Nonwoven web with visually recognizable patterns and improved texture perception

Abstract

A nonwoven web for an absorbent article is provided. The nonwoven web includes a first surface, a second surface, and a visually distinguishable pattern of three-dimensional features on the first surface or the second surface. The three-dimensional features include one or more first regions and a plurality of second regions. The one or more first regions have a first value of average intensive index. The plurality of second regions have a second value of average intensive index. The first value and the second value are different and both are greater than zero. The nonwoven web has a single-layer saturation value ranging from about 1.0 to about 3.5 according to the Delta Saturation and Single-Layer Saturation Test. The nonwoven web has a delta saturation value ranging from about +0.1 to about +3.5 according to the Delta Saturation and Single-Layer Saturation Test.

Description

[Technical Field]

[0001] This disclosure generally relates to nonwoven webs having visually recognizable patterns and improved texture perception. This disclosure also relates to absorbent articles comprising nonwoven webs having visually recognizable patterns and improved texture perception. [Background technology]

[0002] Nonwoven webs are used in many industries, including the medical, hygiene, and cleaning industries. Absorbent articles containing nonwoven webs are used to contain and absorb bodily waste (i.e., urine, feces, and menstruation) from infants, children, and adults. Absorbent articles include, but are not limited to, diapers, pants, adult incontinence products, feminine care products, and absorbent pads. Various components of these absorbent articles contain one or more nonwoven webs. Some exemplary components containing nonwoven webs are, for example, outer cover nonwoven material, top sheet, waistband, leg cuffs, waist cuff, ear loops, belt, and trapping material. High-quality nonwoven webs that function well for their intended purpose are desirable. Because consumers are willing to pay more for absorbent articles with such high-quality nonwoven webs, manufacturers strive to develop and provide high-quality nonwoven webs. Several factors that contribute to high-quality nonwoven webs are texture, perceived absorbency, appearance, and softness. However, texture is difficult to perceive on white nonwoven webs. While it may be desirable to provide white or uncolored nonwoven webs, it is difficult to provide white or uncolored nonwovens with a high level of texture, perceived absorbency, and softness. Therefore, nonwoven webs should be improved. [Overview of the project] [Means for solving the problem]

[0003] This disclosure provides, in part, a nonwoven web having a visually recognizable pattern of three-dimensional features having improved texture perception, improved absorbency perception, and softness. This disclosure also provides an absorbent article comprising, in part, a nonwoven web having a visually recognizable pattern of three-dimensional features having improved texture perception and flexibility. Selected nonwoven textures are thought to further contribute to perceived absorbency and / or flexibility. Unfortunately, highly textured nonwoven webs can also adversely affect skin blemishes and redness as top-sheet nonwovens. Therefore, it is highly desirable to form a three-dimensional or three-dimensional-like texture that contributes to the perception of flexibility and absorbency without causing skin blemishes. The inventors have unexpectedly discovered how a significantly enhanced visual texture contrast or improved texture perception is provided when low concentrations of colorants, pigments, and / or dyes are included as melting additives when forming the masterbatch used to form the filaments of the nonwoven web. This improved texture perception provides the improved nonwoven web of this disclosure. It should be noted that while the nonwoven webs of this disclosure provide improved texture perception, they are still considered “white,” uncolored, or without added colorants, pigments, and / or dyes. White, uncolored, or without added colorants, pigments, and / or dyes does not imply the addition of TiO2. Therefore, this disclosure provides unexpected texture perception benefits by using low concentrations of colorants, pigments, and / or dyes while maintaining the concentration of colorants, pigments, and / or dyes below the concentration that would be perceived by the human eye as having a color other than white. As one example, to enhance texture perception, a low concentration of blue colorant can be added when forming the masterbatch to form the filaments of the nonwoven web, but the nonwoven web still appears white to the human eye.

[0004] The visually identifiable pattern of the three-dimensional features of the nonwoven web of this disclosure may include one or more first regions and a plurality of second regions. One or more first regions may be regions where the nonwoven web is low-basis-weight, high-density, and / or compressed, and the plurality of second regions may be fluffy, high-basis-weight regions. The plurality of second regions may increase the flexibility of the nonwoven web. This combination of improved texture perception and flexibility produces a highly desirable, high-quality nonwoven web.

[0005] This disclosure relates, in part, to nonwoven webs for absorbent articles. A nonwoven web, such as a spunbond nonwoven web, includes a first surface, a second surface, and a visually identifiable pattern of three-dimensional features on the first or second surface. The three-dimensional features include one or more first regions and a plurality of second regions. One or more first regions have a first average intensity value. The plurality of second regions have a second average intensity value. The first and second values ​​are different and both are greater than zero. The nonwoven web has a single-layer chroma value in the range of about 1.0 to about 3.5 according to the Delta Chroma and Single Layer Chroma Test. The nonwoven web has a Delta Chroma value in the range of approximately +0.1 to approximately +3.5, according to Delta Chroma and single-layer chroma tests. [Brief explanation of the drawing]

[0006] The above and other features and advantages of this disclosure, as well as the ways in which they are realized, will become clearer and the disclosure itself will be better understood by referring to the following exemplary descriptions of this disclosure in conjunction with the accompanying drawings. [Figure 1] This is a plan view of an exemplary absorbent article in the form of a tape-type diaper, laid flat with the surface facing the clothing facing the observer. [Figure 2]It is a plan view of an exemplary absorbent article in a state where the surface facing the wearer is facing the observer and is spread out flat. [Figure 3] It is a front perspective view of the absorbent article of FIGS. 1 and 2 in the fastening position. [Figure 4] It is a front perspective view of an absorbent article in the form of pants. [Figure 5] It is a rear perspective view of the absorbent article of FIG. 4. [Figure 6] It is a plan view of the absorbent article of FIG. 4 in a state where it is spread out flat and the surface facing the clothing is facing the observer. [Figure 7] It is a cross-sectional view of the absorbent article taken around line 7-7 of FIG. 6. [Figure 8] It is a cross-sectional view of the absorbent article taken around line 8-8 of FIG. 6. [Figure 9] It is a plan view of an exemplary absorbent core or absorbent article. [Figure 10] It is a cross-sectional view of the absorbent core of FIG. 9 taken around line 10-10. [Figure 11] It is a cross-sectional view of the absorbent core of FIG. 10 taken around line 11-11. [Figure 12] It is a plan view of an exemplary absorbent article which is a sanitary napkin of the present disclosure. [Figure 13A] It is a schematic view showing a cross-section of a filament made of a primary component A and a secondary component B arranged side by side. [Figure 13B] It is a schematic view showing a cross-section of a filament made of a primary component A and a secondary component B in an eccentric sheath / core arrangement. [Figure 13C] It is a schematic view showing a cross-section of a filament made of a primary component A and a secondary component B in a concentric sheath / core arrangement. [Figure 14] It is a perspective photographic view of a three-leaf type two-component fiber. [Figure 15] It is a schematic view of an exemplary apparatus for producing the nonwoven web of the present disclosure. [Figure 16] It is a partial detailed view of the apparatus of FIG. 15 for adhering a part of the nonwoven web of the present disclosure. [Figure 17] Figure 16 is a further detail view of the apparatus for bonding a portion of a nonwoven web of the present disclosure, taken from the details in Figure 17. [Figure 18] This is a partial detail diagram of an apparatus for optionally further bonding a portion of a nonwoven web of the present disclosure. [Figure 19] This is a photograph of an exemplary nonwoven web having a different design from the nonwoven web disclosed herein. [Figure 20] These are photographs of some forming belts with different designs for creating nonwoven webs. [Figure 21] This is a cross-sectional view of a portion of the forming belt, taken around line 21-21 in Figure 20. [Figure 22] This is an image of a portion of the mask used to form at least a part of the forming belt shown in Figure 20. [Figure 23] This graph compares color saturation with the number of layers of nonwoven fabric. [Figure 24] This is an example of a visually identifiable pattern of the three-dimensional features of a nonwoven web. [Modes for carrying out the invention]

[0007] To provide an overall understanding of the principles of structure, function, manufacture, and use of the nonwoven webs having visually recognizable patterns and improved texture perception disclosed herein, various non-limiting forms of this disclosure are described below. One or more embodiments of these non-limiting forms are shown in the accompanying drawings. Those skilled in the art will understand that the nonwoven webs having visually recognizable patterns and improved texture perception described herein and illustrated in the accompanying drawings are non-limiting illustrative forms, and that the scope of the various non-limiting forms of this disclosure is defined solely by the claims. Features shown or described in relation to one non-limiting form can be combined with features of other non-limiting forms. Such modifications and variations are included within the scope of this disclosure.

[0008] Before considering nonwoven webs with visually identifiable patterns, absorbent articles and their components and characteristics are considered as one potential application of nonwoven webs. It will also be understood that nonwoven webs with visually identifiable patterns may have other uses in other products, such as in the medical field, the cleaning and / or dust removal field, and / or the wiping field.

[0009] Overview of absorbent materials Figures 1 to 3 show exemplary absorbent articles 10 according to this disclosure, shown in the form of tape-type diapers. Figure 1 is a plan view of the exemplary absorbent article 10 in a flat, unfolded state (i.e., without elastic contraction) with the surface 2 facing clothing facing the observer. Figure 2 is a plan view of the exemplary absorbent article 10 of Figure 1 in a flat, unfolded state with the surface 4 facing the wearer facing the observer. Figure 3 is a front perspective view of the absorbent articles 10 of Figures 1 and 2 in a fastening state. Because this disclosure can be used to make a wide variety of diapers, such as adult incontinence products, pants, or other absorbent articles such as sanitary napkins and absorbent pads, the absorbent articles 10 of Figures 1 to 3 are shown for illustrative purposes only.

[0010] The absorbent article 10 may include a front waist region 12, a crotch region 14, and a rear waist region 16. The crotch region 14 may extend between the front waist region 12 and the rear waist region 16. The front waist region 12, the crotch region 14, and the rear waist region 16 may each be one-third of the length of the absorbent article 10. The absorbent article 10 may include a front edge 18, a rear edge 20 opposite to the front edge 18, and longitudinally extending, transversely opposing side edges 22 and 24 defined by the chassis 52.

[0011] The absorbent article 10 may include a liquid-permeable top sheet 26, a liquid-impermeable back sheet 28, and an absorbent core 30 at least partially positioned between the top sheet 26 and the back sheet 28. The absorbent article 10 may also include one or more barrier leg cuffs 32 with or without elastic bodies 33, one or more leg elastic bodies 34, one or more elastic waistbands 36, and / or one or more trapping materials 38. The trapping material(s) 38 may be positioned between the top sheet 26 and the absorbent core 30. An outer cover nonwoven material 40, such as a nonwoven web, may cover the garment-facing surface of the back sheet 28. The absorbent article 10 may include a rear ear portion 42 in the rear waist region 16. The rear ear portion 42 may include fasteners 46 and extends from the rear waist region 16 of the absorbent article 10 and can be attached (using the fasteners 46) to the landing area or landing area material 44 of the garment-facing portion of the front waist region 12 of the absorbent article 10. The absorbent article 10 may also have front ear portions 47 in the front waist region 12. Instead of two front ear portions 47, the absorbent article 10 may have a one-piece molded front belt that can also function as a landing area. The absorbent article 10 may have a central lateral (or transverse) axis 48 and a central longitudinal axis 50. The central lateral axis 48 extends perpendicular to the central longitudinal axis 50.

[0012] In other examples, the absorbent article may be in the form of pants having permanent or refastened side seams. Preferred refastened seams are disclosed in U.S. Patent Application Publication 2014 / 0005020 and U.S. Patent No. 9,421,137. Referring to Figures 4 to 8, an exemplary absorbent article 10 in the form of pants is illustrated. Figure 4 is a front perspective view of the absorbent article 10. Figure 5 is a rear perspective view of the absorbent article 10. Figure 6 is a plan view of the absorbent article 10 laid flat with the surface facing the garment facing the observer. Elements in Figures 4 to 8 having the same reference numerals as those described above in relation to Figures 1 to 3 may be the same elements (e.g., absorbent core 30). Figure 7 is an exemplary cross-sectional view of the absorbent article taken around line 7-7 in Figure 6. Figure 8 is an exemplary cross-sectional view of the absorbent article taken around line 8-8 in Figure 6. Figures 7 and 8 show exemplary forms of the front belt 54 and the rear belt 56. The absorbent article 10 may have a front waist region 12, a crotch region 14, and a rear waist region 16. Each of the regions 12, 14, and 16 may be one-third of the length of the absorbent article 10. The absorbent article 10 may have a chassis 52 (sometimes called a central chassis or central panel) including a top sheet 26, a back sheet 28, an absorbent core 30 at least partially positioned between the top sheet 26 and the back sheet 28, and an optional trapping material 38, similar to those described above with respect to Figures 1 to 3. The absorbent article 10 may include a front belt 54 for the front waist region 12 and a rear belt 56 for the rear waist region 16. The chassis 52 can be joined to the wearer-facing surface 4 of the front belt 54 and the rear belt 56, or to the garment-facing surface 2 of the belts 54 and 56. The side edges 23 and 25 of the front belt 54 can be joined to the side edges 27 and 29 of the rear belt 56, respectively, to form two side seams 58. The side seams 58 can be any suitable seam known to those skilled in the art, such as butt seams or overlapping seams. Once the side seams 58 are permanently formed or refastenably closed, the absorbent article 10 in the form of pants has two leg openings 60 and a waist opening perimeter 62.The side seam 58 may be permanently joined using, for example, an adhesive or bond, or it may be closed in a re-fastened manner using, for example, a hook-and-loop fastener.

[0013] belt Referring to Figures 7 and 8, the front belt 54 and the rear belt 56 may include a front inner belt layer 66 and a rear inner belt layer 67, and a front outer belt layer 64 and a rear outer belt layer 65 having an elastomer material (e.g., strands 68 or film (which may be perforated)) at least partially positioned between them. The elastic elements 68 or film may be relaxed (including being cut) to reduce elastic strain on the absorbent core 30, or alternatively, may run continuously across the absorbent core 30. The elastic elements 68 may have uniform or variable spacing between them in any portion of the belt. The elastic elements 68 may also be subjected to the same or different amounts of pre-strain. The front belt 54 and / or the rear belt 56 may have a zone 70 in which the chassis 52 overlaps with the belts 54, 56, which does not contain one or more elastic elements. In other examples, at least some of the elastic elements 68 may extend continuously across the chassis 52.

[0014] The front inner belt layer 66 and the rear inner belt layer 67, and the front outer belt layer 64 and the rear outer belt layer 65 can be joined using adhesives, thermal bonds, pressure bonds, or thermoplastic bonds. Various suitable belt layer configurations can be found in U.S. Patent Application Publication No. 2013 / 0211363.

[0015] The front belt edge 55 and the rear belt edge 57 may extend longitudinally beyond the front chassis edge 19 and the rear chassis edge 21 (shown in Figure 6), or they may share the same end. The front and rear belt side edges 23, 25, 27, and 29 may extend laterally beyond the chassis side edges 22 and 24. The front belt 54 and the rear belt 56 may be continuous from belt side edge to belt side edge (e.g., transverse distance from 23 to 25 and from 27 to 29) (i.e., they have at least one continuous layer). Alternatively, the front belt 54 and the rear belt 56 may be discontinuous from belt side edge to belt side edge (e.g., transverse distance from 23 to 25 and from 27 to 29) so that they are distinct.

[0016] As disclosed in U.S. Patent No. 7,901,393, the longitudinal length of the rear belt 56 (along the central longitudinal axis 50) may be longer than the longitudinal length of the front belt 54, which may be particularly useful for increased hip coverage when the rear belt 56 has a greater longitudinal length than the front belt 54 which is adjacent to or immediately adjacent to the side seam 58.

[0017] The front outer belt layer 64 and the rear outer belt layer 65 may be separated from each other so that each layer is distinct, or alternatively, these layers may be continuous so that the layers run continuously from the front belt edge 55 to the rear belt edge 57. This can also be applied to the front inner belt layer 66 and the rear inner belt layer 67, that is, they may be distinct or continuous in the longitudinal direction. Furthermore, the front inner belt layer 66 and the rear inner belt layer 67 may be distinct in the longitudinal direction while the front outer belt layer 64 and the rear outer belt layer 65 are continuous in the longitudinal direction, resulting in the formation of gaps between them (the gaps between the front outer belt layer 64 and the rear outer belt layer 65, and the gaps between the front inner belt layer 66 and the rear inner belt layer 67 are shown in Figure 7, and the gap between the front inner belt layer 66 and the rear inner belt layer 67 is shown in Figure 8).

[0018] The front belt 54 and rear belt 56 may include slits, holes, and / or perforations to provide increased breathability, flexibility, and a garment-like texture. The underwear-like appearance can be enhanced by substantially aligning the waist and leg edges at the side seams 58 (see Figures 4 and 5).

[0019] The front belt 54 and rear belt 56 may include a pattern (see, for example, 78 in Figure 1). The pattern may extend substantially around the entire circumference of the absorbent article 10, or it may be placed along the entire side seam 58 and / or along the entire proximal front belt seam 15 and rear belt seam 17, or it may be placed adjacent to the seams 58, 15, and 17 in the manner described in U.S. Patent No. 9,498,389 to make the article more underwear-like. The pattern may also be discontinuous.

[0020] Alternatively, instead of attaching belts 54 and 56 to chassis 52 to form pants, individual side panels may be attached to the side edges of chassis 22 and 24.

[0021] Nonwoven webs having visually recognizable patterns and improved texture perception can be used as nonwoven components of a belt, or as part thereof.

[0022] Top sheet The top sheet 26 is the portion of the absorbent article 10 that comes into contact with the wearer's skin. As is known to those skilled in the art, the top sheet 26 can be bonded to the back sheet 28, the absorbent core 30, the barrier leg cuff 32, and / or any other layer. The top sheet 26 can be conformable to the wearer's skin, soft to the touch, and non-irritating. Furthermore, at least a portion or the entirety of the top sheet can be made liquid permeable, thereby allowing liquid bodily waste to easily penetrate through its thickness. Suitable top sheets may be made from a wide range of materials, such as porous foams, mesh foams, perforated plastic films, woven materials, nonwoven webs, woven or nonwoven webs of natural fibers (e.g., wood fibers or cotton fibers), synthetic fibers or filaments (e.g., polyester fibers or polypropylene fibers, or two-component PE / PP fibers, or mixtures thereof), or combinations of natural and synthetic fibers. The top sheet may have one or more layers. The top sheet may be perforated (element 31 in Figure 2), may have any preferred three-dimensional features, and / or may have multiple embossings (e.g., bond patterns). The top sheet may be perforated by strongly bonding the materials and then rupturing the strong bond via a ring roll, as disclosed in U.S. Patent No. 5,628,097 (Benson et al., issued May 13, 1997) and U.S. Patent Application Publication No. 2016 / 0136014 (Arora et al.). Any portion of the 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, pores will typically be present to allow bodily waste to pass through the top sheet.

[0023] Nonwoven webs having visually recognizable patterns and improved texture perception can be used as a nonwoven top sheet or as part thereof.

[0024] Back seat The backsheet 28 is generally a portion of the absorbent article 10 positioned in close proximity to the garment-facing surface of the absorbent core 30. The backsheet 28 can be bonded to the topsheet 26, the outer cover nonwoven material 40, the absorbent core 30, and / or any other layer of the absorbent article by any attachment method known to those skilled in the art. The backsheet 28 prevents, or at least inhibits, bodily waste absorbed and trapped by the absorbent core 10 from soiling articles such as bed sheets, underwear, and / or clothing. The backsheet is typically liquid-impermeable or at least substantially liquid-impermeable. The backsheet may be, for example, a thin plastic film such as a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm, or may include such a film. 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 waste from passing through the backsheet.

[0025] Outer cover nonwoven fabric material The outer cover nonwoven material (sometimes called the backsheet nonwoven) 40 may include one or more nonwoven materials bonded to and covering the backsheet 28. The outer cover nonwoven material 40 forms at least a portion of the garment-facing surface 2 of the absorbent article 10 and effectively "covers" the backsheet 28 such that no film is present on the garment-facing surface 2. Nonwoven webs having visually recognizable patterns and improved texture perception may be used as the outer cover nonwoven material or as part thereof.

[0026] Absorbent core As used herein, the term “absorbent core” 30 refers to a component of the absorbent article 10 that has the greatest absorbency and contains an absorbent material. Referring to Figures 9–11, in some examples the absorbent material 72 may be placed inside a core bag or core wrap 74. The absorbent material may or may not be contoured, depending on the specific absorbent article. The absorbent core 30 includes, or is essentially composed of, a core wrap, the absorbent material 72, and an adhesive encapsulated within the core wrap. The absorbent material may include a superabsorbent polymer, a mixture of a superabsorbent polymer and air felt, air felt alone, and / or a high internal-phase emulsion foam. In some examples the absorbent material may contain at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, at least 99% by weight, or up to 100% by weight of superabsorbent polymer. In such examples the absorbent material may not contain air felt, or may contain at least little air felt. The periphery of the absorbent core may be the periphery of the core wrap, but any preferred shape can be defined, such as a rectangle, a "T", a "Y", an hourglass, or a "dogbone" shape. The periphery of the absorbent core, which generally has a "dogbone" or "hourglass" shape, may be tapered along its width toward the crotch region 14 of the absorbent article 10.

[0027] Referring to Figures 9 to 11, the absorbent core 30 may have areas with little or no absorbent material 72, which can bond the wearer-facing surface of the core bag 74 to the garment-facing surface of the core bag 74. These areas with little or no absorbent material may be referred to as “channels” 76. These channels can be embossed in any preferred shape, and any preferred number of channels may be provided. In other examples, the absorbent core may be embossed to form channel indentations. The absorbent cores in Figures 9 to 11 are merely illustrative absorbent cores. Many other absorbent cores, with or without channels, are also within the scope of this disclosure.

[0028] Barrier Leg Cuff / Leg Elastic Body For example, referring to Figures 1 and 2, the absorbent article 10 may include one or more barrier leg cuffs 32 and one or more leg elastic bodies 34. The barrier leg cuffs 32 may be positioned laterally inward of the leg elastic bodies 34. Each barrier leg cuff 32 may be formed from a single piece of material that extends upward from the wearer-facing surface 4 of the absorbent article 10 and is bonded to the absorbent article 10 so as to provide improved containment of bodily waste near the junction of the wearer's torso and legs. The barrier leg cuff 32 is bounded by a proximal edge that is directly or indirectly bonded to the top sheet and / or back sheet, and a free end edge intended to contact the wearer's skin and form a seal with the skin. The barrier leg cuff 32 may extend at least partially between the front edge 18 and the rear edge 20 of the absorbent article 10 on both sides of the central longitudinal axis 50 and may be present in at least the groin area 14. Each barrier leg cuff 32 may include one or more elastic bodies 33 (e.g., elastic strands or strips) near or at the free end edge. These elastic bodies 33 help the barrier leg cuff 32 form a seal around the wearer's legs and torso. The leg elastic bodies 34 extend at least partially between the front end edge 18 and the rear end edge 20. The leg elastic bodies 34 essentially help the portion of the absorbent article 10 that is close to the chassis side edges 22, 24 to form a seal around the wearer's legs. The leg elastic bodies 34 may extend at least into the crotch area 14.

[0029] Nonwoven webs with visually recognizable patterns and improved texture perception can be used as nonwoven components of barrier leg cuffs, or as part thereof.

[0030] waistband Referring to Figures 1 and 2, the absorbent article 10 may include one or more elastic waistbands 36 or non-elastic waistbands. The elastic waistbands 36 may be positioned on a surface 2 facing the garment or a surface 4 facing the wearer. For example, a first elastic waistband 36 may be located near the front belt edge 18 of the front waist region 12, and a second elastic waistband 36 may be located near the rear edge 20 of the rear waist region 16. The elastic waistbands 36 can seal the absorbent article 10 around the wearer's waist and help at least prevent bodily waste from leaking out of the absorbent article 10 through the outer periphery of the waist opening. In some examples, the elastic waistbands may completely surround the outer periphery of the waist opening of the absorbent article.

[0031] Nonwoven webs having visually recognizable patterns and improved texture perception can be used as nonwoven components of a waistband, or as part thereof.

[0032] Captured material Referring to Figures 1, 2, 7, and 8, one or more trapping materials 38 may be present at least partially between the top sheet 26 and the absorbent core 30. The trapping material 38 is typically a hydrophilic material that provides significant wicking of bodily waste. These materials can dehydrate the top sheet 26 and rapidly move bodily waste into the absorbent core 30. The trapping material 38 may include, for example, one or more nonwoven webs, foams, cellulosic materials, crosslinked cellulosic materials, airlaid cellulosic nonwoven webs, spunlace materials, or combinations thereof. In some examples, part of the trapping material 38 may extend through part of the top sheet 26, part of the top sheet 26 may extend through part of the trapping material 38, and / or the top sheet 26 may be nested with the trapping material 38. Typically, the trapping material 38 may have a width and length smaller than the width and length of the top sheet 26. In the context of a women's pad, the trapping material may be a secondary top sheet. The capture material may have one or more channels (including embossed plates) with respect to the absorbent core 30, as described above. The channels of the capture material may or may not be aligned with the channels of the absorbent core 30. In one embodiment, the first capture material may include a nonwoven web, and the second capture material may include a crosslinked cellulose material. A nonwoven web having a visually recognizable pattern and improved texture perception may be used as a nonwoven component of the capture material, or as part thereof.

[0033] Landing area Referring to Figures 1 and 2, the absorbent article 10 may have a landing area 44 formed on a portion of the garment-facing surface 2 of the outer cover nonwoven fabric material 40. The landing area 44 may be located in the rear waist region 16 if the absorbent article 10 is fastened from front to rear, or in the front waist region 12 if the absorbent article 10 is fastened from rear to front. In some examples, the landing area 44 may be, or include, one or more separate nonwoven fabric materials attached to a portion of the outer cover nonwoven fabric material 40 in the front waist region 12 or the rear waist region 16, depending on whether the absorbent article is fastened at the front or rear. Essentially, the landing area 44 may be configured to receive a fastener 46 and may include, for example, a plurality of loops configured to engage with a plurality of hooks of the fastener 46, or vice versa.

[0034] Nonwoven webs with visually recognizable patterns and improved texture perception can be used as nonwoven components of a landing area, or as part thereof.

[0035] Moisture level indicator / pattern Referring to Figure 1, the absorbent article 10 of the present disclosure may include a pattern 78 and / or a dampness indicator 80 that are visible from the surface 2 facing the garment. The pattern 78 may be printed on the landing area 40, the backsheet 28, and / or other locations. The dampness indicator 80 is typically applied to the side of the backsheet 28 facing the absorbent core so that it can come into contact with bodily waste within the absorbent core 30. In some examples, the dampness indicator 80 may form part of the pattern 78. For example, the dampness indicator may appear or disappear and may form / remove letters within a particular pattern. In other examples, the dampness indicator 80 may be in harmony with the pattern 78 (e.g., identical design, identical pattern, identical color) or not.

[0036] Anterior and posterior aortic region Referring to Figures 1 and 2, as referenced above, the absorbent article 10, in the context of a tape-type diaper, may have a front ear portion 47 and / or a rear ear portion 42. In most tape-type diapers, only one pair of ear portions may be required. One pair of ear portions may include a fastener 46 configured to engage with a landing area or landing area 44. If two pairs of ear portions are provided, in most examples, only one pair of ear portions may have a fastener 46, and the other pair may not have a fastener. The ear portion or part thereof may be elastic, or may have an elastic panel. In one embodiment, an elastic film or elastic strand may be placed between a first nonwoven web and a second nonwoven web. The elastic film may be perforated or not. The ear portion may be molded. The ear portion may be an integrated unit (for example, an extension of the outer cover nonwoven fabric material 40, back sheet 28, and / or top sheet 26), or it may be a separate component attached to the wearer-facing surface 4, the clothing-facing surface 2 of the absorbent article chassis 52, or between the two surfaces 4, 2.

[0037] Nonwoven webs having visually recognizable patterns and improved texture perception can be used as anterior and posterior nonwoven components, or as part thereof.

[0038] sensor Referring again to Figure 1, the absorbent article of this disclosure may include a sensor system 82 for monitoring changes within the absorbent article 10. The sensor system 82 may be separate from or integrated with the absorbent article 10. The absorbent article 10 may include sensors capable of sensing various aspects of the absorbent article 10 in connection with the generation of bodily excretions such as urine and / or feces (for example, the sensor system 82 may sense fluctuations such as temperature, humidity, the presence of ammonia or urea, various vapor components of excretions (urine and feces), changes in the moisture permeability of the clothing-facing layer of the absorbent article, changes in the translucency of the clothing-facing layer, and / or changes in the color of the clothing-facing layer). In addition, the sensor system 82 may sense components of urine such as ammonia or urea, and / or by-products resulting from the reaction of these components with the absorbent article 10. The sensor system 82 may also sense by-products that occur when urine mixes with other components of the absorbent article 10 (e.g., adhesives, AGM). These sensed components or by-products may exist as vapors that can pass through the clothing-facing layer. Furthermore, it may be desirable to include a reactant in the absorbent article that, when mixed with urine or feces, changes its state (e.g., color, temperature) or produces measurable by-products. The sensor system 82 may also sense changes in pH, pressure, odor, presence of gas, blood, chemical or biological markers, or combinations thereof. The sensor system 82 may have components on or near the absorbent article that transmit signals to a receiver located further distal to the absorbent article, such as an iPhone. The receiver can output a result that communicates the state of the absorbent article 10 to the caregiver. In other examples, a receiver may not be provided, but instead the state of the absorbent article 10 may be made visually or audibly apparent from sensors on the absorbent article.

[0039] package The absorbent articles of this disclosure may be packaged. The package may include a nonwoven web, a polymer film, 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 providing an appropriate number of absorbent articles per package. Packaging the 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. Nonwoven webs having visually identifiable patterns and improved texture perception may be used as nonwoven components of the package, or as part thereof.

[0040] sanitary napkins Referring to Figure 12, the absorbent article of this disclosure may be a sanitary napkin 110. The sanitary napkin 110 may include a liquid-permeable top sheet 114, a liquid-impermeable or substantially liquid-impermeable back sheet 116, and an absorbent core 118. The liquid-impermeable back sheet 116 may or may not be vapor-permeable. The absorbent core 118 may have any or all of the features described herein with respect to the absorbent core 30, and in some embodiments, it may have a secondary top sheet 119 (STS) instead of the trapping material disclosed above. The STS 119 may include one or more channels (including embossed variations) as described above. In some embodiments, the channels of the STS 119 may be aligned with the channels of the absorbent core 118. The sanitary napkin 110 may also include wings 120 extending outward with respect to the longitudinal axis 180 of the sanitary napkin 110. The sanitary napkin 110 may also include a transverse axis 190. Wings 120 may be bonded to a top sheet 114, a back sheet 116, and / or an absorbent core 118. The sanitary napkin 110 may also include a front edge 122, a rear edge 124 located longitudinally opposite the front edge 122, a first side edge 126, and a second side edge 128 located longitudinally opposite the first side edge 126. The longitudinal axis 180 may extend from the midpoint of the front edge 122 to the midpoint of the rear edge 124. The transverse axis 190 may extend from the midpoint of the first side edge 128 to the midpoint of the second side edge 128. The sanitary napkin 110 may also have additional features commonly found in sanitary napkins, as known in the art.

[0041] Nonwoven webs with visually recognizable patterns and improved texture perception can be used as nonwoven components of sanitary napkins, or as part thereof.

[0042] Nonwoven web with a visually identifiable pattern Here, we consider nonwoven webs having visually recognizable patterns. Nonwoven webs with visually recognizable patterns and improved texture perception will be discussed later. Visually recognizable patterns can be formed by three-dimensional features. Such nonwoven webs can be used as various components of absorbent articles, or as part of components of absorbent articles, such as top sheets, wings, outer cover nonwoven materials, belts, waistbands, leg cuffs, waist cuffs, landing areas, trapping materials, and / or selvages.

[0043] Any of the nonwoven webs of this disclosure may be air-bonded such that bonding occurs at individual fiber intersections as hot air passes through the nonwoven web. Air bonding may help maintain the flexibility of the nonwoven web compared to more conventional calender bonding. Other bonding methods include calender point bonding, ultrasonic bonding, latex bonding, water flow entanglement, resin bonding, and / or combinations thereof.

[0044] Any of the nonwoven webs of the Disclosure may constitute part or all of the components of an absorbent article. The absorbent article may include, as described above, a liquid-permeable top sheet, a liquid-impermeable back sheet, and an absorbent core at least partially positioned between the top sheet and the back sheet. The absorbent article may include an outer cover nonwoven material that forms at least part of the garment-facing surface of the absorbent article. The outer cover nonwoven material and / or top sheet may include the nonwoven webs of the Disclosure. Other components of the absorbent article, or parts thereof, such as leg cuffs, waist cuffs, belts, landing areas, waistbands, and / or ear sections, may also include the nonwoven webs of the Disclosure.

[0045] A nonwoven web for absorbent articles is provided. The nonwoven web may include a first surface, a second surface, and a visually identifiable pattern of three-dimensional features on the first or second surface. The three-dimensional features may include one or more first regions and a plurality of second regions. One or more first regions differ from the plurality of second regions in terms of average intensity value, where average intensity is basis weight, volume density, and / or caliper.

[0046] Nonwoven webs containing visually identifiable patterns of three-dimensional features may have basis weights in the ranges of approximately 10 gsm to approximately 100 gsm, approximately 10 gsm to approximately 60 gsm, approximately 15 gsm to approximately 50 gsm, approximately 15 gsm to approximately 45 gsm, approximately 20 gsm to approximately 40 gsm, approximately 20 gsm to approximately 35 gsm, and approximately 20 gsm to approximately 30 gsm, specifically including all 0.1 gsm increments within the specified range and within the entire range formed by or within that range.

[0047] Visually recognizable patterns of three-dimensional features can be formed on nonwoven webs by embossing, water entanglement, or by using structured forming belts for placing fibers. Patterns can be formed by embossing or water entanglement in a first or second region. Structured forming belts are discussed herein.

[0048] material The nonwoven webs of the present disclosure may be formed by mechanical web formation, such as a dry laid process using short staple fibers and a carding process. The resulting webs may be bonded using thermal embossing or hydraulic molding / water entanglement processes to create irregular patterns. The nonwoven webs may also contain cotton or other natural fibers. The nonwoven webs may contain one or more layers of meltblown fibers and / or one or more layers of spunbond fibers. Some nonwoven webs may contain a single layer of meltblown fibers and two or more layers of spunbond fibers. Some exemplary nonwoven webs are SMS, SMMS, SSMMS, SMMSS, SMSS, or SSMS webs. The nonwoven webs of the present disclosure may also be co-formed webs. Co-formed webs typically contain a matrix of meltblown fibers mixed with at least one additional fibrous organic material, such as, for example, fluff pulp, cotton, and / or rayon. Co-formed webs can be further structured by embossing or laying composite materials on a structured belt during the co-formation process. In one example, when a nonwoven web is made on a structured forming belt, continuous spunbond fibers are used to produce the nonwoven web (as described below). The nonwoven web may comprise continuous one-component polymer filaments comprising a primary polymer component. The nonwoven web may comprise continuous multi-component polymer filaments comprising a primary polymer component and a secondary polymer component. The filament may be a continuous two-component filament comprising primary polymer component A and secondary polymer component B. The two-component filament has a cross section, length, and outer surface. Components A and B can be arranged in substantially separate areas across the cross section of the two-component filament and can extend continuously along the length of the two-component filament. Secondary component B constitutes at least a portion of the outer surface of the two-component filament continuously along the length of the two-component filament. Polymer components A and B can be melt-spun into multi-component fibers using a conventional melt-spinning apparatus. The apparatus can be selected based on the desired configuration of the multi-components. Commercial melt spinning machines are available from Hills, Inc. (located in Melbourne, Florida).The spinning temperature is in the range of approximately 180°C to 230°C. Two-component spunbond filaments can have an average diameter of, for example, approximately 6 micrometers to 40 micrometers, or approximately 12 micrometers to 40 micrometers.

[0049] Components A and B can be arranged in a side-by-side configuration as shown in Figure 13A, or in an eccentric sheath / core configuration as shown in Figure 13B, to obtain filaments exhibiting natural helical crimp. Alternatively, components A and B can be arranged in a concentric sheath / core configuration as shown in Figure 13C. Furthermore, components A and B can be arranged in a multi-lobed sheath / core configuration as shown in Figure 14. Other multi-component fibers can be produced using the compositions and methods of the present disclosure. Two-component and multi-component fibers may have a divided pie configuration, a ribbon configuration, a sea-island configuration, or any combination thereof. The sheath may be continuous or discontinuous around the core. The fibers of the present disclosure may have different geometric shapes, including circular, elliptical, star-shaped, rectangular, and various other geometric shapes. Methods for extruding multi-component polymer filaments into such configurations are generally known to those skilled in the art.

[0050] A wide variety of polymers, including polyolefins (such as polyethylene, polypropylene, and polybutylene), polyesters, polyamides, polyurethanes, and elastomer materials, are suitable for carrying out this disclosure. Non-limiting examples of polymer materials that can be spun into filaments include natural polymers (such as starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, chitin, chitosan, polyisoprene (cis and trans), peptides, and polyhydroxyalkanoates), as well as synthetic polymers (such as thermoplastic polymers (polyester, nylon, polyolefins (such as polypropylene, polyethylene, polyvinyl alcohol, and polyvinyl alcohol derivatives), sodium polyacrylate (absorbent gel material), and polymers consisting of polyolefin copolymers such as polyethylene-octene or monomer blends of propylene and ethylene), as well as biodegradable or compostable materials such as polylactic acid filaments, polyvinyl alcohol, filaments, and polycaprolactone filaments). Examples of thermoplastic polymers include, but are not limited to, polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, styrene-butadiene-styrene block copolymer, styrene-isoprene-styrene block copolymer, polyurethane, and mixtures thereof. In another example, the thermoplastic polymer is selected from the group consisting of polypropylene, polyethylene, polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, polycaprolactone, and mixtures thereof. Alternatively, the polymer may include, for example, polymers derived from bio-based monomers such as biopolyethylene, biopolypropylene, bioPET, or PLA.

[0051] The primary component A and secondary component B can be selected to result in the resulting two-component filament having improved adhesion and flexibility in the nonwoven fabric. The primary polymer component A may have a lower melting point than the secondary polymer component B.

[0052] Primary polymer component A may include polyethylene, polypropylene, or a random copolymer of propylene and ethylene. Secondary polymer component B may include polypropylene, or a random copolymer of propylene and ethylene. Polyethylene may include linear low-density polyethylene and high-density polyethylene. Furthermore, secondary polymer component B may include polymers that are additives to improve the natural helical crimp of the filament, lower the filament bonding temperature, and enhance the abrasion resistance, strength, and flexibility of the resulting fabric.

[0053] For example, inorganic fillers such as magnesium, aluminum, silicon, and titanium oxides may be added as inexpensive fillers or processing aids. Pigments and / or color-melting additives may also be added.

[0054] The fibers of the nonwoven webs disclosed herein may further contain a sufficient amount of lubricant to impart a desirable tactile feel to the fibers. As used herein, “lubricant” or “slip agent” means an external lubricant. When melted and mixed with the resin, the slip agent gradually seeps or migrates to the surface during cooling or after manufacturing, forming a uniform, invisible, thin coating that provides a permanent lubrication. The slip agent may be a rapid bloom slip agent.

[0055] During manufacturing, post-processing, or both, the nonwoven webs of the present disclosure can be made hydrophilic or hydrophobic by treating them with a surfactant or other agent. For example, a nonwoven web used as a top sheet can be made permeable to bodily excretions such as urine and menstrual blood by treating it with a hydrophilic material or surfactant. In other absorbent articles, the nonwoven web may be kept in its naturally hydrophobic state, or may be made more hydrophobic by adding a hydrophobic substance or surfactant.

[0056] Suitable materials for preparing multi-component filaments of the nonwoven webs of this disclosure may include PP3155 polypropylene and PP3854 polypropylene, both available from Exxon Mobil Corporation.

[0057] Process for manufacturing structured formed belts and nonwoven webs As described above, the nonwoven webs of the present disclosure may be produced by embossing, water entanglement, or by using a structured forming belt for placing fibers or filaments. The structured forming belt and the production process are described in more detail below. The nonwoven web may be formed directly on the structured forming belt in a single forming process using continuous spunbond filaments. The nonwoven web may exhibit a shape and texture corresponding to the shape and texture of the structured forming belt.

[0058] This disclosure may utilize a melt spinning process. Melt spinning may occur, for example, at a temperature of about 150°C to about 280°C, or about 190°C to about 230°C. The spinning speed of the fibers may be faster than 100 m / min, for example, about 1,000 to about 10,000 m / min, about 2,000 to about 7,000 m / min, or about 2,500 to about 5,000 m / min. The spinning speed may affect the brittleness of the spun fibers, but generally, the higher the spinning speed, the lower the brittleness of the fibers. Continuous fibers can be produced by the spunbond method or meltblown treatment.

[0059] Referring to Figure 15, a typical process line 330 for producing several exemplary nonwoven webs fabricated on a structured forming belt of the present disclosure is shown. While process line 330 is configured to produce nonwoven webs of two-component continuous filaments, it should be understood that the present disclosure also includes nonwoven webs fabricated from one-component or multi-component filaments having more than two components. The two-component filaments may or may not be trifoliate.

[0060] The process line 330 may include a pair of extruders 332 and 334, each driven by an extruder drive unit 331 and 333, respectively, to extrude primary polymer component A and secondary polymer component B separately. Polymer component A can be supplied from a first hopper 336 to the corresponding extruder 332, and polymer component B can be supplied from a second hopper 338 to the corresponding extruder 334. Polymer components A and B can be supplied from extruders 332 and 334, each through polymer conduits 340 and 342, to filters 344 and 345, and to melt pumps 346 and 347 that pressurize the polymer into a spinning pack 348. Spinning dies for extruding two-component filaments are generally known to those skilled in the art.

[0061] Generally speaking, the spinning pack 348 includes a housing which comprises a plurality of stacked plates having openings in a predetermined pattern arranged to form channels for separately directing polymer components A and B through the spinning die. The spinning pack 348 has openings arranged in one or more rows. The openings of the spinning die form a curtain of filaments extending downward as the polymer is extruded from the spinning die. For the purposes of this disclosure, the spinning die may be configured to form side-by-side eccentric sheath / core type or sheath / core type two-component filaments as shown in Figures 13A-13C, as well as non-circular fibers such as trefoil fibers as shown in Figure 14. Furthermore, the fibers may be of a one-component type having one polymer component, such as polypropylene.

[0062] The process line 330 may include a quenching blower 350 positioned adjacent to the filament curtain extending from the spinneret. Air from the quenching air blower 350 can quench the filaments extending from the spinneret. The quenching air can be supplied from one side of the filament curtain or from both sides of the filament curtain.

[0063] The attenuator 352 may be positioned below the spinneret and capable of receiving the quenched filament. Fiber draw units or suction devices used as attenuators in the melt spinning of polymers are generally known in the art. Fiber draw units suitable for use in the process of forming nonwoven webs of the present disclosure may include linear fiber attenuators of the type shown in U.S. Patent No. 3,802,817, and eductive guns of the types shown in U.S. Patents No. 3,692,618 and U.S. Patent No. 3,423,266.

[0064] Generally speaking, the attenuator 352 may include an elongated vertical passage through which the filament is drawn by sucking in air flowing in from the sides of the passage and flowing downwards. A structured, endless forming belt 360, at least partially perforated, may be positioned below the attenuator 352 and can receive continuous filament from the outlet opening of the attenuator 352. The forming belt 360 can move around guide rollers 362. A vacuum device 364 positioned below the portion of the structured forming belt 360 where the filament is deposited sucks the filament against the forming surface. In Figure 15, the forming belt 360 is shown as a belt, but it should be understood that the forming belt may be in other forms, such as a drum. Details of a specific formed forming belt are described below.

[0065] In the operation of process line 330, hoppers 336 and 338 are filled with polymer components A and B, respectively. Polymer components A and B are melted and extruded by extruders 332 and 334 through polymer conduits 340 and 342 and spinning pack 348, respectively. The temperature of the molten polymer varies depending on the temperature of the polymer used, but when polyethylene is used as primary component A and secondary component B, the polymer temperature can be, for example, in the range of about 190°C to about 240°C.

[0066] As the extruded filament extends below the spinneret, an airflow from the quenching blower 350 quenches the filament at least partially, inducing crystallization of the molten filament in certain filaments. The quenching air can flow substantially perpendicular to the length of the filament at a temperature of about 0°C to about 35°C and a speed of about 100 to about 400 feet / min. The filament may be quenched well before being collected onto the forming belt 360, so that the filament and the forced air passing through the forming belt 360 can be aligned. Quenching the filament reduces its stickiness so that the filaments do not stick together too tightly before bonding, allowing the filaments to move or be aligned on the forming belt 360 during collection of the filament onto the forming belt 360 and during the formation of the nonwoven web.

[0067] After rapid cooling, the filament is drawn into the vertical passage of the attenuator 352 by the flow of the fiber draw unit. The attenuator may be located 30 to 60 inches below the bottom of the spinneret.

[0068] The filaments can be deposited onto the formed, moving forming belt 360 through the outlet opening of the attenuator 352. As the filaments are in contact with the forming surface of the forming belt 360, the vacuum device 364 draws air and filaments into the forming belt 360, forming a continuous filament nonwoven web that conforms to the shape of the structured forming surface of the structured forming belt 360. As described above, the filaments are rapidly cooled, so the filament adhesion is not excessive, and the vacuum can move or align the filaments on the forming belt 360 as they are collected on the forming belt 330 and formed into a nonwoven web.

[0069] The process line 330 may include one or more bonding devices, such as cylindrical compression rolls 370 and 372 that form a nip, through which a nonwoven web can be compressed (e.g., calendered), and these compression rolls can also be heated to bond the fibers. Heating one or both of the compression rolls 370, 372 can bring improved properties and advantages to the nonwoven web by bonding a portion of the nonwoven web. For example, it is believed that heating sufficient to bring about thermal bonding improves the tensile properties of the nonwoven web. The compression rolls may be a pair of smooth-surfaced stainless steel rolls having independent heating control units. The compression rolls can be heated by an electrical element or by the circulation of hot oil. The gap between the compression rolls can be hydraulically controlled to apply a desired pressure to the nonwoven web as it passes through the compression rolls on the forming belt. As an example, if the caliper of the forming belt is 1.4 mm and the spunbond nonwoven web has a basis weight of 25 gsm, the nip gap between the compaction rolls 370 and 372 can be approximately 1.4 mm.

[0070] The upper compaction roll 370 can be heated sufficiently to solidify or melt the fibers on the first surface of the nonwoven web 310, thereby strengthening the nonwoven web and allowing it to be removed from the forming belt 360 without loss of integrity. For example, as shown in Figures 16 and 17, as the rolls 370 and 372 rotate in the direction indicated by the arrows, the belt 360 on which the spunbond web is placed enters the nip formed by the rolls 370 and 372. The heated roll 370 can form adhesive fibers 380 on at least the first surface of the nonwoven web 310 by heating the portion of the nonwoven 310 (i.e., region 321) that is pressed against the roll 370 by the raised resin elements of the belt 360. As can be understood from the description herein, the adhesive region thus formed may have a pattern of raised elements of the forming belt 360. By adjusting the temperature and residence time, bonding can be mainly limited to the fibers closest to the first surface of the nonwoven web 310, or thermal bonding can be performed on the second surface. The bonding may be a discontinuous mesh structure, for example, as point bonding portions 390, as discussed below.

[0071] The raised elements of the forming belt 360 can be selected to establish various mesh structure properties in the adhesive region between the forming belt and the nonwoven web 310. This mesh structure corresponds to the resin constituting the raised elements of the forming belt 360 and can include substantially continuous, substantially semi-continuous, discontinuous, or a combination of these options. Since the forming belt 360 is associated with the appearance of the mesh structure, these mesh structures may describe the raised elements of the forming belt 360, or they may be the structure of the forming belt 360 in the XY plane, or they may be three-dimensional features of the nonwoven web 310.

[0072] After compression, the nonwoven web 310 leaves the forming belt 360 and can be calendered through nips formed by calender rolls 371 and 373. The nonwoven web 310 may then be wound onto a reel 375 or transported directly to the manufacturing of products such as absorbent articles. As shown in the schematic cross-sectional view of Figure 18, these calender rolls 371 and 373 can be stainless steel rolls having an engraved pattern roll 384 and a smooth roll 386. The engraved roll may have raised sections 388 that can provide further compression and adhesion to the nonwoven web 310. The raised sections 388 can be a regular pattern of relatively small, spaced "pins" that form a pattern of relatively small point adhesion sections 390 on the nips of the calender rolls 371 and 373. The percentage of point adhesion sections (%) on the nonwoven web 10 can be, for example, about 3% to about 30%, or about 7% to about 20%. The engraved pattern can be in the form of pins, which are regularly spaced close together, generally cylindrical in shape, and have generally flat tops, with the height of the pins ranging from, for example, about 0.5 mm to about 5 mm or about 1 mm to about 3 mm. The pin bonding calender roll can form regularly spaced dot bonding areas 390 on the nonwoven web 10, as shown in the embodiment of Figure 19. Further bonding can be achieved, for example, by hot air penetration bonding. Figure 19 shows a heart-shaped pattern produced by the same structured forming belt technique that can be used to produce a nonwoven web of the present disclosure.

[0073] As used herein, “point bonding” refers to a method of heat bonding nonwoven webs. This method involves passing the web through a nip between two rolls, which consist of a heated male patterned or engraved metal roll and a smooth or patterned metal roll. The male patterned roll may have a number of raised, generally cylindrical pins that produce circular point bonding areas. The smooth roll may or may not be heated, depending on the application. In a nonwoven fabric production line, a nonwoven web, which may be an unbonded nonwoven web, is fed into a calender nip, and the fiber temperature is raised to the point where the fibers fuse together at the tips of the engraved points in contact with the smooth roll. The heating time is typically several milliseconds. The properties of the nonwoven web depend on process settings such as roll temperature, web line speed, and nip pressure, all of which can be determined by those skilled in the art to obtain the desired degree of point bonding. Other types of point bonding, commonly known as high-temperature calender bonding, can use different geometric shapes (other than circular) for bonding, such as ellipses, lines, and circles. In the example, spot bonding produces a pattern of dots that are circles with a diameter of 0.5 mm, with a total bonding area of ​​10%. Other bonding shapes may have raised pins, for example, with the longest dimension across the bonding surface of the pins being approximately 0.1 mm to 2.0 mm, and the total bonding area ranging from approximately 5% to approximately 30%.

[0074] As shown in Figure 19, a heated compaction roll 370 can form an adhesive pattern 380 (which may be an interconnected heart-shaped adhesive section) on the first surface of the nonwoven web 310 (not shown in Figure 19 because it faces away from the viewer), and a carving calender roll 373 can form relatively small dot adhesive sections 390 on the second surface 314 of the nonwoven web. The dot adhesive sections 390 can fix frayed fibers that are prone to fraying or pilling when the nonwoven web 310 is used. The advantages of the resulting structure of the nonwoven web 310 are most evident, for example, when used as a top sheet or outer cover nonwoven material for absorbent articles such as diapers. When used in absorbent articles, the first surface of the nonwoven web 310 can be relatively flat (compared to the second surface 14) and may have a relatively large amount of adhesion to form adhesive portions 380 in the area of ​​the nonwoven web where a heated compression roll is pressed by the raised elements of the forming belt 360. This adhesion provides structural integrity to the nonwoven web 310, but may still be relatively hard or rough against the user's skin. Therefore, the first surface of the nonwoven web 310 may be oriented in a way that faces the inside of the article, i.e., away from the wearer's body or facing the clothing, in the case of diapers or sanitary napkins. Similarly, the second surface 314 is the side that faces the wearer during use and can be in contact with the body. Relatively small point adhesive portions 390 may be less perceptible to the user visually or tactilely, and the relatively flexible three-dimensional features can be kept soft to the body during use while remaining free from visually noticeable fuzz and pilling. Additional adhesions may be used instead of, or in addition to, the adhesions described above. Aerodynamic couplings can also be used.

[0075] The forming belt 360 can be manufactured according to the methods and processes described in U.S. Patent No. 6,610,173 granted to Lindsay et al. on 26 August 2003, or U.S. Patent No. 5,514,523 granted to Trokhan et al. on 7 May 1996, or U.S. Patent No. 6,398,910 granted to Burazin et al. on 4 June 2002, or U.S. Patent No. 8,940,376 granted to Stage et al. on 27 January 2015, each having improved features and patterns disclosed herein for manufacturing spunbond nonwoven webs. These disclosures by Lindsay, Trokhan, Burazin, and Stage describe structured forming belts, exemplified by papermaking belts made of cured resin on a woven reinforcing member, which, with modifications, can be used to form the nonwoven webs of the present disclosure as described herein.

[0076] An embodiment of a structured forming belt 360 that can be manufactured in accordance with the disclosure of U.S. Patent No. 5,514,523 is shown in Figure 20. As taught in the said patent, a reinforcing member 394 (such as a woven belt of filaments 396) is completely coated with a liquid photosensitive polymer resin to a predetermined thickness. A film or negative mask incorporating repeating elements of a desired raised element pattern (e.g., Figure 22) is placed juxtaposed on the liquid photosensitive resin. The resin is then exposed to light of an appropriate wavelength through the film (e.g., ultraviolet light for UV-curable resins). This exposure to light cures the resin in the exposed areas (i.e., the white or unprinted areas of the mask). When the uncured resin (the resin under the opaque areas of the mask) is removed from the system, the cured resin remains, forming the pattern shown in the figure (e.g., the cured resin element 392 shown in Figure 20).

[0077] The formed belt 360 may include a cured resin element 392 on a woven reinforcing member 394. The reinforcing member 394 can be made from a filament fabric 396 commonly known in the art of papermaking belts, such as a resin-coated papermaking belt. The cured resin element may have the general structure shown in Figure 20 and is made using a mask 397 having the dimensions shown in Figure 22. As shown in the schematic cross-sectional view of Figure 21, the cured resin element 392 flows around the reinforcing member 394, cures and "fixes" there, and may have a distal end width (DW) of about 0.020 inches to about 0.060 inches, or about 0.025 inches to about 0.030 inches, and an overall height above the reinforcing member 394 called over burden (OB), of about 0.030 inches to about 0.120 inches, or about 0.50 inches to about 0.80 inches, or about 0.040 inches. Figure 22 shows a portion of mask 397, illustrating the design and typical dimensions of one repeating unit of a repeating heart-shaped design, as shown herein merely as one embodiment. The white portion 398 is transmissive to ultraviolet light, which in the belt manufacturing process described in U.S. Patent No. 5,514,523 allows the ultraviolet light to cure the underlying resin layer, which is cured to form raised elements 392 on the reinforcing member 394. After the uncured resin is washed away, a formed belt 360 having the cured resin design shown in Figure 20 is produced by joining the ends of the formed belt, which may be determined by the design of the apparatus, as shown in Figure 15.

[0078] The nonwoven webs disclosed herein may be fluid permeable. The entire nonwoven web may be considered fluid permeable, or some areas may be fluid permeable. As used herein in relation to a nonwoven web, fluid permeability means that the nonwoven web has at least one area that allows liquid to pass through under the conditions of use of a consumer product or absorbent article. For example, when used as a top sheet for a disposable absorbent article, the nonwoven web may have at least one area that has a certain level of fluid permeability that allows urine to pass through to the absorbent core below. As used herein in relation to a particular area, fluid permeability means that the area exhibits a porous structure that allows liquid to pass through.

[0079] Due to the nature of the structured forming belt and other device elements, as described herein, the three-dimensional features of the nonwoven web may have an average intensity that differs between a first and a second region, or between features, to give the nonwoven web useful properties when used in personal care articles, clothing, medical products, and cleaning products. For example, the first region may have a different basis weight or density than the second region, and both may have a different basis weight or density than the third region, thereby giving useful aesthetic and functional properties with respect to fluid capture, distribution, and / or absorbency in diapers or sanitary napkins.

[0080] The difference in average strength between different regions of a nonwoven web is thought to be due to the distribution and compression of fibers resulting from the apparatus and methods described herein. Fiber distribution occurs during the fiber laying process, unlike post-manufacturing processes such as embossing. Since fibers can move freely during processes such as melt spinning, and their movement is determined by the properties and air permeability of the forming belt's features, as well as other processing parameters, the fibers are considered to become more stable and permanently formed within the nonwoven web.

[0081] In a structured formed belt having multiple zones, the air permeability of each zone may be variable such that the intensity of the average basis weight and average volume density of the zone can change. The variable air permeability of the various zones causes fiber migration during placement. The air permeability may be about 400 to about 1000 cfm, or about 400 to about 800 cfm, or about 500 cfm and about 750 cfm, or about 650 to about 700 cfm, specifically including all 0.1 cfm increments within a specified range and within the entire range formed by or within that range.

[0082] The structured forming belt may include an endless perforated member having a first surface and a second surface, a curable resin extending from the first surface of the perforated member, and a visually identifiable pattern of three-dimensional features on the endless perforated member. The three-dimensional features may include one or more first regions and a plurality of second regions. One or more first regions may contain resin, while the plurality of second regions may not contain resin.

[0083] Bio-based components for absorbent article components The components of the disposable absorbent articles described herein (i.e., diapers, disposable pants, adult incontinence products, sanitary napkins, panty liners, etc.) are as described herein, as described in U.S. Patent Application Publication No. 2007 / 0219521(A1) published September 20, 2007, U.S. Patent Application Publication No. 2011 / 0139658(A1) published June 16, 2011, and U.S. Patent Application Publication No. 2011 / 0139658(A1) published June 16, 2011. The materials may be at least partially composed of the biosource components described in U.S. Patent Application Publication No. 2011 / 0139657(A1), U.S. Patent Application Publication No. 2011 / 0152812(A1) by Hird et al., published June 23, 2011, U.S. Patent Application Publication No. 2011 / 0139662(A1) by Hird et al., published June 16, 2011, and U.S. Patent Application Publication No. 2011 / 0139659(A1) published June 16, 2011. These components include, but are not limited to, top sheet nonwovens, back sheet film, back sheet nonwovens, side panel nonwovens, barrier leg cuff nonwovens, superabsorbent layers, nonwoven trapping layers, core wrap nonwovens, adhesives, fastener hooks, and fastener landing area nonwovens, as well as film bases.

[0084] In some embodiments, the components of the disposable absorbent article contain a biobase content value of about 10% to about 100%, in another embodiment about 25% to about 75%, and in yet another embodiment about 50% to about 60%, using Method B of ASTM D6866-10.

[0085] To determine the biobase content of any disposable absorbent article components by applying the methodology of ASTM D6866-10, it is necessary to obtain representative samples of the disposable absorbent article components for testing. In one form, the components of the disposable absorbent article can be ground into fine particles of less than approximately 20 mesh using a known grinding method (e.g., a Wiley® mill), and a representative sample of a suitable mass can be taken from the randomly mixed particles.

[0086] The nonwoven web may include multicomponent fibers or bicomponent fibers, and at least one or two or more of the components are bio-based. Examples include side-by-side, sheath / core, or sea-island configurations, and one or more or all of the components are bio-based.

[0087] Emtec In addition to providing improved texture perception, the nonwoven webs of the present disclosure provide improved softness and texture. The present disclosure further resolves the conflict between high softness and high visible texture. According to the Emtec test herein, flexibility, texture (i.e., smoothness), and / or stiffness can be measured by an Emtec Tissue Softness Analyzer. Tactile softness is measured as TS7. Texture / smoothness is measured as TS750. Stiffness is measured as D.

[0088] A portion or all of the nonwoven web of the present disclosure may have a TS7 value in the range of about 1 dB V 2 rms to about 4.5 dB V 2 rms, about 2 dB V 2 rms to about 4.5 dB V 2 rms, or about 2 dB V 2 rms to about 4.0 dB V 2 rms. A portion or all of the nonwoven web of the present disclosure may also have a TS7 value in the range of about 4 dB V 2 rms to about 30 dB V 2 rms, about 6 dB V 2 rms to about 30 dB V 2 rms, about 6 dB V 2 rms to about 20 dB V 2 rms, about 6 dB V 2 rms to about 15 dB V 2 rms, about 6 dB V 2 rms to about 12 dB V 2 rms, or about 6.5 dB V 2 rms to about 10 dB V 2The TS750 value may be in the range of rms. Part or all of the surface of the top sheet of this disclosure facing the wearer may also have a D value in the range of about 1 mm / N to about 10 mm / N, about 3 mm / N to about 8 mm / N, about 2 mm / N to about 6 mm / N, about 2 mm / N to about 4 mm / N, or about 3 mm / N to about 4 mm / N. All values ​​are measured according to the Emtec test of this specification. The TS7 value is tactile flexibility, and therefore a small number is desirable (the lower the number, the more flexible the material). The TS750 value is texture, and therefore a large number is desirable (the higher the number, the more textured the material). Having a low TS7 value and a high texture value is typically contradictory in that the nonwoven has more texture and is less flexible. The applicant does not wish to be bound by theory, but has still found unexpected results with highly textured nonwovens that are very soft.

[0089] Nonwoven web with improved texture and absorbency perception, and improved flexibility. As discussed herein, the nonwoven webs for absorbent articles of this disclosure provide improved texture and absorbency perception, as well as improved flexibility. The nonwoven webs for absorbent articles may include a first surface, a second surface, and a visually identifiable pattern of three-dimensional features on the first surface and / or the second surface. The nonwoven webs may include continuous fibers. The three-dimensional features may include one or more, or more, first regions and a plurality of second regions. One or more first regions may have a first value of average intensity. The plurality of second regions may have a second value of average intensity. The first and second values ​​may be different and both may be greater than zero. Average intensity may be basis weight, caliper, and / or volume density. Nonwoven webs may have single-layer chroma values ​​in the range of approximately 1.0 to approximately 3.5, or approximately 1.5 to approximately 3.5, according to delta chroma and single-layer chroma tests. Nonwoven webs may have delta chroma values ​​in the range of approximately +0.1 to approximately +3.5, approximately +0.5 to approximately +3.5, approximately +1.0 to approximately +3.5, or approximately +1.5 to approximately +3.5, according to delta chroma and single-layer chroma tests.

[0090] Nonwoven webs may include bonding at fiber intersections formed by passing hot air through the nonwoven web and using a process called aerated bonding. In other examples, nonwoven webs may be water-flow entangled. In other examples, nonwoven webs may include calender bonding configured to join fibers together. In yet another example, nonwoven webs may be formed on a structured forming belt as described herein with respect to Figures 15 to 22.

[0091] The nonwoven webs of the present disclosure may include a second visually identifiable pattern of three-dimensional features on a first or second surface. The second visually identifiable pattern of three-dimensional features may differ from the visually identifiable pattern. The three-dimensional features may include one or more third regions and more fourth regions. One or more third regions may differ from the more than fourth regions in average intensity values ​​such as basis weight, caliper, and / or volume density.

[0092] The nonwoven webs of this disclosure may include multi-component fibers, such as two-component fibers (see, for example, Figures 13A to 13C). At least one component of the multi-component fiber may be bio-based, such as PLA, bio-PE, or bio-PP.

[0093] The nonwoven webs of this disclosure may have basis weights in the range of approximately 10 gsm to approximately 100 gsm, approximately 15 gsm to approximately 50 gsm, or approximately 15 gsm to approximately 40 gsm, according to basis weight testing. The nonwoven webs may be spunbond nonwoven webs.

[0094] The nonwoven web of this disclosure, according to Emtec testing, is approximately 1 dB V 2 rms~about 4.5dB V 2 According to the TS7 value in the rms range and Emtec testing, approximately 6 dB V 2 rms ~ approximately 30dB V 2The nonwoven webs of this disclosure may have a TS750 value in the rms range. According to Emtec testing, the D values ​​may be in the range of approximately 2 mm / N to approximately 6 mm / N. The ranges of TS7, TS750, and D characterize the improved flexibility of the nonwoven webs of this disclosure.

[0095] The nonwoven webs discussed herein may form one or at least part of, or all of, of the absorbent articles, such as the nonwoven components described above.

[0096] A nonwoven web for absorbent articles may include a first surface, a second surface, a plurality of continuous spunbond fibers, and a visually identifiable pattern of three-dimensional features on the first or second surface. The three-dimensional features may include one or more first regions and a plurality of second regions. One or more first regions may have a first average strength value. The plurality of second regions may have a second average strength value. The first and second values ​​may be different. The first and second values ​​are greater than zero. Average strength may be basis weight, volume density, and / or caliper. The nonwoven web may have a single-layer chroma value in the range of about 1.0 to about 3.5, or about 1.5 to about 3.5, according to delta chroma and single-layer chroma tests. Nonwoven webs may have delta chroma values ​​in the range of approximately +0.1 to approximately +3.5, approximately +0.5 to approximately +3.5, approximately +1.0 to approximately +3.5, or approximately +1.5 to approximately +3.5, according to delta chroma and single-layer chroma tests.

[0097] A nonwoven web for absorbent articles may include a first surface, a second surface, and a first visually identifiable pattern of three-dimensional features on the first or second surface. The nonwoven web may include continuous fibers. The three-dimensional features may include one or more first regions and more second regions. One or more first regions may differ from the more second regions in a first average intensity value. The first portion of the nonwoven web with the first visually identifiable pattern may have a single-layer chroma value in the range of about 1.0 to about 3.5, or about 1.5 to about 3.5, according to delta chroma and single-layer chroma tests. The first portion of the nonwoven web with the first visually identifiable pattern may have delta chroma values ​​in the range of approximately +0.1 to approximately +3.5, approximately +0.5 to approximately +3.5, or approximately +1.0 to approximately +3.5, according to delta chroma and single-layer chroma tests. The nonwoven web may include a second visually identifiable pattern of three-dimensional features on the first or second surface. The three-dimensional features may include one or more third regions and multiple fourth regions. One or more third regions may differ from multiple fourth regions in the second average intensity value. The first and second average intensities may be basis weight, caliper, and / or volume density.

[0098] A spunbond or other nonwoven web for absorbent articles may include a first surface, a second surface, and a visually identifiable pattern of three-dimensional features on the first or second surface. The three-dimensional features may include one or more first regions and more second regions. One or more first regions may have a first average intensity value. More than one second region may have a second average intensity value. The first and second values ​​may be different. The first and second values ​​are greater than zero. The spunbond or other nonwoven web may have a single-layer chroma value in the range of about 1.0 to about 3.5, or about 1.5 to about 3.5, according to delta chroma and single-layer chroma tests. Spunbond or other nonwoven webs may have delta chroma values ​​in the range of approximately +0.1 to +3.5, approximately +0.5 to +3.5, approximately +1.0 to +3.5, or approximately +1.5 to +3.5, according to delta chroma and single-layer chroma tests. Part or all of a nonwoven web may have a delta chroma of approximately 1 dB V, according to Emtec testing. 2 rms~about 4.5dB V 2 It may have a TS7 value in the rms range. Part or all of the nonwoven web may have approximately 6 dB V according to Emtec testing. 2 rms ~ approximately 30dB V 2 It may have a TS750 value within the rms range.

[0099] The nonwoven webs of this disclosure may have multiple three-dimensional features and / or openings. Exemplary materials having three-dimensional features and / or openings are disclosed in U.S. Patent No. 10,206,826, granted to Olaf Erik ISELE et al. on February 19, 2019. The nonwoven webs may have single-layer chroma values ​​in the range of about 1.0 to about 3.5, or about 1.5 to about 3.5, according to delta chroma and single-layer chroma tests. The nonwoven webs may have delta chroma values ​​in the range of about +0.1 to about +3.5, about +0.5 to about +3.5, about +1.0 to about +3.5, or about +1.5 to about +3.5, according to delta chroma and single-layer chroma tests.

[0100] The nonwoven webs of this disclosure may have low concentrations of colorants, additives, and / or dyes to aid in the perception of texture, absorbency, and softness. The low concentrations of colorants, additives, and / or dyes may be low enough that the nonwoven web still appears "white" to the human eye. For example, if a dark blue-green colorant, additive, and / or dye is used, the resulting nonwoven material will still appear white to the human eye, but the texture of the nonwoven web will be more enhanced to the eye. This results in an improved perception of absorbency and softness.

[0101] As an example, a colorant masterbatch can be used, which is a solid additive containing a pigment in the range of about 15% to about 65% activity, typically having a carrier resin such as polypropylene, polyethylene, and / or polyester. The colorant masterbatch is designed to deliver a specific target color, which is referred to as the “let-down ratio.” For example, in a nonwoven web, a masterbatch with a 2% let-down ratio will produce the target color when 2% of the masterbatch is blended with 98% of the corresponding nonwoven resin, such as polypropylene, polyethylene, and / or polyester. Conventional let-down ratios can range from about 1.5% to about 5%. However, at this level of let-down ratio, the nonwoven web will appear colored to the human eye, for example, a dark blue-green. In this disclosure, this level of addition of the masterbatch is significantly lower to enhance texture perception, absorbency perception, and softness perception, and the color is not visible to the human eye (i.e., the nonwoven web still appears white).

[0102] An example colorant can be purchased from Ampacet Corporation (address: 660 White Plans Rd., Tarrytown, NY 10591). One example colorant is a blue colorant manufactured by Ampacet Corporation under the brand name Ampacet 4600664-N.

[0103] Figure 23 is a graph of saturation (y-axis) and the number of layers of the nonwoven material (x-axis). The first material had no colorants, additives, and / or dyes. The colorants, additives, and / or dyes in the second to fifth materials in the examples of Figure 23 were blue. The second material had 0.25% by weight of colorants, additives, or dyes in the nonwoven composition (the molten composition used to produce the fibers). The third material had 0.37% by weight of colorants, additives, and / or dyes in the nonwoven composition. The fourth material had 0.5% by weight of colorants, additives, and / or dyes in the nonwoven composition. The fifth material had 0.75% by weight of colorants, additives, and / or dyes in the nonwoven composition. Table 1 below shows the data plotted in the graph of Figure 23. In the fourth and fifth materials, the nonwoven web began to appear "blue," while the second and third materials still appeared "white."

[0104] As an example, the weight percent of the nonwoven fabric composition containing the blue colorant, additive, or dye may be, for example, about 0.15% to about 0.4%, about 0.15% to about 0.375%, about 0.15% to about 0.35%, about 0.15% to about 0.325%, about 0.15% to about 0.3%, about 0.15% to about 0.275%, about 0.15% to about 0.25%, about 0.175%, about 0.2%, about 0.225%, or about 0.25%, specifically including all increments of 0.001 within the specified range and within the entire range formed by or within that range. Other ranges may also be suitable for different colors other than blue.

[0105] [Table 1]

[0106] The nonwoven webs of this disclosure may have single-layer saturation values ​​in the range of approximately 0.5 to approximately 4, approximately 0.5 to approximately 3.5, approximately 0.75 to approximately 3.5, approximately 1.0 to approximately 3.5, approximately 1.25 to approximately 3.5, approximately 1.5 to approximately 3.5, approximately 1.75 to approximately 3.5, approximately 1.9 to approximately 3.9, approximately 1.9, approximately 2.2, approximately 3.1, or approximately 3.9, specifically including all increments of 0.1 within the specified range and within the entire range formed by or within that range.

[0107] The nonwoven webs of this disclosure may have delta saturation values ​​in the range of approximately +0.1 to +6, approximately +0.25 to +6, approximately +0.5 to +6, approximately +1 to +6, approximately +1 to +5, approximately +1 to +4.5, approximately +1 to +4.1, approximately +0.1 to +3.5, approximately +0.5 to +3.5, approximately +1 to +3.5, approximately +1.5 to +3.5, approximately +1.0 to +4, approximately +1.0 to +4, approximately +1.0 to +4.1, approximately +1.7 to +4.1, approximately +1.7, approximately +2.2, approximately +3.2, or approximately +4.1, specifically including all increments of 0.1 within the specified range and within the entire range formed by or within that range.

[0108] Figure 24 shows an exemplary visually identifiable pattern of a three-dimensional feature for a nonwoven web of the present disclosure. The three-dimensional feature includes a plurality of first regions 1000 and a plurality of second regions 1002.

[0109] Test method Air Permeability Test Method The size of the airflow passing through the formed belt is measured in cubic feet per minute (cfm) using an air permeability test. The air permeability test is performed using a Texas Instruments Model FX3360 Portair air permeability tester, available from Textest AG (Sonnenbergstrasse 72, CH 8603 Schwerzenbach, Switzerland). This device uses a 20.7 mm orifice plate for air permeability in the range of 300–1000 cfm. If the air permeability is less than 300 cfm, the orifice plate needs to be smaller. If it exceeds 1000 cfm, the orifice plate needs to be larger. By measuring air permeability in multiple localized areas of the formed belt, the difference in air permeability across the entire formed belt can be measured.

[0110] Test Procedure 1. Start the FX3360 device. 2. Select the default method with the following settings. a. Material: Standard b. Measurement characteristics: Air permeability (AP) c. Test pressure: 125 Pa (Pascals) dT coefficient: 1.00 e. Test point pitch: 0.8 inches. A 3.20.7 mm orifice plate is placed at the symmetrical position on the upper surface of the forming belt (the surface with the three-dimensional protrusions). 4. Select "Spot Measurement" on the test device's touchscreen. 5. Reset the sensor before taking measurements if necessary. 6. After resetting, select the "Start" button to begin measurement. 7. Wait until the measurement stabilizes and record the CFM measurement on the screen. 8. Select the "Start" button again to stop the measurement.

[0111] Basis weight test The basis weight of the nonwoven webs described herein can be measured by several available methods, but a simple representative method involves taking an absorbent article or other consumer product, removing any elasticity that may be present, and stretching the absorbent article or other consumer product to its full length. Subsequently, 45.6 cm 2 Using a die with a certain area, cut a piece of nonwoven web (e.g., top sheet, outer cover) from approximately the center of the absorbent article or other consumer product, at a position that avoids, as much as possible, the nonwoven web being detached from other layers and using any binder that may be used to fasten the nonwoven web to all other layers that may exist (using a low-temperature spray such as Cyto-Freeze (Control Company (Houston, Texas)) if necessary). Subsequently, weigh the sample and divide by the area of ​​the die to obtain the basis weight of the nonwoven web. Report the results in units of 0.1 grams / square meter (gsm) as an average of five samples.

[0112] Delta saturation and single-layer saturation tests Delta chroma and single-layer chroma values ​​are indicators of the presence and intensity of color in a layer of material. Generally, chroma is defined in CIE 1976 L* a * b * Color saturation is calculated from reflectance measurements. Saturation is measured using a spectrophotometer with a computer interface (a suitable instrument is the HunterLab LabScan XE running Universal Software, available from Hunter Associates Laboratory Inc. (Reston, VA)). All tests are conducted in a humidified room maintained at approximately 23±2°C and 50±2% relative humidity.

[0113] To obtain a sample, the absorbent article is taped to a rigid, flat surface in a planar configuration with the layer of material to be tested facing upwards. Any elastic material can be cut to facilitate the flattening of the article. Using a razor blade, the sample layer material is cut away from the lower layer of the article. The sample layer material is carefully removed, ensuring that its longitudinal and transverse elongation is maintained and material strain is avoided. If necessary, a low-temperature spray (such as Cyto-Freeze (Control Company (Houston TX))) may be used to remove the test specimen from the lower layer. Three material replica layers obtained from three substantially similar articles are prepared for analysis. The raw material layers are prepared for testing by stretching them under the same processing conditions and to the same degree as when used on the absorbent article. Before testing, the samples are pre-conditioned for about 2 hours at approximately 23°C ± 2°C and approximately 50% ± 2% relative humidity.

[0114] Standardize the instrument using black tiles supplied by the manufacturer, then white tiles, with a 2.00-inch port size (software indicates a 1.75-inch field of view). Calibrate the instrument using the supplied standard tiles according to the manufacturer's specifications. CIE 1976 L * a * b * Configure the software to measure color using a color scale, a D65 light source, and a 10° standard observer.

[0115] Place a single-layer sample on the measurement port. Gently pull the sample taut without stretching it, ensuring it does not lean into the port, then place a standard white tile as the background. Ensure that the area of ​​the sample to be measured faces the port and completely covers it. Individual L * a * , and b * The values ​​are read and recorded, then the white tiles are removed, a second material layer is added on top of the first layer, and then the white tiles are used as the background. The second reading is obtained and recorded, and then, in the same manner, a third layer of material is added on top of the first two layers, and the third reading is obtained and recorded. The saturation values ​​of each of the readings of the three material layers are calculated according to the following formula.

[0116]

number

[0117] The chroma value of a single layer of material is recorded as a single-layer chroma value in units of 0.1. The delta chroma value is then calculated by subtracting the chroma value obtained from a single material layer from the chroma values ​​obtained from three material layers. The delta chroma value is recorded in units of 0.1, indicating whether it is a positive or negative value. This test is repeated with five substantially similar sets of samples, and the individual results are recorded. The average single-layer chroma value and average delta chroma value are calculated and reported in units of 0.1.

[0118] ESETEC Exam The Emtec test is performed on a portion of the nonwoven web under test. In this test, TS7, TS750, and D values ​​are measured using an Emtec Tissue Softness Analyzer ("Emtec TSA") (Emtec Electronic GmbH, Leipzig, Germany) connected to a computer running Emtec TSA software (version 3.19 or equivalent). The Emtec TSA includes a rotor with a vertical blade rotating over the test specimen at a specified calibrated rotational speed (set by the manufacturer) and a contact force of 100 mN. The contact between the vertical blade and the test specimen generates vibrations in both the blade and the specimen, and the resulting sound is recorded by a microphone in the instrument. The recorded sound file is then analyzed by the Emtec TSA software to determine the TS7 and TS750 values. The D value is a measure of the specimen's stiffness and is increased from 100 mN to 600 mN based on the vertical distance required for the blade's contact force on the test specimen. Sample preparation, instrument operation, and test procedures shall be carried out in accordance with the instrument manufacturer's specifications.

[0119] Sample preparation Test specimens are prepared by cutting a square or circular portion of the target area from the nonwoven web of the absorbent article. While it is preferable not to use freeze spray to remove the nonwoven web to be analyzed from the absorbent article, it is acceptable to use freeze spray on the distal area to assist in initiating layer separation. The test specimens are cut to a length and width (diameter in the case of circular specimens) of approximately 90 mm to 120 mm so that they can be properly clamped in the TSA instrument. (If the absorbent article does not contain a sufficiently large area of ​​the target substrate to extract a sample of the size specified above, equivalent material can be sampled from a roll stock.) Test specimens are selected so that there are no perforations, wrinkles, or folds within the test area. Six substantially identical duplicate specimens are prepared for testing.

[0120] Before performing the TSA test, all samples should be equilibrated under TAPPI's standard temperature and relative humidity conditions (23°C ± 2°C and 50% ± 2%) for at least 2 hours, and the TSA test should also be performed under TAPPI conditions.

[0121] Test Procedure The instruments are calibrated using a single-point calibration method according to Emtec's instructions, using appropriate reference standards (so-called "ref.2 samples") or equivalents available from Emtec.

[0122] The test specimen is mounted in the instrument with the target surface facing upwards, and the test is performed according to the manufacturer's instructions. The software displays the values ​​of TS7, TS750, and D when the automated instrument test routine is complete. TS7 and TS750 are each 0.01 dBV. 2 The values ​​are recorded in rms units, and D is recorded in 0.01 mm / N units. The test specimen is then removed from the apparatus and disposed of. This test procedure is performed individually on the corresponding target surface of each of the six duplicate specimens (the surface of the top sheet specimen that faces the clothing, and the surface of the outer cover nonwoven material specimen that faces the clothing).

[0123] The values ​​for TS7, TS750, and D are averaged (arithmetic mean) across six sample replicas. The mean values ​​for TS7 and TS750 are 0.01 dBV. 2 The values ​​are reported in rms units. The average value of D is reported in 0.01 mm / N units.

[0124] Method for measuring intensive properties using micro-CT This micro-CT method for measuring intensified properties measures basis weight, thickness, and volume density within a visually distinguishable area of ​​a substrate sample. The method is based on the analysis of 3D X-ray sample images obtained with a micro-CT instrument (preferably the Scanco μCT 50, available from Scanco Medical AG (Switzerland), or an equivalent). The micro-CT instrument is a conical beam microtomograph with a shielding cabinet. A maintenance-free X-ray tube is used as a source with an adjustable focal diameter. The X-ray beam passes through the sample, and a portion of the X-rays are attenuated by the sample. The degree of attenuation correlates with the mass of the material through which the X-rays must pass. The transmitted X-rays continue to enter a digital detector array, generating a 2D projection image of the sample. A 3D image of the sample is generated by collecting multiple individual projection images of a rotated sample and then reconstructing these projection images as a single 3D image. The instrument controls image acquisition and stores raw data in conjunction with computer-based software. Next, 3D images are analyzed using image analysis software (preferably MATLAB or equivalent, available from The Mathworks, Inc. (Natick, MA)) to measure the intensive properties of basis weight, thickness, and volume density of regions within the sample.

[0125] Sample preparation: To obtain a sample for measurement, a single layer of dried substrate material is spread flat and a circular piece with a diameter of 30 mm is punched out.

[0126] If the base material is a layer of absorbent material, such as a top sheet, back sheet nonwoven fabric, trapping layer, distribution layer, or other constituent layer, the absorbent material is attached to a hard, flat surface with tape to form a planar shape. Each base material layer is carefully separated from the absorbent material. If necessary, a scalpel and / or a low-temperature spray (Cyto-Freeze, Control Company (Houston TX)) can be used to remove the base material layer from further underlying layers, thereby preventing stretching of the material in the longitudinal and transverse directions. Once the base material layer has been removed from the material, the sample is punched out as described above.

[0127] If the base material is in the form of a wet wipe, open a new package of wet wipes and remove the entire stack from the package. Take one wipe from the middle of the stack, spread it flat, and allow it to dry completely before punching out the sample for analysis.

[0128] A sample can be cut from any location that includes a visually distinguishable area to be analyzed. Within a single area, the region to be analyzed is a region associated with a three-dimensional feature that defines a single microregion. The microregion includes at least two visually distinguishable areas. The area, three-dimensional feature, or microregion may be visually distinguishable due to variations in texture, height, or thickness. Regions in different samples taken from the same substrate material may be analyzed and compared with one another. When selecting a location to take a sample, care should be taken to avoid folds, wrinkles, or tears.

[0129] Image acquisition: The micro-CT apparatus is prepared and calibrated according to the manufacturer's specifications. The sample is placed between two rings of low-density material with an inner diameter of 25 mm in a suitable holder. This ensures that the central portion of the sample is horizontal and can be scanned without any other material directly adjacent to its top and bottom surfaces. Measurements must be taken in this area. The 3D image field of view is in the XY plane with sides of approximately 35 mm, having a resolution of approximately 5000 × 5000 pixels, and a sufficient number of 7-micrometer thick slices are collected to completely encompass the Z direction of the sample. The reconstructed 3D image resolution includes 7-micrometer isotropic voxels. Images are acquired using a 45 kVp and 133 μA power supply without further low-energy filters. These current and voltage settings can be optimized to ensure sufficient X-rays penetrate the sample and maximize the contrast of the projection data, but once optimized, they are kept constant for all substantially similar samples. A total of 1500 projection images are acquired with an integration time of 1000 milliseconds and three averages. These projection images are reconstructed into 3D images and saved in 16-bit RAW format to preserve the complete detector output signal for analysis.

[0130] Image processing: Load the 3D image into the image analysis software. The threshold 3D image separates and removes background signals from air, but retains signals from sample fibers within the substrate.

[0131] Three intensive 2D images are generated from the threshold 3D image. The first is the basis weight image. To generate this image, the value of each voxel in the XY plane slice is summed with all the values ​​of the corresponding voxels in the other Z-direction slices, which contain the signal from the sample. This generates a 2D image, where each pixel has a value equal to the cumulative signal throughout the entire sample.

[0132] A basis weight calibration curve is generated to convert the raw data values ​​in the basis weight image to actual values. A substrate with substantially the same composition as the sample to be analyzed and with a uniform basis weight is obtained. At least 10 duplicate samples of the calibration curve substrate are obtained according to the procedure described above. The basis weight of each single-layer calibration sample is accurately measured by measuring the mass in units of 0.0001 g, dividing by the area of ​​the sample, and converting to g / m² (gsm), and the average is calculated in units of 0.01 gsm. A micro-CT image of the single-layer calibration sample substrate is obtained according to the procedure described above. The micro-CT image is processed according to the procedure described above to generate a basis weight image containing the raw data values. The actual basis weight value of this sample is the average basis weight value measured on the calibration sample. Next, two layers of calibration substrate samples are stacked on top of each other, and a micro-CT image of the two layers of calibration substrate is obtained. A raw data image of the combined basis weight of both layers is generated. The actual basis weight value is equal to twice the average basis weight value measured on the calibration sample. The procedure is repeated to generate raw basis images for all layers, where a single layer of calibration substrate is stacked, a micro-CT image of each layer is obtained, and the actual basis weight is equal to the number of layers multiplied by the average basis weight measured on the calibration sample. A total of at least four different basis calibration images are obtained. To ensure accurate calibration, the basis weight values ​​of the calibration samples must include values ​​above and below the basis weight value of the original sample being analyzed. The calibration curve is generated by performing a linear regression of the raw data against the actual basis weight values ​​for the four calibration samples. This linear regression must have an R² value of at least 0.95; otherwise, the entire calibration procedure is repeated. Next, the raw data values ​​are converted to actual basis weights using this calibration curve.

[0133] The second intensive property of the 2D image is the thickness image. To generate this image, the top and bottom surfaces of the sample are identified, and the distance between these surfaces is calculated to obtain the sample thickness. The top surface of the sample is identified by starting with the uppermost Z-direction slice and evaluating each slice as the process progresses through the sample, thereby identifying the position of the Z-direction voxel for every pixel position in the XY plane where the sample signal was first detected. To identify the bottom surface of the sample, the same procedure is followed, except that all the Z-direction voxels to be identified are the positions in the XY plane where the sample signal was last detected. Once the top and bottom surfaces are identified, they are smoothed using a 15x15 median filter to remove signals from stray fibers. A 2D thickness image is then generated by counting the number of voxels between the top and bottom surfaces for each pixel position in the XY plane. This raw thickness value is then converted to the actual distance in micrometers by multiplying the voxel count by the thickness resolution of a 7 μm slice.

[0134] The third intensive property of 2D images is the volume density image. To generate this image, divide the pixel values ​​of each XY plane in the basis image (in gsm units) by the corresponding pixels in the thickness image (in micrometer units). The unit of the volume density image is g / cubic centimeter (g / cc).

[0135] Intensive properties of basis weight, thickness, and volume density obtained by micro-CT: The analysis begins by identifying the region to be analyzed. The region is an area associated with a three-dimensional feature that defines a single microregion. The microregion contains at least two visually distinguishable areas. Regions, three-dimensional features, or microregions may be visually distinguishable due to variations in texture, height, or thickness. Next, the boundaries of the region to be analyzed are identified. The region boundaries are identified by visually distinguishing differences in intensified properties compared to other regions within the sample. For example, the region boundary can be identified based on visually distinguishing differences in thickness compared to other regions of the sample. Any intensified property can be used to distinguish the boundaries of any region of the physical sample itself in an intensified image obtained by micro-CT. Once the region boundaries are identified, an elliptical or circular "Region of Interest (ROI)" is drawn inside that region. The ROI should be at least 0.1 mm. 2 It is necessary to select an area that has a certain area and possesses an intensive property value representing the specified region. From each of the three intensive property images, calculate the average basis weight, thickness, and volume density within the ROI. Record these values ​​in units of 0.01 gsm for basis weight, 0.1 micrometers for thickness, and 0.0001 g / cc for volume density of that region.

[0136] Examples / Combinations A. A nonwoven web for absorbent articles, wherein the nonwoven web is The first surface and The second surface and Multiple continuous spunbond fibers, A visually recognizable pattern of three-dimensional features on a first surface or a second surface, wherein the three-dimensional features include a visually recognizable pattern comprising one or more first regions and a plurality of second regions, One or more first regions have a first average intensity value, and multiple second regions have a second average intensity value, and the first and second values ​​are different, and the first and second values ​​are greater than zero, and the average intensity is basis weight, volume density, or caliper. The nonwoven web has a single-layer chroma value in the range of approximately 1.0 to approximately 3.5 according to delta chroma and single-layer chroma tests, and Nonwoven web for absorbent articles, having a delta chroma value in the range of approximately +0.1 to approximately +3.5 according to delta chroma and single-layer chroma tests. B. A nonwoven web for absorbent articles as described in paragraph A, wherein the nonwoven web has a single-layer chroma value in the range of about 1.5 to about 3.5 according to delta chroma and single-layer chroma tests, and the nonwoven web has a delta chroma value in the range of about +0.5 to about +3.5 according to delta chroma and single-layer chroma tests. C. Nonwoven web for absorbent articles, wherein the nonwoven web is The first surface and The second surface and A first visually identifiable pattern of a three-dimensional feature on a first surface or a second surface, wherein the three-dimensional feature comprises a first visually identifiable pattern including one or more first regions and a plurality of second regions, One or more first regions differ from multiple second regions in the first average intensity value. The first portion of the nonwoven web of the first visually identifiable pattern has a single-layer chroma value in the range of approximately 1.0 to approximately 3.5 according to delta chroma and single-layer chroma tests. A first portion of a nonwoven web with a first visually identifiable pattern has a delta chroma value in the range of approximately +0.1 to approximately +3.5 according to delta chroma and single-layer chroma tests, and a first visually identifiable pattern of three-dimensional features on a first or second surface. A nonwoven web for absorbent articles, comprising: a second visually identifiable pattern of three-dimensional features on a first or second surface, wherein the three-dimensional features comprise one or more third regions and a plurality of fourth regions, and the one or more third regions differ from the plurality of fourth regions in a second average intensity. D. A nonwoven web for absorbent articles as described in paragraph C, wherein a first portion of the nonwoven web of a first visually identifiable pattern has a single-layer chroma value in the range of about 1.5 to about 3.5 according to a delta chroma and single-layer chroma test, and a first portion of the nonwoven web of a first visually identifiable pattern has a delta chroma value in the range of about +0.5 to about +3.5 according to a delta chroma and single-layer chroma test. E. A nonwoven web for absorbent articles as described in paragraph D, wherein the second portion of the nonwoven web of the second visually identifiable pattern has a single layer chroma in the range of about 1.0 to about 3.5 according to a delta chroma and single layer chroma test, and the second portion of the nonwoven web of the second visually identifiable pattern has a delta chroma in the range of about +0.1 to about +3.5 according to a delta chroma and single layer chroma test. F. A nonwoven web for absorbent articles as described in any one of paragraphs C to E, wherein the first average strength and the second average strength are basis weight, caliper, or volume density. G. A spunbond nonwoven web for absorbent articles, wherein the spunbond nonwoven web is The first surface and The second surface and A visually recognizable pattern of three-dimensional features on a first surface or a second surface, wherein the three-dimensional features include a visually recognizable pattern comprising one or more first regions and a plurality of second regions, One or more first regions have a first average intensity value, and multiple second regions have a second average intensity value, and the first and second values ​​are different, and the first and second values ​​are greater than zero. The spunbond nonwoven web has a single-layer chroma value in the range of approximately 1.0 to approximately 3.5, according to delta chroma and single-layer chroma tests. Spunbond nonwoven web for absorbent articles, having a delta chroma value in the range of approximately +0.1 to approximately +3.5 according to delta chroma and single-layer chroma tests. H. Nonwoven web for absorbent articles, wherein the nonwoven web is The first surface and The second surface and A plurality of three-dimensional features extending from a first surface or a second surface, The nonwoven web has a single-layer chroma value in the range of approximately 1.0 to approximately 3.5 according to delta chroma and single-layer chroma tests, and Nonwoven web for absorbent articles, having a delta chroma value in the range of approximately +0.5 to approximately +3.5 according to delta chroma and single-layer chroma tests. I. A nonwoven web for absorbent articles, wherein the nonwoven web is The first surface and The second surface and A plurality of three-dimensional features extending from a first surface or a second surface, The nonwoven web has a single-layer chroma value in the range of approximately 1.0 to approximately 3.5, according to delta chroma and single-layer chroma tests. The nonwoven web has a delta chroma value in the range of approximately +0.5 to approximately +3.5, according to delta chroma and single-layer chroma tests. A portion of the nonwoven web showed approximately 1 dB V according to Emtec testing. 2 rms~about 4.5dB V 2 The TS7 value is in the rms range, and a portion of the nonwoven web shows approximately 6 dB V according to Emtec testing. 2 rms ~ approximately 30dB V 2 Nonwoven web for absorbent articles having a TS750 value in the rms range.

[0137] The dimensions and values ​​disclosed herein should not be understood as being 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."

[0138] All documents referenced herein, including any patents or patent applications that are cross-referenced or related, and any patent applications or patents on which this application claims priority or benefit thereof, are incorporated herein by reference in their entirety unless otherwise explicitly stated to be excluded or limited. No document reference 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, if 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 the term in this document shall prevail.

[0139] While specific forms of this disclosure have been 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 this disclosure. Therefore, all such changes and modifications that fall within the scope of this disclosure are intended to be covered by the attached claims.

Claims

1. A nonwoven web for absorbent articles, wherein the nonwoven web is The first surface and The second surface and A visually identifiable pattern of three-dimensional features on the first surface or the second surface, wherein the three-dimensional features include one or more first regions and a plurality of second regions, The one or more first regions have a first average intensity value, the plurality of second regions have a second average intensity value, the first value and the second value are different, and the first value and the second value are greater than zero. When the aforementioned nonwoven web is stacked in three layers, it has a single-layer chroma value in the range of 3.6 to 4.4 according to delta chroma and single-layer chroma tests. A nonwoven web for absorbent articles, wherein the nonwoven web has a delta chroma value in the range of +1.7 to +2.2 according to the delta chroma and single-layer chroma test.

2. The nonwoven web for absorbent articles according to claim 1, wherein the first average strength and the second average strength are basis weights.

3. The nonwoven web for absorbent articles according to claim 1 or 2, wherein the first average strength and the second average strength are volume density.

4. A nonwoven web for an absorbent article according to any one of claims 1 to 3, wherein the nonwoven web includes bonding at fiber intersections formed by passing hot air through the nonwoven web.

5. A nonwoven web for an absorbent article according to any one of claims 1 to 4, wherein the nonwoven web includes calendering configured to bond fibers together.

6. The nonwoven web for an absorbent article according to any one of claims 1 to 5, wherein the nonwoven web includes a second visually identifiable pattern of three-dimensional features on the first surface or the second surface, the three-dimensional features include one or more third regions and a plurality of fourth regions, and the one or more third regions differ from the plurality of fourth regions in terms of average intensity value.

7. The nonwoven web for an absorbent article according to any one of claims 1 to 6, wherein the nonwoven web comprises multi-component fibers, and at least one component of the multi-component fibers is bio-based.

8. The nonwoven web for absorbent articles according to any one of claims 1 to 7, wherein the nonwoven web has a basis weight in the range of 10 gsm to 100 gsm according to a basis weight test, and the nonwoven web is a spunbond nonwoven web.

9. A portion of the aforementioned nonwoven web showed 1 dB V according to the Emtec test. ２ rms~4.5dB V ２ The TS7 value is in the range of rms, and the portion of the nonwoven web has a value of 6 dB V according to the Emtec test. ２ rms ~30dB V ２ A nonwoven web for an absorbent article according to any one of claims 1 to 8, having a TS750 value in the range of rms.

10. The nonwoven web for absorbent articles according to claim 9, wherein the portion of the nonwoven web has a D value in the range of 2 mm / N to 6 mm / N according to the Emtec test.

11. An absorbent article comprising a nonwoven fabric web as described in any one of claims 1 to 10.

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