The top sheet 124 is generally a portion of the absorbent article 100 that can be positioned at least partially in contact with the wearer, or more proximal to the wearer. A suitable top sheet 124 may be made from a wide range of materials, such as porous foam, mesh foam, perforated plastic film, or natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or woven or nonwoven webs of a combination of natural and synthetic fibers. The top sheet 124 is generally supple and soft to the wearer's skin and non-irritating. Generally, at least a portion of the top sheet 124 is liquid-permeable, allowing liquids to pass through its thickness easily. The top sheet 124 may be perforated. The top sheet may be perforated by overbonding the material and then breaking the overbond with a ring roll, as disclosed in U.S. Patent No. 5,628,097.

[0078] Any portion of the top sheet may be coated with skincare compositions, antimicrobial agents, surfactants, and / or other beneficial agents. The top sheet may be hydrophilic or hydrophobic, or may have hydrophilic portions or layers and / or hydrophobic portions or layers. If the top sheet is hydrophobic, it will typically have pores to allow bodily waste to pass through it.

[0079] Absorbent core The absorbent core 128 may include a wide variety of liquid absorbent materials commonly used in disposable diapers and other absorbent articles. Examples of suitable absorbent materials include crushed wood pulp, commonly referred to as air felt crepe paper cotton; meltblown polymers including coforms; chemically stiffened, modified, or crosslinked cellulose fibers; tissue paper including tissue paper packaging and tissue paper laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; or any other known absorbent materials or combinations of materials. In one embodiment, at least a portion of the absorbent core may be substantially cellulose-free, contain less than 10% by weight of cellulose fibers, less than 5% by weight of cellulose fibers, less than 1% by weight of cellulose fibers, contain trace amounts of cellulose fibers, or contain no cellulose fibers. It should be understood that trace amounts of cellulosic material do not substantially affect at least one of the thinness, flexibility, and absorbency of the substantially cellulose-free portion of the absorbent core. Among other advantages, if at least a portion of the absorbent core is substantially cellulose-free, this portion of the absorbent core is considered to be significantly thinner and more flexible than a similar absorbent core containing more than 10% by weight of cellulose fibers. The amount of absorbent material present in the absorbent core, such as absorbent particulate polymer material, may vary, but in certain embodiments, it may be present in the absorbent core in amounts of more than about 80% by weight of the absorbent core, or more than about 85% by weight of the absorbent core, or more than about 90% by weight of the absorbent core, or more than about 95% by weight of the core.

[0080] The absorbent material may be deposited as an absorbent layer having a substantially rectangular contour. The layer of absorbent material may also have a non-rectangular outer perimeter ("molded" core), and in particular, the absorbent material may be defined as tapering along its width toward the central region of the core (or "dogbone" shape). In this way, the absorbent material deposition area may have a relatively narrow width in the region of the core intended to be located within the crotch area of ​​the absorbent article. This can result in, for example, better wearing comfort. Other shapes such as "T-shape," "Y-shape," or "hourglass" can also be used for the area of ​​absorbent material.

[0081] In some embodiments, the absorbent core may include one or more channels 129 which are substantially free of absorbent particulate polymer material. The channels 129 may be extended longitudinally or transversely. The absorbent core may further include two or more channels. The channels may be linear, curved, angled, or any functional combination thereof. In a non-limiting example, two channels are arranged symmetrically around a longitudinal axis.

[0082] Back seat The backsheet 126 is generally positioned to be at least a portion of the surface of the absorbent article 100 that faces clothing. The backsheet 126 may be bonded to the topsheet 124, the absorbent core 128, and / or any other layer of the absorbent article by any attachment method known to those skilled in the art. The backsheet 126 may be designed to prevent excrement absorbed and contained within the absorbent article 100 from soiling articles that may come into contact with the absorbent article 100, such as bed sheets and underwear. In certain embodiments, the backsheet 126 is substantially impermeable to water. The backsheet may be or include a thin plastic film, such as a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm. Other suitable backsheet materials may include breathable materials that allow vapor to escape from the absorbent article while still preventing or at least inhibiting bodily excrement from passing through the backsheet.

[0083] The backsheet 126 may also consist of two or more layers. The backsheet 126 may include an outer cover and an inner layer. The outer cover material 40 may include bonding patterns, pores, and / or three-dimensional features. The outer cover material 40 may be a nonwoven material such as a water-entangled nonwoven material. The inner layer may be made from a substantially liquid-impermeable film such as a polymer film. The outer cover and the inner layer may be joined together by an adhesive or any other suitable material or method.

[0084] Ears / fasteners The absorbent article 100 may include one or more ear portions 130, for example, an anterior ear portion 132 located in a first lumbar region and / or a posterior ear portion 134 located in a second lumbar region. The ear portions 130 may be integral with the chassis or may be separate elements joined to the chassis 120 at chassis attachment joints 102 that can join one or more layers of the ear portions to the chassis. It should be understood that the anterior ear portion 132 and the posterior ear portion 134 may be attached to different layers of the chassis. The ear portions 130 may be stretchable or elastic. The ear portions 130 may be formed from one or more nonwoven webs, woven webs, knitted fabrics, polymer films and elastomers, perforated films, sponges, foams, scrims, or any combination and / or laminates of the foregoing.

[0085] In some embodiments, the selvage 130 may contain an elastomer, thereby making the selvage elastic or stretchable. In certain embodiments, the selvage 130 may be formed of an elastic laminate such as a nonwoven / elastomerized material laminate or a nonwoven / elastomerized material / nonwoven laminate, which also results in the selvage being stretchable. The selvage 120 may be stretchable in the transverse direction of the article. In some embodiments, the selvage is elastic in the transverse direction. In further embodiments, the selvage 130 may be stretched more in the transverse direction than in the longitudinal direction. Alternatively, the selvage may be stretched more in the longitudinal direction than in the transverse direction. In certain non-limiting examples, the selvage may contain one or more inelastic regions along separate elastic regions.

[0086] In some embodiments, the selvage includes a laminate of one or more nonwoven fabrics and one or more elastic materials, such as a laminate 10 having any of the features or laminate layers described herein.

[0087] Any suitable nonwoven fabric may be used in the selvage 130. Suitable nonwoven fabrics may have a basis weight of at least about 8 gsm, or less than about 30 gsm, or about 17 gsm or less, or about 10 gsm to about 17 gsm. Typically, nonwoven fabrics with lower basis weights reduce the overall strength of the selvage. However, selvages designed according to the principles herein can achieve high strength despite the use of nonwoven fabrics with lower basis weights. If the selvage 130 includes two or more nonwoven fabrics, the nonwoven fabrics may have the same basis weight or different basis weights. Similarly, the nonwoven fabrics may have the same or different layer structures. Furthermore, the nonwoven fabrics in the selvage may have the same or different characteristics in the backsheet, topsheet, leg gasket system, and / or waist features.

[0088] The ear portion may be, for example, an ultrasonically coupled ear portion as disclosed in U.S. Patent Application No. 15 / 674,559. The ear portion may also be a gathered laminate 24. Alternatively, the ear portion may be activated by the process disclosed in, for example, U.S. Patent Publication No. 2013 / 0082418, U.S. Patents No. 5,167,897, No. 5,993,432, No. 5,156,793, No. 5,167,897, No. 7,062,983, and No. 6,843,134.

[0089] The lugs may be joined to the chassis at the chassis mounting joint 102. In some non-limiting examples, the chassis mounting joint is located in the inelastic region of the lugs.

[0090] The absorbent article 100 may also include a fastening system 148. When fastened, the fastening system 148 interconnects the first lumbar region 116 and the posterior lumbar region 118, creating a lumbar periphery that can surround the wearer while the absorbent article 100 is being worn. The fastening system 148 may include fastening elements 150 such as tape tabs, hook and loop fastening components, interlocking fasteners such as tabs and slots, buckles, buttons, snaps, and / or hermaphroditic fastening components, but any other known fastening means are generally acceptable. The absorbent article may include a landing zone into which the fastening elements can engage and / or a release tape to protect the fastening elements from damage before use. Several exemplary surface fastening systems are disclosed in U.S. Patents No. 3,848,594, No. 4,662,875, No. 4,846,815, No. 4,894,060, No. 4,946,527, No. 5,151,092, and No. 5,221,274. An exemplary mutual engagement fastening system is disclosed in U.S. Patent No. 6,432,098. In some embodiments, the fastening system 148 and / or element 150 are foldable.

[0091] The fastening system 148 may be joined to any suitable part of the article 100 by any suitable means. The fastening system may be joined to the lugs between layers.

[0092] Leg gasket system The absorbent article 100 may include a leg gasket system 170 attached to the chassis 120, the leg gasket system may include one or more cuffs. The leg gasket system may include a pair of barrier leg cuffs 172. Each barrier leg cuff may be formed from a single piece of material bonded to the absorbent article, so as to extend upward from the wearer-facing surface of the absorbent article, and can provide improved containment of fluids and other bodily waste near the junction of the wearer's torso and legs. The barrier leg cuff is bounded by a proximal edge bonded directly or indirectly to the top sheet 124 and / or back sheet 126, and a free edge 175 intended to contact the wearer's skin and form a seal. In some embodiments, the free edge 175 includes a folded edge. The barrier leg cuff 172 extends at least partially between the anterior waist edge 113 and the posterior waist edge 119 of the absorbent article on the opposite side of the longitudinal centerline 105 and is located at least within the groin area. The barrier leg cuff may be joined to the chassis of the article at its proximal edge by bonding, fusion bonding, or a combination of other preferred bonding processes.

[0093] The barrier leg cuff may be integrated with the top sheet 124 or back sheet 126, or it may be a separate material bonded to the chassis of the article. Each barrier leg cuff 172 may include one or more elastic elements 155 adjacent to the free edge 175 to provide better sealing.

[0094] In addition to the barrier leg cuff 172, the article may include a gasket cuff 176 bonded to the chassis of the absorbent article, particularly the top sheet 124 and / or back sheet 126, and positioned outside the barrier leg cuff 172. The gasket cuff 176 may provide a better seal around the wearer's thigh. The gasket cuff may include a proximal edge and a free edge 177. The free edge 177 may include a folded edge. Each gasket cuff may include one or more elastic elements 155 in the chassis of the absorbent article between the top sheet 124 and the back sheet 126 in the area of ​​the leg opening. The barrier leg cuff and / or gasket cuff, in whole or in part, may be treated with a lotion or another skincare composition.

[0095] In further embodiments, the leg gasket system includes a barrier leg cuff integrated with a gasket cuff. Suitable leg gasket systems, which may be part of an absorbent article, are disclosed in U.S. Patent Applications No. 62 / 134,622, No. 14 / 077,708, and U.S. Patents No. 8,939,957, No. 3,860,003, No. 7,435,243, and No. 8,062,279.

[0096] Elastic lumbar region features As shown in Figure 10, the absorbent article 100 may include at least one elastic waist feature 180 that helps provide improved fit and containment. The elastic waist feature 180 is generally intended to contract and dynamically conform to the wearer's waist. The elastic waist feature includes a waistband, a waist cuff having a pocket formed from a portion of the waist feature 180 that is detached from the chassis 120, and a waist panel designed to fit snugly around the wearer's abdomen. Non-limiting examples of elastic waist features are disclosed in U.S. Patent Applications No. 13 / 490,543, No. 14 / 533,472, and No. 62 / 134,622. The waist feature 180 may be bonded to the chassis 120 at a first waist region 114 and / or a second waist region 118. The waist feature may be used in conjunction with ear portions 130 to provide desirable stretch and flexibility for a proper fit of the article to the wearer. The waist feature may include a laminate 10 having any of the features described herein. The waist feature may be stretchable or elastic in the lateral and / or longitudinal directions. In some embodiments, the waist feature 180 includes a belt 220. The waist feature may be attached to the chassis at a waist feature connector 182.

[0097] Absorbent pants for adults or infants In some embodiments, article 100 may include absorbent pants 300 as shown in Figures 11A and 11B. The absorbent pants may include a chassis 120, a belt 320 positioned around the wearer's waist, and optionally a leg gasket system 170. Figure 11B depicts an exemplary precursor structure of the pants of Figure 11A, which is laid flat and in an open configuration that stretches laterally with respect to elastically induced contraction. In the final assembly of the pants, the front belt portion 322 is joined to the rear belt portion 323 at a seam 324, which may be permanent or retightenable. To form the pants 300, the pre-structure is folded along or around the lateral centerline 110 so that the top sheet 124 faces inward, and the longitudinal edges of the front belt 322 and the rear belt portion 323 are joined at the seam 324 to form a pants structure having leg openings, a front waist edge, and a rear waist edge. Thus, the pants 300 may include pre-formed continuous waist openings and pre-formed continuous leg openings for the wearer when the pants 300 are worn.

[0098] The front belt portion 322 and the rear belt portion 323 may be the outermost structures forming the front and rear regions of the pants 300. The pants may include an outer wrap 326 that encloses the entire front, crotch, and rear regions and forms the outermost pant-shaped structure. In some embodiments, the outer cover of the backsheet forms the outer wrap. The outer wrap 326 may be formed from one or more sections of a nonwoven web and may be cut to a contour that provides a suitably adjusted contour of the leg opening edge, if desired.

[0099] The belt 320 may include a laminate 10 of the present disclosure having any of the aforementioned features, including one or more nonwoven fabric layers and one or more elastomer layers. The laminate layers may be joined by ultrasonic bonding.

[0100] According to some non-limiting examples, the nonwoven fabric used in the belt portion may include a material that provides good recovery when removed by external pressure.

[0101] The elastomer layer of the waist feature, such as the belt portion, may include one or more elastic members 155. The elastic members 155 may be elastomerous fibers, such as LYCRA® fibers available from INVISTA (Wichita, KS), at various decitex levels. The elastic members 155 may also include any heat-shrinkable elastic material known in the art. Other suitable elastic materials may be made from a variety of other materials, including but not limited to rubber, styreneethylbutylenestyrene, styreneethylenepropylenestyrene, styreneethylenepropylenestyrene, styrenebutadienestyrene, styreneisoprenestyrene, polyolefin elastomers, elastomer polyurethanes, and other elastomer materials known in the art, as well as combinations thereof. In some non-limiting examples, the elastic member may be an extruded stranded elastic body having any number of strands (or filaments). In some embodiments, the elastic member may have a decitex in the range of 50 to 2000, or any integer value relating to any decitex value within this range. Those skilled in the art may select a suitable decitex based on the desired amount of shrinkage and other principles discussed herein. In further embodiments, the elastic member may be in the form of a film. Examples of films are described in prior patent applications (see, for example, U.S. Patent Application Publication 2010 / 0040826). The film can be made using various resins combined in at least one of several sublayers, thereby providing the film with different advantages.

[0102] In addition, the elastic member 155 may have multiple configurations. For example, its width may vary, a single strand or multiple parallel or non-parallel strands of the elastic material may be used, various shapes including straight and curved lines may be used, or various cross-sectional shapes may be used (circular, rectangular, square, etc.).

[0103] The lumbar region (e.g., the belt portion) and / or the layers of the chassis 120 may be joined together around the elastic strand 155 by an adhesive deposited between the layers, by thermal bonding, by pressure bonding, or a combination thereof. In other examples, one or more elastic members may be strips or fragments of film formed from an elastomer material. If the elastic member is elongated, it may be desirable that the strand 155 be oriented laterally by its longer dimension, or even substantially aligned laterally, as shown in Figure 11B, for example.

[0104] Other forms of the belt portion or waist feature may include at least three waist elastic members, at least five elastic members, at least ten waist elastic members, or at least fifteen waist elastic members, or about two to about thirty-five waist elastic members, or about five to about twenty-five waist elastic members.

[0105] In one embodiment, adjacent elastic members 155 are spaced at least 3.5 mm apart, optionally at least 4 mm apart, optionally at least 4.5 mm apart, optionally at least 5 mm apart, optionally at least 5.5 mm apart, optionally at least 6 mm apart, optionally at least 6.5 mm apart, optionally at least 7 mm apart, optionally at least 7.5 mm apart, optionally at least 8 mm apart, optionally at least 8.5 mm apart, optionally at least 9 mm apart, optionally at least 9.5 mm apart, optionally at least 10 mm apart, optionally at least 10.5 mm apart, optionally at least 11 mm apart, optionally at least 11.5 mm apart, and optionally at least 12 mm apart in the longitudinal direction from one edge of the member to the other edge of the member. For example, the spacing between adjacent elastic members can be uniformly set to 7 mm, or it can be set to a variable spacing (i.e., two adjacent elastic members are 3 mm apart, and another two are 6.5 mm apart, etc.).

[0106] During the manufacturing of the lumbar feature, the elastic member 155 may be pre-deformed to a desired degree when incorporated into the lumbar feature. During the subsequent relaxation of the lumbar feature, the elastic member will contract laterally toward their undeformed lengths. This may cause gathering in the layers of the lumbar feature, generally forming wrinkles or folds with ridges and valleys extending in the z-direction across the length of the elastic member 155.

[0107] In further embodiments, the elastic components may be individually coated with an adhesive ("strand coating") before being incorporated into the waist laminate in order to bond the components of the waist feature laminate together. Various coating methods and techniques, including strand coating methods and techniques, are shown, for example, in U.S. Patents No. 5,340,648, No. 5,501,756, No. 5,507,909, No. 6,077,375, No. 6,200,635, No. 6,235,137, No. 6,361,634, No. 6,561,430, No. 6,520,237, No. 6,582,518, No. 6,610,161, No. 6,613,146, No. 6,652,693, No. 6,719,846, and No. 6,737,102. The adhesive used may be an elastic and flexible hot-melt adhesive suitable for attaching pre-deformed elastic materials to a substrate (such as OMNIMELT BLOCKS 22H2401F available from Bostik, Inc. (Wauwatosa, Wisconsin), or ZEROCREEP® from AVANCE, etc.).

[0108] In certain embodiments, as suggested in Figure 11B, the corners of the front and / or rear belt portions may be cut off. The corners may be cut along a straight line or along a cut path that is curved with respect to the rest of the belt portion, either concave or convex, so as to be desirable to obtain a particular curved leg edge contour. In conjunction with such cuts and the configuration of the elastic strands, it may be desirable to provide interlayer bonding along the edges of each belt portion 322, 323. Such bonding can help prevent any separation of layers along the edges, which may contribute to creating an uneven appearance, and can also help to efficiently pull the rear belt portion inward laterally toward the central chassis 120 under the contraction force of the elastic strands below seam 324. The bonding may be performed by mechanical bonding / pressure bonding as described in U.S. Patents No. 4,854,984 and No. 4,919,738, for example, by thermal bonding or welding, or by depositing an interlayer adhesive. In non-limiting examples, such connections may form patterns along the edges. Such connections may generally complement any inter-layer connections that hold the respective belt portions 322, 23 together as a laminated structure.

[0109] The side seam 324 may be permanent or retightenable. A permanent seam may be formed between the front and rear belt portions by any joining mechanism, and the front and rear belt portions cannot be forcibly separated without causing significant damage to one or both of the front and rear belt portions, or without including a mechanism that allows for substantial reattachment or retightening. The joining that forms the permanent seam may include pressure joining, thermal joining / welding, ultrasonic joining, or adhesive joining. A retightenable seam may be formed between the front and rear belt portions by any mechanism configured to allow for substantially nondestructive forced separation of the front and rear belt portions, and subsequent substantial reattachment or retightening at the same location. An example of such a mechanism is a hook-and-loop fastening system, e.g., a VELCRO fastening system. Hook components of a suitable size and shape may be coupled along their longitudinal edge to one of the front belt portion or the rear belt portion, or along their longitudinal edge to the other of the front belt portion or the rear belt portion, in a position where they can engage together to form a seam 224. Examples are illustrated in U.S. Patent Applications No. 61 / 787,416, 61 / 787,332, and 61 / 666,065.

[0110] Exemplary belt and absorbent pant structures are disclosed in U.S. Patent Applications No. 14 / 598,783 and No. 14 / 032,595.

[0111] package The absorbent articles 100 of this disclosure may be placed in a package. The package may include a polymer film, paper, and / or other materials. Figures and / or markings relating to the properties of the absorbent articles may be formed, printed, positioned, and / or placed on the outer portion of the package. Each package may contain multiple absorbent articles. The absorbent articles may be packaged under compression to reduce the package size while still providing a sufficient amount of absorbent articles per package. Packaging absorbent articles under compression allows caregivers to easily handle and store the packages, and also provides manufacturers with reduced distribution costs due to package size.

[0112] The packaging may include a polymer film containing recycled materials, for example, about 20% to 100%, 30% to 90%, 30% to 80%, 40% to 60%, or 50% recycled material. The recycled material may include post-industrial recycled material (PIR) and / or post-consumer recycled material (PCR). In some cases, the polymer film used in the packaging may include two outer layers and one or more inner layers. One or more inner layers may contain recycled material, or contain more recycled material than the outer layers. The recycled material may include recycled polyethylene. The recycled material may include recycled polyethylene PIR from trimmings from packaging operations.

[0113] The packaging material may include paper, paper-based materials, paper with one or more barrier layers, or paper / film laminates. The packaging material may be in the range of about 50 gsm to about 100 gsm or about 70 gsm to about 90 gsm, and the one or more barrier layers may be in the range of about 3 gsm to about 15 gsm. With or without one or more barrier layers, the paper-based packaging material may exhibit a mechanical tensile strength of at least 5.0 kN / m, at least 3 percent mechanical expansion and contraction, at least 3 kN / m mechanical transverse tensile strength, and at least 4 percent transverse fracture expansion and contraction, as determined by ISO 1924-3.

[0114] Paper-based packaging materials, or paper-based packaging materials including a barrier layer or film, may be recyclable or recyclable in normal paper recycling operations. The degree of recyclability of paper-based packaging can be determined by the recyclability percentage. Paper-based packaging of the Disclosure may exhibit a recyclability percentage of 70 percent or more, 80 percent or more, or 90 percent or more. Paper-based packaging of the Disclosure may have a recyclability percentage of about 70 percent to about 99.9 percent, about 80 percent to about 99.9 percent, or about 90 percent to about 99.9 percent. For example, packaging materials of the Disclosure may exhibit a recyclability percentage of about 95 percent to about 99.9 percent, about 97 percent to about 99.9 percent, or about 98 percent to about 99.9 percent. The recyclability percentage of paper-based packaging can be determined by Category II testing PTS-RH:021 / 97 (draft October 2019), conducted by Papiertechnische Stiftung, located at Pirnaer Strasse 37, 01809 Heidenau, Germany. In another example, the paper-based packaging of this disclosure may show an overall "pass" test result when determined by Category II method PTS-RH:021 / 97 (draft October 2019). Any of the paper-based packaging may have opening features such as perforations and may also have handles.

[0115] Accordingly, the packaging of absorbent articles of this disclosure may have an in-bag stacking height of less than approximately 110 mm, less than approximately 105 mm, less than approximately 100 mm, less than approximately 95 mm, less than approximately 90 mm, less than approximately 85 mm, less than approximately 80 mm, less than approximately 78 mm, less than approximately 76 mm, less than approximately 74 mm, less than approximately 72 mm, or less than approximately 70 mm, in accordance with the in-bag stacking height test described herein. Alternatively, the packaging of absorbent articles of this disclosure may have an in-bag stacking height of approximately 70 mm to approximately 110 mm, approximately 70 mm to approximately 105 mm, approximately 70 mm to approximately 100 mm, approximately 70 mm to approximately 95 mm, approximately 70 mm to approximately 90 mm, approximately 70 mm to approximately 85 mm, approximately 72 mm to approximately 80 mm, or approximately 74 mm to approximately 78 mm, in accordance with the in-bag stacking height test described herein.

[0116] Figure 12 illustrates an exemplary package 1000 containing multiple absorbent articles 1004. The package 1000 defines an internal space 1002 in which the multiple absorbent articles 1004 are placed. The multiple absorbent articles 1004 are arranged as one or more stacks 1006.

[0117] Test method Joint Dimension Test Method The joint dimension test method is used to measure various dimensions of permanent and releasable joints in a laminate. This test measures the size of the joint (joint size) and the distance between adjacent joints (joint separation distance), as illustrated in Figure 13. For the purposes of this method, a joint is an intentional bond of two or more layers, and is a deformed area that occurs during the bonding process (e.g., a bond site or reduced caliper in molten fibers or molten thermoplastic materials). Dimensional measurements are determined from images of the bonded laminate and obtained using image capture tools (microscope, camera, or similar image capture tools) and image analysis software. Images of the bonded laminate are captured while the laminate is fully stretched. In the case of corrugated laminates, the specimen is fully stretched when the corrugation is substantially flattened by stretching the laminate while ensuring that the inelastic substrate of the laminate is not plastically deformed. In the case of non-corrugated laminates, the specimen is considered to fully stretch without such stretching while lying flat. Before testing, the sample / test specimen is pre-conditioned for 2 hours under the same environmental conditions, at approximately 23°C ± 2°C and a relative humidity of approximately 50% ± 2%.

[0118] In this method, a "unit bubble" is the smallest pattern containing both permanent and releasable bonds, and when repeated through a combination of translation, reflection, and rotation, it creates the entire bond pattern under investigation. Within the captured image, unit bubbles are identified, and both permanent and releasable bonds are distinguished and identified within the unit bubble pattern. If permanent and releasable bonds cannot be distinguished by inspection, a bond ratio test method is used to examine similar unit bubbles to distinguish permanent bonds from releasable bonds.

[0119] The dimensions of the joints in the expansion and longitudinal directions are measured per selected unit area. The joint size in the expansion or transverse direction and the longitudinal direction perpendicular to the transverse direction is defined as the shortest (minimum) straight-line distance of the joint area (i.e., the deformation area) in the transverse and longitudinal directions, respectively.

[0120] For permanent joints, measure and record the joint size in the expansion direction and the joint size in the longitudinal direction using the captured image of the unit bubble. Similarly, for releasable joints, measure and record the joint size in the expansion direction and the joint size in the longitudinal direction using the captured image of the unit bubble. Repeat this procedure for a total of three unit bubbles. Calculate and report the arithmetic mean of the recorded values ​​and report it as the joint size for permanent and releasable joints. Report the value rounded to the nearest 0.1 mm.

[0121] The junction separation distance is defined as the shortest (minimum) straight-line distance between any two individual junction sites (either permanent or detachable). As illustrated in Figure 13, determine the perimeters of the first junction site and the perimeters of two different junction sites, and measure the shortest straight-line distance between them. Record the values ​​and repeat for a total of three unit bubbles. Calculate and report the arithmetic mean of the recorded values ​​and report it as the junction separation distance, rounded to the nearest 0.1 mm.

[0122] Peeling force test method The peel force test method is used to determine the forces involved in separating and peeling the top and bottom layers of a laminated specimen. A suitable tensile testing machine, such as the MTS Model Alliance RT / 1 with TestWorks4® software or equivalent, is used. The tensile testing machine is placed in a temperature-controlled room at 23°C ± 2°C and 50 ± 10% relative humidity. The instrument is calibrated according to the manufacturer's instructions for use. The data acquisition speed is set to at least 50 Hz. The grip used for the test is wider than the specimen. For example, a grip with a width of 50.8 mm may be used. The grip is a pneumatic grip with one flat surface and opposing surfaces, designed to concentrate the entire gripping force along a single line perpendicular to the direction of the test stress, with a semicircular projection (radius = 6 mm, e.g., part number: 56-163-827 from MTS Systems Corp.) or equivalent from the opposing surface to minimize specimen slippage. The load cell is selected so that the force being measured is 5% to 95% of the load cell's capacity. The initial distance between the lines of the gripping force (gauge length) is adjusted according to the permanent strain of the sample. The load reading on the instrument is zeroed out to compensate for the mass of the fixture and gripping part.

[0123] Identify corrugated or expandable portions on absorbent article products having bonding patterns that include releasable or secondary bonding. Collect at least four test specimens containing releasable bonding and cut them from the same portion of the same absorbent article product to ensure that the test specimens are not damaged during the separation process. The expansion direction of the test specimen is the direction in which the test specimen is intended to expand or contract within the product. Cut test specimens with dimensions of 25 mm in the expansion direction and at least 40 mm in the direction perpendicular to the expansion direction, or as close to 40 mm as possible if at least 40 mm is not obtainable. The test specimens are carefully cut from the absorbent article from the corrugated or expandable portions of the laminate. Before testing, precondition the test specimens for 2 hours under the same environmental conditions at approximately 23°C ± 2°C and approximately 50% ± 2% relative humidity. Starting from one of the ends of the test specimen, peel off the test specimen by separating the first substrate layer from the rest of the laminate at the bonding joint without damaging the layers until a sufficient amount of test specimen is separated so that the test specimen can be attached to the gripper. The first substrate may be the upper or bottom substrate layer of the laminate. The first substrate is attached to one of the gripping parts, and the remaining layer is attached to the other gripping part.

[0124] The specimen is attached to the gripping section so that there is no slack and the load to be measured is 0.00N to 0.02N. The specimen is mounted in the center of the gripping section so that the peeling direction of the specimen, perpendicular to the stretching direction, is parallel to the applied tensile stress. The specimen is positioned between the gripping sections such that the first gripping section holds the first substrate and the second gripping section holds the second substrate, thereby peeling the first substrate from the second substrate in a 180° peeling direction. If the specimen size is smaller or larger, bonded specimens of other dimensions may be used in the peel force test method, however, those skilled in the art should recognize that the effective bonding area should remain in the center of the specimen. The peel test is started and the specimen is stretched at 127 mm / min at a data acquisition rate of at least 50 Hz until the specimen is completely separated. The peel force (N) is averaged from 5 mm after the start of the crosshead movement to at least 5 mm before the end of the crosshead movement, and this is reported as the specimen peel force (N). The peeling force (N) is typically averaged over a travel of at least 30 mm. The specimen peeling force (N / cm) is calculated using the following formula:

[0125]

number

[0126] For test specimens tested according to the specified dimensional method, the width of the test specimen shall be equal to 1 inch or 2.54 cm.

[0127] The arithmetic mean of the specimen peeling forces (N / cm) for the four specimens is recorded as the average peeling force (N / cm) for either the top or bottom layer.

[0128] The delamination procedure is performed on both the top and bottom layers of the laminate. The larger of the average delamination force of the top layer and the average delamination force of the bottom layer is reported as the delamination force of the laminate, rounded to the nearest 0.01 N / cm.

[0129] To calculate the peel force of the releasable joint, a specimen is cut that is wider than the width of the releasable joint, contains only the releasable joint, and is long enough to allow the 40 mm travel distance required by the peel test method described above. The peeling procedure is also performed on both the top and bottom layers of the laminate. The smaller of the average peel force of the top layer and the average peel force of the bottom layer is reported as the peel force of the releasable joint, rounded to the nearest 0.01 N. For the peel force of the releasable joint, the peel force is normalized and recorded as N per average number of joints. The number of joints per width in the specimen is calculated as follows: Starting from a joint on the specimen, a straight line is drawn in the primary stretch direction (the width direction of the specimen and an angle of 5 degrees or less). The number of joints that intersect the line is counted. This is repeated three times, drawing a line from a different joint each time. The number of joints that intersect each line is recorded, and the arithmetic mean is recorded as the average number of joints per width, rounded to the nearest 0.1 joints. The release force of the releasable joint is calculated using the following formula.

[0130]

number

[0131] The arithmetic mean of the releaseable bond peel force (N / bond) from the four test specimens is rounded to the nearest 0.01 N / bond and recorded as the average releaseable bond peel force (N / bond).

[0132] Hysteresis Test Method Hysteresis testing is used to characterize specific strain or load values ​​after a stretching cycle. Hysteresis testing is performed using commercially available tensile testing machines (e.g., Instron Engineering Corp. (Canton, MA), SINTECH-MTS Systems Corporation (Eden Prairie, MN), or equivalent). The test is performed under laboratory conditions of 23°C ± 2°C and 50% ± 2% relative humidity. The specimen is conditioned for 24 hours prior to the test.

[0133] Identify corrugated or expandable portions on absorbent articles having bonding patterns that include releaseable and permanent bonding portions. Cut test specimens from the area of ​​the absorbent article to the dimensions listed in the table below for the test performed.

[0134] Test protocol 1. Select an appropriate gripping section and load cell. The gripping section must have one flat surface and be wide enough to grip the specimen along its entire width. The gripping section must also provide sufficient force and a suitable surface area to ensure the specimen does not slip during testing. The gripping section is a pneumatic gripping section with one flat surface and opposing surfaces, designed to concentrate the total gripping force along a single line perpendicular to the direction of the test stress, with a semicircular projection (radius = 6 mm, e.g., part number: 56-163-827 from MTS Systems Corp.) or equivalent from the opposing surface to minimize specimen slippage. The load cell is selected so that the tensile response from the specimen being tested is between 5% and 95% of the load cell capacity used. Calibrate the testing machine according to the manufacturer's instructions. 2. Set the distance between the gripping parts (gauge length) for each test performed (see table below). 3. Place the test specimen on the plane of the gripping section so that the uniform width is aligned perpendicular to the gauge length direction. Mount the test specimen so that its expansion and contraction direction is the test direction. Secure the test specimen with the upper gripping section, allowing the specimen to hang loosely, and then close the lower gripping section. 4. Preload: Set the slack to a preload of 0.05 N / in and set the preload crosshead speed to 13 mm / min. This means that data acquisition will begin when the slack is removed with a force of 0.05 N / in (at a constant crosshead speed of 13 mm / min). Strain is the adjusted gauge length (l), which is the length of the specimen between the gripping parts of the tensile testing machine with a force of 0.05 N / in. iniIt is calculated based on the following. This adjusted gauge length is taken as the initial specimen length, which corresponds to 0% strain. The percentage of strain at any point in the test is defined as the change in length relative to the adjusted gauge length, obtained by dividing by the adjusted gauge length and multiplying by 100. 5(a). First cycle load: The test specimen is pulled to a given endpoint (load or strain) at a constant crosshead speed defined in the table below. The length of the expanded and contracted specimen between the gripping parts is l max I will report it as such. 5(b). First cycle unloading: The specimen is held at the end of step 5(a) for 30 seconds, and then the crosshead is moved at a constant crosshead speed defined in step 5(a) above, from its starting position (0% strain or initial specimen length, l ini ) return to the original state. 5(c) Hold the test specimen in a relaxed state for 1 minute. 5(d). Second cycle: Repeat steps 5(a) and 5(b).

[0135] [Table 1]

[0136] The force applied to the sample during the test is recorded as a function of the applied strain. From the generated data, the following quantities are collected and reported: i. The length of the test specimen between the gripping parts in a preloaded slack of 0.05 N / in, rounded to the nearest 0.01 mm (l ini ). ii. The length of the specimen between the gripping parts in the first cycle under a given strain or force, rounded to the nearest 0.01 mm (l max ). iii. The length of the specimen between the gripping parts at a second cycle load of 0.05 N / in, rounded to the nearest 0.001 mm (l ext ). iv. Regarding the laminate performance test settings, the force at 50% strain during the first load cycle (reported as the load force at 50%) is rounded to the nearest 0.01 N / in. v. Regarding the laminate performance test settings, the force at 50% strain during the second unloading cycle (reported as the unloading force at 50%) is rounded to the nearest 0.01 N / in.

[0137] Permanent strain % is rounded to the nearest 0.01%, (l ext -l ini ) / (l max -l ini ) * It is defined as 100%.

[0138] The test is repeated on three separate samples, and the arithmetic mean is reported.

[0139] Laminate stretching test method The stretch of the laminate (ear, waist, cuff, etc.) is measured using a constant-speed stretch tensile testing machine such as those from MTS Alliance. The equipment is set up and the test specimens are pre-conditioned according to the hysteresis test method described above. The test is performed under laboratory conditions of 23°C ± 2°C and 50% ± 2% relative humidity. The test specimens are conditioned for 24 hours prior to the test.

[0140] Identify corrugated or stretchable portions on an absorbent article product having a bonding pattern that includes releasable and permanent bonds. Cut a test specimen from this area of ​​the absorbent article product to the dimensions listed in the table below. Measure the stretch of the laminate using the test specimen dimensions, gauge length, and test speed listed in the table below.

[0141] [Table 2]

[0142] Test protocol: 1) Select an appropriate gripping section and load cell. The gripping section must have one plane and be wide enough to grip the specimen along its entire width. The gripping section should also provide sufficient force and a suitable surface area to ensure that the specimen does not slip during testing. The gripping section is a pneumatic gripping section with one flat surface and opposing surfaces, designed to concentrate the total gripping force along a single line perpendicular to the direction of the test stress, with a semicircular projection (radius = 6 mm, e.g., part number: 56-163-827 from MTS Systems Corp.) or equivalent from the opposing surface to minimize specimen slippage. The load cell is selected so that the tensile response from the specimen being tested is between 5% and 95% of the load cell capacity used. Calibrate the testing machine according to the manufacturer's instructions for use. 2) Set the distance between the gripping parts (gauge length) as shown in the table. 3) Place the test specimen on the flat surface of the gripping part so that the uniform width is aligned perpendicular to the gauge length direction. Mount the specimen so that the direction of expansion and contraction of the specimen is the direction of the test. Secure the test specimen with the upper gripping part so that the specimen hangs loosely, then close the lower gripping part. 4) Preload: Set the slack to a preload of 0.05 N per inch and set the preload crosshead speed to 13 mm / min. This means that data acquisition will begin when the slack is removed with a force of 0.05 N per inch (at a constant crosshead speed of 13 mm / min). Strain is the adjusted gauge length (l), which is the length of the specimen between the grips of the tensile testing machine with a force of 0.05 N per inch. ini It is calculated based on the following. This adjusted gauge length is taken as the initial specimen length, which corresponds to 0% strain. The percentage of strain at any point in the test is defined as the change in length relative to the adjusted gauge length, obtained by dividing by the adjusted gauge length and multiplying by 100. 5) If specified, pull the specimen to the endpoint at the test speed, or pull the specimen at the test speed until it breaks. Breakage is defined as a sudden drop in force of at least 50%.

[0143] From the data, the elongation at a force of 0.5 N / in, elongation at a force of 1.5 N / in, elongation at a force of 4 N / in, elongation at the fracture point, and load at the fracture point are determined. Elongation is calculated as (length of the specimen between the gripping parts at a given force - l ini It is defined as ) and recorded rounded to the nearest 0.1 mm.

[0144] Record the fracture point load, rounded to the nearest 0.01 Newton.

[0145] For each product example, five replica test specimens will be tested. For each of the four test specimens, the average elongation at a force of 0.5 N / in, the average elongation at a force of 1.5 N / in, the average elongation at a force of 4 N / in, the average elongation at the fracture point, and the average load at the fracture point will be reported.

[0146] Bonding ratio test method Prepare the test specimen according to the laminate stretching test method. Identify the regions containing permanent and releasable bonds.

[0147] The test specimens are tested according to the laminate stretching test method described above, and the endpoint of step 5 of the method is defined in the table below.

[0148] [Table 3]

[0149] After stretching the test specimen to the desired length or force, hold the specimen in that state. Visually examine the joints in the stretched specimen. Record the number of released joints as releaseable joints, and record the number of non-released joints as permanent joints.

[0150] Four test specimens are tested. For each specimen, the number of releasable connections and the number of permanent connections are recorded. The connection ratio for each specimen is calculated by dividing the number of permanent connections by the number of releasable connections. The average connection ratio is determined by calculating the average (arithmetic mean) of the individual connection ratios for each of the four specimens. The connection ratios and average connection ratios are recorded rounded to the nearest 0.1.

[0151] Air permeability test method The air permeability of a laminate or substrate (e.g., film, nonwoven fabric, or component of an article) is determined by measuring the flow velocity of standard-condition air through a test specimen, driven by a specific pressure drop. This test is particularly suitable for materials with relatively high gas permeability, such as nonwoven fabrics and perforated laminates. ASTM D737 is used with the following modifications:

[0152] Use a Textest FX 3300 instrument or equivalent available from Textest AG, Switzerland, or Advanced Testing Instruments ATI, Spartanburg SC, USA. Follow the procedures described in the operating instructions for the Textest FX 3300 air permeability tester manual, under Airtightness Testing and Functional and Calibration Checks. If using a different instrument, follow similar provisions regarding airtightness and calibration as specified in the manufacturer's instructions.

[0153] The test specimen is cut from the absorbent article portion, which includes the releasable and permanent joints. The test specimen is tested while in a relaxed state, and the area tested should include the releasable and permanent joints.

[0154] The test was 5cm 2 The test is performed using an area test head, and the pressure drop is adjusted to obtain a stable reading. The results are recorded with three significant figures. The average (arithmetic mean) of five test specimens is calculated, and the air permeability value (m) is calculated. 3 / m 2 Report as ( / minute).

[0155] Method for testing the stacking height inside a bag The height of the stacked layers inside the bag of absorbent material packaging is measured as follows:

[0156] device A thickness testing machine equipped with a flat, rigid horizontal sliding plate is used. The thickness testing machine is configured such that the horizontal sliding plate moves freely in the vertical direction, while the horizontal sliding plate is always maintained in a horizontal orientation just above a flat, rigid horizontal base plate. The thickness testing machine 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 each plate contacts (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 g (8.34 N) to the absorbent article package, which can be achieved by placing a suitable weight in the center of the upper surface of the horizontal sliding plate that does not contact the package, such that the total mass of the sliding plate plus an additional weight equals 850 ± 1 g.

[0157] Test Procedure The absorbent article package is equilibrated at 23±2°C and 50±5% relative humidity before measurement.

[0158] Raise the horizontal sliding plate and position the absorbent material package in the center under the horizontal sliding plate so that the absorbent material inside the package is oriented horizontally (see Figure 12). Minimize the impact on the measurement by folding any handles or other packaging mechanisms on the surface of the package that would come into contact with any of the plates flat against the surface of the package. Slowly lower the horizontal sliding plate until it touches the top surface of the package, then release it. Ten seconds after releasing the horizontal sliding plate, measure the gap between the horizontal plates to within ±0.5 mm. Measure five identical packages (packages of the same size and the same number of absorbent materials) and report the arithmetic mean as the package width. Calculate the "stack height in the bag" = (package width / number of absorbent materials per stack) × 10 and report it to within ±0.5 mm.

[0159] The dimensions and values ​​disclosed herein should not be understood as strictly limited to the exact numerical values ​​listed. Instead, unless otherwise indicated, each such dimension is intended to mean both the listed value and the functionally equivalent range encompassing that value. For example, a dimension disclosed as "40 mm" is intended to mean "approximately 40 mm." Furthermore, for all numerical ranges specified in this application, it should be understood that the range includes all numerical increments within the listed range and all ranges within or formed therein. For example, numerical increments may be 0.1 mm, 1 gsm, and / or 0.1 mm 2 It is possible.

[0160] All documents referenced herein, including all patents or patent applications that are cross-referenced or related, and all patent applications or patents to which this application claims priority or benefit thereof, are incorporated herein by reference in their entirety unless expressly excluded or otherwise limited. No reference to any document shall be deemed prior art to any invention disclosed or claimed herein, nor shall it be deemed to teach, suggest or disclose any 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 any document incorporated by reference, the meaning or definition given to that term in this document shall prevail.

[0161] While specific embodiments of this disclosure have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications are possible without departing from the spirit and scope of the invention. Accordingly, it is intended that all such changes and modifications within the scope of the invention be covered in the appended claims.

Claims

1. Absorbent articles, Top sheet and Back seat and, An absorbent core is disposed between the top sheet and the back sheet, A laminate comprising an elastomer layer and a nonwoven fabric layer, comprising at least one elastic tab, An absorbent article wherein the laminate has a plurality of primary ultrasonic bonding portions and a plurality of secondary ultrasonic bonding portions, the elastomer layer and the nonwoven fabric layer are permanently attached by the primary ultrasonic bonding portions and remain releasably attached by the secondary ultrasonic bonding portions, the secondary ultrasonic bonding portions release when the laminate, which has a length of 25.4 mm in the stretching direction, is stretched by more than 5 mm in the stretching direction.

2. The absorbent article according to claim 1, wherein the coupling ratio, which is the ratio of the number of primary ultrasonic couplings to the number of secondary ultrasonic couplings, is greater than 1.

3. The absorbent article according to claim 1, wherein the number of primary ultrasonic couplings is greater than the number of secondary ultrasonic couplings.

4. The absorbent article according to claim 1, wherein the secondary ultrasonic bonding portion is released when a force of 0.3 N / cm or more is applied to the laminate.

5. The absorbent article according to claim 1, wherein the at least one elastic tab includes a first portion and a second portion opposite to the first portion, and the first portion of the at least one elastic tab is bonded to at least one of the top sheet and the back sheet at a chassis mounting joint.

6. The absorbent article according to claim 5, wherein the plurality of secondary ultrasonic coupling portions do not overlap with the chassis mounting coupling portion.

7. The absorbent article according to claim 1, wherein the plurality of secondary ultrasonic bonding portions are uniformly distributed across the laminate.

8. The absorbent article according to claim 1, wherein the plurality of primary ultrasonic couplings form one or more closed-cell units formed by at least five of the primary ultrasonic couplings surrounding a region not containing the primary ultrasonic couplings, and at least a portion of the secondary ultrasonic couplings is disposed within the one or more closed-cell units.

9. The absorbent article according to claim 1, wherein the plurality of primary ultrasonic coupling portions form a predetermined coupling pattern when the plurality of secondary ultrasonic coupling portions are open.

10. The absorbent article according to claim 1, wherein the nonwoven fabric layer of the laminate comprises at least one of spunbond nonwoven fabric, carding nonwoven fabric, water-entangled nonwoven fabric, air-through bonded nonwoven fabric, and spunlace nonwoven fabric.

11. The absorbent article according to any one of claims 1 to 10, wherein the surface of one or more layers of the laminate is formed in a corrugated shape.

12. Absorbent articles, Top sheet and Back seat and, An absorbent core is disposed between the top sheet and the back sheet, A laminate comprising an elastomer layer and a nonwoven fabric layer, comprising at least one elastic tab, An absorbent article wherein the laminate has a plurality of primary ultrasonic bonding portions and a plurality of secondary ultrasonic bonding portions, the elastomer layer and the nonwoven fabric layer are permanently bonded by the primary ultrasonic bonding portions and remain releasably bonded by the secondary ultrasonic bonding portions, the secondary ultrasonic bonding portions release when the laminate is stretched in the stretching direction with a force of at least 0.2 N / cm.

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