Absorbent article having an absorbent core cavity

Abstract

The absorbent article comprises an inner layer, an outer layer, and an absorbent core disposed between the inner layer and the outer layer. The absorbent core defines a plurality of cavities extending inward from the outer surface of the absorbent core along the transverse direction. The inner layer is bonded to the absorbent core through a plurality of embossing portions. Each of the plurality of cavities is aligned along the transverse direction with its respective embossing portion among the plurality of embossing portions. The cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​its respective embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction.

Description

Background Technology

[0001] Conventional absorbent personal care products for women and adults, also referred to as sanitary pads, often comprise a cover, an absorbent core having a fluff that absorbs and stores menstrual blood, and a waterproof membrane. Certain conventional sanitary pads also include an intermediate layer between the cover and the absorbent core. The intermediate layer may facilitate the transfer of menstrual blood from the cover to the absorbent core. However, transfer through the intermediate layer may be restricted so that the menstrual blood does not flow rapidly into the absorbent core but remains within the intermediate layer, which may cause the wearer to feel damp. Additionally, in conventional sanitary pads, menstrual blood may remain mainly just below the site of contamination on the sanitary pad rather than spreading within the absorbent core.

[0002] Absorbent articles, such as sanitary pads, having features to improve the movement of menstrual blood from the cover to the absorbent core and / or the movement of menstrual blood away from the area immediately below the contamination site would be useful.

[0003] Generally, the present disclosure provides an absorbent article, such as a sanitary pad, having features to facilitate the movement of menstrual blood from a cover to an absorbent core and / or the movement of menstrual blood away from the area immediately below the contamination site. The absorbent article may comprise an absorbent core, and at the bottom of the absorbent core there are cavities or pockets that are essentially devoid of cellulose fibers. An inner layer and / or a transfer layer may be embossed onto the absorbent core through a plurality of embossings. Each of the embossings may be aligned with its respective pocket. Thus, for example, each of the embossings may be located immediately above its respective pocket. The absorbent core may comprise densified regions having cellulose fluff that is densified compared to adjacent portions of the absorbent core. The absorbent article may advantageously have improved rewetting and / or stain size at the contamination site on the top of the absorbent article compared to conventional absorbent articles so that the wearer feels more comfortable.

[0004] In one exemplary embodiment, the absorbent article comprises an inner layer, a transfer layer, an outer layer, and an absorbent core. The absorbent core is disposed between the transfer layer and the outer layer. The transfer layer is disposed between the inner layer and the absorbent core. The absorbent core comprises a cellulose fluff. The absorbent core has an inner surface and an outer surface spaced apart along the transverse direction. The inner surface of the absorbent core faces the inner layer, and the outer surface of the absorbent core faces the outer layer. The absorbent core defines a plurality of cavities extending inward from the outer surface of the absorbent core along the transverse direction. The inner layer and the transfer layer are bonded to the absorbent core through a plurality of embossing portions. Each of the plurality of cavities is aligned with its respective embossing portion among the plurality of embossing portions along the transverse direction. The cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​its respective embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction.

[0005] In another exemplary embodiment, the absorbent article comprises an inner layer, an outer layer, and an absorbent core disposed between the inner layer and the outer layer. The absorbent core comprises a cellulose fluff. The absorbent core has an inner surface and an outer surface spaced apart along the transverse direction. The inner surface of the absorbent core faces the inner layer, and the outer surface of the absorbent core faces the outer layer. The absorbent core defines a plurality of cavities extending inward from the outer surface of the absorbent core along the transverse direction. The inner layer is bonded to the absorbent core through a plurality of embossing portions. Each of the plurality of cavities is aligned with its respective embossing portion among the plurality of embossing portions along the transverse direction. The cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​its respective embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction.

[0006] In another exemplary embodiment, a method for forming an absorbent article comprises the steps of: applying a cellulose fluff over a plurality of pins on a forming drum; forming an absorbent core with the cellulose fluff, wherein the absorbent core defines a plurality of cavities extending inwardly along the transverse direction, each of the plurality of cavities corresponding to a respective pin among the plurality of pins; embossing an inner layer and a transfer layer on the absorbent core through a plurality of embossing portions, wherein each of the plurality of cavities is aligned with a respective embossing portion among the plurality of embossing portions along the transverse direction, and the cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​each embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction; and attaching an outer layer to the absorbent core on the opposite side of the inner layer.

[0007] These and other features, aspects, and advantages of the present disclosure will be better understood by referring to the following description and the appended claims. The accompanying drawings, which are incorporated into and form part of this specification, serve to illustrate embodiments of the present disclosure and, together with the description, explain the principles of the present disclosure. Brief explanation of the drawing

[0008] To those skilled in the art, a complete and actionable disclosure regarding the present disclosure, including the best mode of the present disclosure, is described in this specification with reference to the attached drawings. FIG. 1 is a plan view of an absorbent article according to an exemplary embodiment of the subject matter. FIG. 2 is a cross-sectional view of an exemplary absorbent article of FIG. 1 taken along line 2-2 of FIG. 1. FIG. 3 is a plan view of an array of embossing portions in the central part of an exemplary absorbent article of FIG. 1. FIG. 4 is a schematic diagram of a system for forming an absorbent article according to an exemplary embodiment of the subject matter. FIG. 5 is a partial side view of the molding drum and protrusions of the exemplary system of FIG. 4. FIG. 6 is a partial side view of the embosser and embossing pins of the exemplary system of FIG. 4. The repetitive use of reference numerals in this specification and drawings is intended to indicate the same or similar features or elements of the present invention. Specific details for implementing the invention

[0009] The present disclosure relates to an absorbent article, such as a sanitary pad, having features generally for facilitating the movement of menstrual blood from a cover to an absorbent core and / or the movement of menstrual blood away from the immediate area of ​​contamination. The absorbent article may comprise an inner layer, a transfer layer, an outer layer, and an absorbent core. The inner layer may be the body-facing layer of the absorbent article, and the outer layer may be located opposite the inner layer and directed away from the wearer's body. The transfer layer may be disposed between the inner layer and the absorbent core, and the absorbent core may be disposed between the transfer layer and the outer layer. The inner surface of the absorbent core may face the inner layer, and the outer surface of the absorbent core may face the outer layer. The absorbent core may define a plurality of cavities extending inward from the outer surface of the absorbent core along the transverse direction. The cavities may be essentially devoid of cellulose fibers. The inner layer and the transfer layer may be bonded to the absorbent core through a plurality of embossing portions. Each of the plurality of cavities may be aligned with its respective embossing portion among the plurality of embossing portions along the transverse direction, and the cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction may be larger than the cross-sectional area of ​​its respective embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction. Menstrual blood in the inner layer may flow into the cavities within the absorbent core through the inner layer and the delivery layer (e.g., through the embossing portions). Menstrual blood may collect within the absorbent core and then diffuse outward into the absorbent core.

[0010] It should be understood by those skilled in the art that the present disclosure is merely an explanation of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0011] When introducing elements of the present disclosure or preferred embodiment(s) thereof, the articles “one,” “one,” “that,” and “the” are intended to imply that there is one or more of the elements. As used herein, the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both).” Throughout the specification and claims, as used herein, approximation expressions are applied to modify any quantitative expression that may be acceptablely varied without causing a change in the underlying function involved. Therefore, terms such as “about,” “approximately,” and “substantially,” or values ​​modified by such terms, are not limited to the specified exact values. In at least some cases, approximate expressions may correspond to the precision of the instrument used to measure the value. For example, an approximate expression may refer to a difference within 10 percent (10%).

[0012] The term “substantially absent” is not limited to being completely or entirely absent when used to describe an amount of material, and may correspond to a lack of any perceptible or detectable amount of the material mentioned. Thus, for example, a certain area is “substantially absent” of material when the amount of material within the relevant area is less than the precision of an instrument or test recognized in the industry for measuring the amount of material within the material. In certain exemplary embodiments, a certain area may be “substantially absent” of material when the amount of material within the area is less than 5 wt%, less than 4 wt%, less than 3 wt%, less than 2 wt%, less than 1 wt%, less than 0.5 wt%, or less than 0.1 wt% of the composition of the area.

[0013] definition:

[0014] As used herein, the term “absorbent article” refers to an article placed in contact with or in close proximity to (i.e., adjacent to) the wearer’s body and capable of absorbing and containing various liquid, solid, and semi-solid exudates discharged from the body. Such absorbent articles are intended to be disposed of after a limited period of use, rather than being washed or restored for reuse, as described herein. It should be understood that the subject matter is applicable to various disposable absorbent articles, including but not limited to diapers, training pants, youth pants, swim shorts, sanitary pads, sanitary pads, feminine pads, panty liners, and panty shields, as well as incontinence products.

[0015] As used herein, the term “airlaid” refers to a web produced by an airlaying process. In an airlaying process, bundles of small fibers having typical lengths ranging from about three (3) to about fifty-two (52) millimeters (mm) are separated and entrained within an air supply and then deposited onto a forming screen, typically with the aid of a vacuum supply. The randomly deposited fibers are then bonded together, for example, using hot air to activate a binder component or a latex adhesive. Airlaying is taught, for example, in U.S. Patent No. 4,640,810 of Laursen et al., incorporated herein by reference in its entirety for all purposes.

[0016] As used herein, the term “joined” refers to the combination, bonding, connection, attachment, etc. of two elements. Two elements will be considered joined to each other when the two elements are directly joined, bonded, connected, attached, etc. to each other, or when they are indirectly joined, bonded, connected, attached, etc. to each other, such as when joined to an intermediate element. Joining may occur, for example, through adhesives, pressure bonding, heat bonding, ultrasonic bonding, stitching, suturing, and / or welding.

[0017] The term “carded web” in this specification refers to a web comprising natural or synthetic staple fibers having a fiber length of typically less than about 100 mm. Bales of staple fibers undergo an opening process to separate the fibers, and the fibers are then sent to a carding process in which the fibers are separated, combed, and aligned in the machine direction, after which the fibers are deposited onto a wire moving for further processing. Such a web typically undergoes some type of bonding process, such as thermal bonding using heat and / or pressure. In addition to, or instead of, the fibers may undergo a bonding process to join the fibers together, for example, by the use of powder adhesive. The carded web may undergo fluid entanglement, such as hydroentangling, to further entangle the fibers together and thereby improve the integrity of the carded web. Once bonded, the carded web will typically have higher machine direction strength than cross machine direction strength due to the alignment of the fibers in the machine direction.

[0018] As used herein, the term “coform” refers to a composite material comprising a mixture of a thermoplastic fiber and a second non-thermoplastic material or a stabilized matrix. As an example, a coform material may be manufactured by a process in which at least one meltblown die head is positioned near a chute to allow other materials to be added to the web while the web is being formed. Such other materials may include, but are not limited to, fibrous organic materials such as woody or non-woody pulp, e.g., cotton, rayon, recycled paper, pulp fluff, and also superabsorbent particles, inorganic and / or organic absorbent materials, treated polymer staple fibers, etc. Some examples of such coform materials are disclosed in U.S. Patent No. 4,100,324 of Anderson et al., U.S. Patent No. 4,818,464 of Lau, U.S. Patent No. 5,284,703 of Everhart et al., and U.S. Patent No. 5,350,624 of Georger et al., each of which is incorporated herein by reference in its entirety for all purposes.

[0019] As used herein, the term “conjugate fiber” refers to a fiber in which at least two polymer feeds are extruded from separate extruders and spun together to form a single fiber. Conjugate fibers are also sometimes referred to as two-component or multi-component fibers. The polymers are arranged in separate zones that are substantially constant across the cross-sections of the conjugate fibers and extend continuously along the length of the conjugate fibers. The configuration of such conjugate fibers may be, for example, a sheath / core arrangement in which one polymer is surrounded by another polymer, or a parallel arrangement, a pie arrangement, or an “islands-in-the-sea” arrangement. Conjugated fibers are taught in U.S. Patent No. 5,108,820 of Kaneko et al., U.S. Patent No. 4,795,668 of Krueger et al., U.S. Patent No. 5,540,992 of Marcher et al., U.S. Patent No. 5,336,552 of Strack et al., U.S. Patent No. 5,425,987 of Shawver et al., and U.S. Patent No. 5,382,400 of Pike et al., each incorporated herein by reference in its entirety for all purposes. In the case of two-component fibers, the polymers may be present in 75 / 25, 50 / 50, 25 / 75, or any other desired ratio. Additionally, polymer additives, such as processing aids, may be included in each section.

[0020] Throughout this description, the term "placed" and expressions "placed on," "placed on," "placed within," "placed between," and variations thereof (e.g., descriptions of articles "placed" interposed between the words "placed" and "on") are intended to imply that one element may be integral with another element, or that one element may be a separate structure joined to another element or placed together with or near it. Accordingly, a component "placed on" an element of an absorbent article may be formed or applied directly or indirectly to the surface of the element, formed or applied between layers of a multilayer element, formed or applied to a substrate placed together with or near the element, formed or applied within a layer of the element or another substrate, or other variations or combinations thereof.

[0021] The term “film” in this specification refers to a thermoplastic film manufactured using an extrusion and / or forming process, such as a cast film or a blown film extrusion process. The term includes non-fluid-transmitting films, such as but not limited to perforated films, slit films, and other porous films constituting liquid-transmitting films, as well as barrier films, filled films, breathable films, and oriented films.

[0022] The term “liquid impermeability” herein refers to a layer or multilayer laminate in which, under normal conditions of use, body fluid exudates such as urine do not pass through the layer or laminate at the point of liquid contact in a direction generally perpendicular to the plane of the layer or laminate.

[0023] The term "liquid permeability" in this specification refers to any material that is not liquid impermeable.

[0024] As used herein, the term "machine direction" (MD) refers to the length of the fabric in the direction in which the fabric is produced, in contrast to "cross machine direction" (CD), which refers to the width of the fabric in a direction generally perpendicular to the machine direction.

[0025] As used herein, the term “meltblown web” refers to a nonwoven web formed by a process in which a molten thermoplastic material is extruded into a high-speed gas (e.g., air) stream that converges as molten fibers through a plurality of fine, generally circular, die capillaries—which elongates the fibers of the molten thermoplastic material to reduce their diameter, which may be up to the microfiber diameter. The meltblown fibers are then carried by the high-speed gas stream and deposited on a collection surface to form a web of randomly distributed meltblown fibers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,241 of Buten et al., incorporated herein by reference in its entirety for all purposes. Generally speaking, the meltblown fibers may be substantially continuous or discontinuous, generally have a diameter smaller than 10 micrometers, and are generally adhesive when deposited on a collection surface.

[0026] As used herein, the term “nonwoven fabric” refers to a web having a structure of individual fibers or threads interlaid in a manner not identifiable as in knitted fabrics. Nonwoven fabrics or webs have been formed from many processes, such as, for example, melt-blowing processes, spunbonding processes, and through-air bonded carded web (also known as BCW and TABCW) processes. The basis weight of a nonwoven web can generally vary from about 5 (5), 10 (10), or 20 (20) gsm to about 120 (120), 125 (125), or 150 (150) gsm.

[0027] The term “rewetting” is used herein to refer to the re-transfer of liquid from the absorbent core to the body or wearer side of the top sheet when a disposable absorbent article is in use. Accordingly, rewetting is a measure of the fluid retention capacity of the absorbent article under load. Low rewetting implies low re-transfer of liquid from the fluid transport layer and / or the absorbent core to the body or wearer side of the top sheet. The rewetting characteristics of the absorbent article are determined by the procedure outlined in the Test Procedure section below. Unless otherwise indicated, rewetting values ​​are reported herein in grams.

[0028] As used herein, the term “spunbond web” refers to a web comprising substantially continuous fibers of small diameter. The fibers are formed by extruding a molten thermoplastic material from a plurality of fine, generally circular, capillaries of a spinneret, wherein the diameter of the extruded fibers is rapidly reduced, for example, by eductive drawing and / or other well-known spunbonding mechanisms. The production of spunbond webs is described and illustrated, for example, in U.S. Patent No. 4,340,563 of Appel et al., U.S. Patent No. 3,692,618 of Dorschner et al., U.S. Patent No. 3,802,817 of Matsuki et al., U.S. Patent No. 3,338,992 of Kinney, U.S. Patent No. 3,341,394 of Kinney, U.S. Patent No. 3,502,763 of Hartman, U.S. Patent No. 3,502,538 of Levy, U.S. Patent No. 3,542,615 of Dobo et al., and U.S. Patent No. 5,382,400 of Pike et al., each incorporated herein by reference in its entirety for all purposes. Spunbond fibers are generally non-adhesive when deposited on a collection surface. Spunbond fibers are sometimes less than about forty (40) micrometers in diameter, and often can be about five (5) to about twenty (20) micrometers.

[0029] As used herein, the terms “superabsorbent polymer,” “superabsorbent,” or “SAP” will be used interchangeably and refer to a polymer capable of absorbing and retaining an extremely large amount of liquid relative to its own mass. Water-absorbing polymers classified as crosslinkable hydrogels absorb aqueous solutions through hydrogen bonding with water molecules and other polar forces. The ability of an SAP to absorb water is based in part on its ionicity (the ratio of ion concentration in an aqueous solution) and the functional polar groups of the SAP that have an affinity for water. SAPs are typically prepared by polymerizing acrylic acid blended with sodium hydroxide in the presence of an initiator to form a sodium polyacrylate salt (sometimes referred to as sodium polyacrylate). Other materials are used to manufacture superabsorbent polymers, such as polyacrylamide copolymers, ethylene maleic anhydride copolymers, cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and starch grafted copolymers of polyacrylonitrile. SAP may be present in absorbent articles in the form of particles or fibers, or as a coating or other material or fiber.

[0030] Absorbent items:

[0031] Generally, absorbent articles are disclosed in this specification.

[0032] Referring to FIGS. 1 and 2, an absorbent article (100) according to an exemplary embodiment of the subject matter is illustrated in the form of a feminine hygiene product such as a sanitary pad or sanitary pad. It should be understood that the subject matter is not limited to the exemplary embodiment illustrated in FIGS. 1 and 2 and is suitable for use with various other absorbent articles, such as but not limited to diapers or incontinence products. The absorbent article (100) may have a longitudinal direction (L), a lateral direction (A), and a transverse direction (T) that are mutually perpendicular.

[0033] The absorbent article (100) may have a front region (102), a rear region (104), and a central region (106) located between the front region (102) and the rear region (104), for example, along the longitudinal direction (L). The absorbent article (100) may have a first lateral end edge (103), a second lateral end edge (105) opposite the first lateral end edge (103), and a pair of opposite longitudinal side edges (107) extending between the first lateral end edge (103) and the second lateral end edge (105) and connecting them. The absorbent article (100) may have a wearer-facing liquid-permeable top sheet layer (110) and a garment-facing liquid-impermeable layer (120). An absorbent core (130) may be positioned between a top sheet layer (110) and a liquid impermeable layer (120). The absorbent article (100) may have an exudate control layer (140) in fluid communication with the top sheet layer (110). In an exemplary embodiment, the control layer (140) may be positioned between the top sheet layer (110) and the absorbent core (130), for example, as illustrated in FIGS. 1 and FIGS. 2. Both the top sheet layer (110) and the liquid impermeable layer (120) may extend past the outermost peripheral edges of the absorbent core (130), for example, along the longitudinal direction (L) and / or lateral direction (A), and may be joined together, wholly or partially, along the peripheral using a known bonding technique to form a sealed peripheral region (109). For example, the top sheet layer (110) and the liquid impermeable layer (120) can be joined together by adhesive bonding, ultrasonic bonding, or any other suitable bonding technique known in the art.

[0034] Each of the above components of the absorbent article (100), as well as additional components, will be described in more detail in this specification.

[0035] In exemplary embodiments, the absorbent article (100) may include a pair of wings (160) extending outwardly in a lateral direction (A) from the absorbent article (100). The wings (160) are positioned over the edges of the wearer's underwear, so that the wings (160) are positioned between the edges of the wearer's underwear and the wearer's thighs. The wings (160) may serve at least two purposes. First, the wings (160) may prevent contamination of the wearer's underwear by forming a barrier along the edges of the underwear. Second, the wings (160) may be provided with attachment aids (not shown), such as garment adhesive or hooks, to keep the absorbent article (100) firmly and properly positioned on the underwear. The wings (160) may wrap around the crotch area of ​​the wearer's underwear to help secure the absorbent article (100) to the wearer's underwear when in use. Each wing (160) may be folded under the crotch area of ​​the wearer's underwear, and an attachment aid may form a firm attachment to the opposite wing (160) or directly to the surface of the wearer's underwear. In an exemplary embodiment, the wing (160) may be an extension of the material forming the top sheet layer (110) and / or the liquid impermeable layer (120) and may be bonded together along the sealed peripheral area (109). Such a wing (160) may be formed integrally with the main part of the absorbent article (100). In various exemplary embodiments, the wing (160) may be composed of a material similar to the top sheet layer (110), the liquid impermeable layer (120), or a combination of these materials. In various embodiments, the wing (160) may be a separate element bonded to the main body of the absorbent article (100).Examples of processes for manufacturing the absorbent article (100) and the wing (160) include, but are not limited to, those described in U.S. Patent No. 4,059,114 of Richards, U.S. Patent No. 4,862,574 of Hassim et al., U.S. Patent No. 5,342,647 of Heindel et al., U.S. Patent No. 7,070,672 of Alcantara et al., U.S. Patent Application Publication No. 2004 / 0040650 of Venturino et al., and International Application Publication WO1997 / 040804 of Emenaker et al., each of which is incorporated herein by reference in its entirety. It should be understood that the wing (160) is optional and that in various exemplary embodiments, the absorbent article (100) may be constructed without the wing (160).

[0036] Top sheet layer :

[0037] The top sheet layer (110) may also be referred to herein as the “inner layer.” The top sheet layer (110) may define the body-facing surface (112) of the liquid-permeable absorbent article (100) to come into direct contact with the wearer’s body and to receive body exudate. The top sheet layer (110) is preferably provided for comfort and functions to direct body exudate away from the wearer’s body toward the absorbent core (130) through its own structure. The top sheet layer (110) may preferably retain little to no liquid within it, so the top sheet layer (110) provides a relatively comfortable and non-irritating surface next to the wearer’s skin of the absorbent article (100).

[0038] The top sheet layer (110) may be a single material layer or, alternatively, a plurality of layers laminated together. The top sheet layer (110) may be composed of any material, for example, one or more woven sheets, one or more fibrous nonwoven sheets, one or more film sheets, for example, a blown or extruded film which itself may be a single or multiple layer, one or more foam sheets, for example, mesh, open-cell or closed-cell foam, a coated nonwoven sheet, or a combination of any of these materials. Such a combination may be laminated into an integrated flat sheet structure by adhesive, thermal, or ultrasonically to form the top sheet layer (110).

[0039] In an exemplary embodiment, the top sheet layer (110) may be composed of various nonwoven webs such as a meltblown web, a spunbond web, a hydro-intangled spunlace web, or an air-bonded carded web. Examples of suitable top sheet layer (110) materials may include, but are not limited to, natural fiber webs (e.g., cotton), rayon, hydro-intangled webs, bonded carded webs of polyester, polypropylene, polyethylene, nylon, or other heat-bondable fibers (e.g., two-component fibers), polyolefins, copolymers of polypropylene and polyethylene, linear low-density polyethylene, and aliphatic esters such as polylactic acid. Microperforated film and net materials may also be used as a laminate of these materials or a combination of these materials. An example of a suitable top sheet layer (110) may be a bonded carded web made of polypropylene and polyethylene, such as that available from Sandler Corp., Germany. U.S. Patent No. 4,801,494 by Datta et al., U.S. Patent No. 4,908,026 by Sukiennik et al., and International Application Publication WO 2009 / 062998 by Texol teach various other top sheet materials that may be used as the top sheet layer (110), each of which is incorporated herein by reference in its entirety. Additional top sheet layer (110) materials may include, but are not limited to, those described in U.S. Patent No. 4,397,644 of Matthews et al., U.S. Patent No. 4,629,643 of Curro et al., U.S. Patent No. 5,188,625 of Van Iten et al., U.S. Patent No. 5,382,400 of Pike et al., U.S. Patent No. 5,533,991 of Kirby et al., U.S. Patent No. 6,410,823 of Daley et al., and U.S. Patent Application Publication No. 2012 / 0289917 of Abuto et al., each of which is incorporated herein by reference in its entirety.

[0040] In various exemplary embodiments, the top sheet layer (110) may include a plurality of openings formed through it to allow body exudate to pass more easily into the absorbent core (130). The openings may be arranged randomly or uniformly throughout the top sheet layer (110). The size, shape, diameter, and number of the openings may be changed to suit the absorbent article (100).

[0041] In an exemplary embodiment, the top sheet layer (110) may have a basis weight in the range of about 5 (5), 10 (10), 15 (15), 20 (20), or 25 (25) gsm to about 50 (50), 100 (100), 120 (120), 125 (125), or 150 (150) gsm. For example, in an exemplary embodiment, the top sheet layer (110) may be composed of a through-air bonded carded web having a basis weight in the range of about 15 (15) gsm to about 100 (100) gsm. In another example, the top sheet layer (110) may be composed of a through-air bonded carded web having a basis weight of about twenty (20) gsm to about fifty (50) gsm, for example, a through-air bonded carded web readily available from nonwoven material manufacturers, for example, Xiamen Yanjan Industry in Beijing, DaYuan Nonwoven Fabrics, etc.

[0042] In various exemplary embodiments, the top sheet layer (110) may be at least partially hydrophilic. In exemplary embodiments, a portion of the top sheet layer (110) may be hydrophilic, and a portion of the top sheet layer (110) may be hydrophobic. In exemplary embodiments, the portion of the top sheet layer (110) that may be hydrophobic may be a material that is essentially hydrophobic or a material treated with a hydrophobic coating.

[0043] In various exemplary embodiments, the top sheet layer (110) may be a multi-component top sheet layer (110) by having, for example, two or more different nonwoven or film materials, wherein the different materials are positioned at distinct locations in the lateral direction (L) of the absorbent article (100). For example, the top sheet layer (110) may be a two-layer or multi-component material having a central portion positioned along the longitudinal centerline (111) of the absorbent article (100) and crossing it, wherein the lateral portions are positioned next to and bonded to each side edge of the central portion. The central portion may be composed of a first material, and the lateral portions may be composed of a material that may be the same as or different from the material of the central portion. In such exemplary embodiments, the central portion may be at least partially hydrophilic, and the lateral portions may be essentially hydrophobic or treated with a hydrophobic coating. Examples of the structure of the multi-component top sheet layer (110) are generally described in U.S. Patent No. 5,961,505 of Coe, U.S. Patent No. 5,415,640 of Kirby, and U.S. Patent No. 6,117,523 of Sugahara, each of which is incorporated herein by reference in its entirety.

[0044] In an exemplary embodiment, the central portion of the top sheet layer (110) may be positioned symmetrically with respect to the longitudinal centerline (111) of the absorbent article (100). The longitudinally oriented central portion of such a center may be a through-air bonded carded web ("TABCW") having a basis weight of about fifteen (15) to about one hundred (100) gsm. The nonwoven, woven, and open film top sheet layer materials described above may also be used as the central portion of the top sheet layer (110). In an exemplary embodiment, the central portion may be composed of a TABCW material having a basis weight of about twenty (20) gsm to about fifty (50) gsm, such as those available from Xiamen Yanzhan Industry in Beijing, Dayuan Nonwoven Nonwoven Fabrics, etc. Alternatively, open films, such as those available from film suppliers such as Texol in Italy and Tredegar in the United States, may be used. Different nonwoven, woven, or film sheet materials may be used as side portions of the top sheet layer (110). The selection of such top sheet layer (110) materials may vary based on the overall desired properties of the top sheet layer (110). For example, to prevent leakage in the areas of the side portions and to increase dryness, it may be desirable to have a hydrophilic material in the center portion and a hydrophobic-barrier type material in the side portions. Such side portions may be bonded to the center portion adhesively, thermally, ultrasonically, or otherwise along or adjacent to side edges oriented longitudinally of the center portion. Traditional absorbent article adhesives may be used to bond the side portions to the center portion. Either the center portion and / or the side portions may be treated with surfactants and / or skin-health beneficial agents as well known in the art.

[0045] Such longitudinally oriented side portions may be single or multilayer structures. In exemplary embodiments, the side portions may be adhesively or otherwise bonded laminates. In various exemplary embodiments, the side portions may consist of an upper fibrous nonwoven layer, such as a spunbond material, laminated to a lower layer of a hydrophobic barrier film material. Such a spunbond layer may be formed of a polyolefin, such as polypropylene, and may include a wetting agent if necessary. In various exemplary embodiments, the spunbond layer may have a basis weight of about 10 or 12 gsm to about 30 or 70 gsm and may be treated with a hydrophilic wetting agent. In various exemplary embodiments, the film layer may have openings that allow fluid to permeate into the lower layers and may be either a single layer or a multilayer structure. In various exemplary embodiments, such a film may be a polyolefin, such as polyethylene, having a basis weight of about 10 (10) to about 40 (40) gsm. A structural adhesive may be used to laminate the spunbond layer to the film layer in an additional amount of about 1 / 10 (0.1) gsm to 15 (15) gsm. When the film barrier layer is used in the design of the entire top sheet layer (110), the film barrier layer may include an opacifying agent, such as a film pigment, which acts as a masking element by helping the film to mask stains along the side edges of the absorbing article (100). In this way, the film layer may serve to limit the visibility of fluid contamination stains along the side edges of the absorbing article (100) when viewed from above the top sheet layer (110). The film layer can also serve as a barrier layer to prevent re-wetting of the top sheet layer (110) as well as to prevent fluid flow from the side edges of the absorbent article (100).In various embodiments, the lateral portion may be a laminate such as a spunbond-meltblown-meltblown-spunbond layer ("SMMS") laminate, a spunbond-film laminate, or alternatively, a combination of other nonwoven laminates.

[0046] Absorbent core :

[0047] An absorbent core (130) may be positioned between the top sheet layer (110) and the liquid impermeable layer (120) of the absorbent article (100). The absorbent core (130) may generally exhibit some level of compressibility and conformability, be non-irritating to the wearer's skin, and be any single-layer structure or combination of layer components capable of absorbing and retaining liquids and other bodily exudates. In various exemplary embodiments, the absorbent core (130) may be formed from various different materials and may include any number of desired layers. For example, the absorbent core (130) may comprise one or more layers (e.g., two layers) of absorbent web material consisting of cellulose fibers (e.g., wood pulp fibers), other natural fibers, synthetic fibers, woven or nonwoven sheets, scrim netting or other stabilizing structures, superabsorbent materials, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, lotions, odor control agents, as well as combinations thereof. In an exemplary embodiment, the absorbent web material may comprise a matrix of cellulose fluff and may also comprise a superabsorbent material. The cellulose fluff may comprise a blend of wood pulp fluff, such as that available from Weyerhaeuser Corp., which is bleached and superabsorbent wood pulp containing mainly softwood fibers.

[0048] In an exemplary embodiment, if necessary, the absorbent core (130) may comprise a superabsorbent material. Examples of suitable superabsorbent materials include poly(acrylic acid), poly(methacrylic acid), poly(acrylamide), poly(vinyl ether), maleic anhydride copolymers with vinyl ether and α-olefin, poly(vinylpyrrolidone), poly(vinylmorpholone), poly(vinyl alcohol), and salts and copolymers thereof. Other superabsorbent materials include unmodified and modified natural polymers such as hydrolyzed acrylonitrile-grafted starch, acrylic acid-grafted starch, methyl cellulose, chitosan, carboxymethyl cellulose, and hydroxypropyl cellulose, and natural gums such as alginates, xanthan gum, and locust bean gum. Mixtures of natural and fully or partially synthetic superabsorbent polymers may also be used. The superabsorbent material can be present in any amount as desired within the absorbent core (130).

[0049] Regardless of the combination of absorbent materials used in the absorbent core (130), the absorbent material can be formed into a web structure by employing various conventional methods and techniques. For example, the absorbent web (46) can be formed by techniques such as, but not limited to, dry forming techniques, air forming techniques, wet forming techniques, foam forming techniques, and combinations thereof. Co-form nonwoven materials may also be employed. Methods and apparatus for carrying out such techniques are well known in the art.

[0050] The shape of the absorbent core (130) may vary as desired and may include one of various shapes including, but not limited to, triangular, rectangular, dog-bone, elliptical, trapezoidal, T-shaped, I-shaped, and hourglass shapes. In an exemplary embodiment, the absorbent core (130) may have a shape that corresponds largely to the overall shape of the absorbent article (100). The dimensions of the absorbent core (130) may be substantially similar to the dimensions of the absorbent article (100), but it will be understood that even if the dimensions of the absorbent core (130) are similar, they will often be smaller than the dimensions of the overall absorbent article (100) to be properly accommodated inside the absorbent article. The size and absorbent capacity of the absorbent core (130) are generally compatible with the size of the intended wearer and the liquid load imparted by the intended use of the absorbent article (100). Additionally, the size and absorbent capacity of the absorbent core (130) may vary to accommodate a range of wearers from infants to adults.

[0051] The absorbent core (130) is about 120 (120), 125 (125), 130 (130), 150 (150), 160 (160), 170 (170), 180 (180), 190 (190), 200 (200), 210 (210), 220 (220), 225 (225), 230 (230), 240 (240), 250 (250), 260 (260), 270 (270), 280 (280), 290 (290), 300 (300), 310 (310), 320 (320), 330 (330), 340 (340), or 350 (350) millimeters (mm) to about 335 (355), It can have a length in the range of 360, 380, 385, 390, 395, 400, 410, 415, 420, 425, 440, 450, 460, 480, 500, 510, 520, 530, 540, 550, 600, 610, 620, or 630 millimeters (mm). The absorbent core (130) may have a width in the central area (106) ranging from about thirty (30), forty (40), fifty (50), fifty-five (55), sixty (60), sixty-five (65) or seventy (70) mm to about seventy-five (75), eighty (80), eighty-five (85), ninety (90), ninety-five (95), one hundred (100), one hundred-five (105), one hundred-ten (110), one hundred-five (115), one hundred-twenty (120), one hundred-twenty-five (125), one hundred-thirty (130), one hundred-forty (140), one hundred-five (150), one hundred-sixty (160), one hundred-seventy (170) or one hundred-eighty (180) millimeters (mm).The width of the absorbent core (130) located within the front region (102) and / or rear region (104) of the absorbent article (100) may be in the range of about fifty (50), fifty-five (55), sixty (60), sixty-five (65), seventy (70) mm, seventy-five (75), eighty (80), eighty-five (85), ninety (90), or ninety-five (95) millimeters (mm) to about one hundred (100), one hundred-five (105), one hundred-ten (110), one hundred-five (115), one hundred-twenty (120), one hundred-twenty-five (125), or one hundred-thirty (130) millimeters (mm). As described in the specification, the absorbent core (130) may have a length and width that may be less than or equal to the length and width of the absorbent article (100).

[0052] In an exemplary embodiment, the absorbent article (100) may be a feminine hygiene product having the following ranges of length and width of an absorbent core (130) having an hourglass shape: the length of the absorbent core (130) may be in the range of about 150 (150), 160 (160), 170 (170), or 180 (180) millimeters (mm) to about 190 (190), 200 (200), 210 (210), 220 (220), 230 (230), 240 (240), 250 (250), 260 (260), 270 (270), 280 (280), 290 (290), 300 (300), 310 (310), or 320 (320) millimeters (mm); The width of the absorbent core (130) in the central region (106) may be in the range of about thirty (30), forty (40), or fifty (50) millimeters (mm) to about sixty (60), seventy (70), eighty (80), ninety (90), or one hundred (100) millimeters (mm).

[0053] For example, materials and / or structures suitable for the absorbent core (130) include, but are not limited to, those described in U.S. Patent No. 4,610,678 by Weisman et al., U.S. Patent No. 6,060,636 by Yahiaoui et al., U.S. Patent No. 6,610,903 by Latimer et al., U.S. Patent No. 7,358,282 by Krueger et al., and U.S. Application Publication No. 2010 / 0174260 by Di Luccio et al., each of which is incorporated herein by reference in its entirety.

[0054] In an exemplary embodiment, the absorbent core (130) may be a single-layer structure and may comprise, for example, a matrix of cellulose fluff and a superabsorbent material. In various exemplary embodiments, the absorbent core (130) may have at least two layers of material, such as a body-facing layer and a garment-facing layer. In an exemplary embodiment, the two layers may be identical to each other. In an exemplary embodiment, the two layers may be different from each other. In such an exemplary embodiment, the two layers may provide an absorbent article (100) having different absorption properties as suited. In an exemplary embodiment, the body-facing layer of the absorbent core (130) may be composed of an airlaid material, and the garment-facing layer of the absorbent core (130) may be composed of a superabsorbent polymer-containing compression sheet. In such an exemplary embodiment, the airlaid material may have a basis weight of about forty (40) to about two hundred (200) gsm, and the superabsorbent polymer-containing compressed sheet may be a cellulose fluff-based material that is enclosed by a tissue carrier and may be a combination of SAP and cellulose pulp having a basis weight of about forty (40) to about four hundred (400) gsm.

[0055] Liquid impermeable layer :

[0056] The liquid impermeable layer (120) is also referred to herein as the “outer layer.” The liquid impermeable layer (120) may be generally liquid impermeable and may be a part of the absorbent article (100) facing the wearer’s clothing. The liquid impermeable layer (120) may allow air or vapor to pass to the outside of the absorbent article (100) while still blocking the passage of liquid. Any liquid impermeable material may generally be used to form the liquid impermeable layer (120). The liquid impermeable layer (120) may be a single layer or multiple layers, and one or more of these layers may themselves comprise similar or different materials. Suitable materials that may be used may be microporous polymer films, e.g., polyolefin films or polyethylene or polypropylene, nonwoven fabrics, nonwoven laminates, and film / nonwoven laminates. The specific structure and composition of the liquid impermeable layer (120) may be selected from various known films and / or fabrics, wherein the specific material is appropriately selected to provide a desired level of liquid barrier, strength, abrasion resistance, tactile properties, aesthetics, etc. In various exemplary embodiments, a polyethylene film having a thickness ranging from about 0.2 or 0.5 mil to about 3.0 or 5.0 mil may be used. One example of the liquid impermeable layer (120) may be a polyethylene film such as that available from Pliant Corp., Schaumburg, Illinois, USA. Other examples may include a calcium carbonate-filled polypropylene film. In another exemplary embodiment, the liquid impermeable layer (120) may be a hydrophobic nonwoven material having water barrier properties, for example, a nonwoven laminate, and an example thereof may be a four-layer laminate of spunbond, meltblown, meltblown, and spunbond.

[0057] In an exemplary embodiment, the liquid impermeable layer (120) may be a two-layer structure comprising an outer layer material and an inner layer material that can be bonded together. The outer layer may be any suitable material and may provide the wearer with a texture or appearance generally similar to cloth. An example of such a material may be a 100% (100%) polypropylene bonded-carded web with a diamond bonding pattern available from Sandler AG, Germany. Another example of a material suitable for use as the outer layer may be a 20 (20) gsm spunbond polypropylene nonwoven web. The inner layer may be vapor permeable (i.e., "breathable") or vapor impermeable. The inner layer may be made of a thin plastic film, but other liquid impermeable materials may also be used. The inner layer can prevent liquid body exudate from leaking from the absorbent article (100) and wetting items such as bed sheets and clothing, as well as the wearer and caregiver.

[0058] Accordingly, the liquid impermeable layer (120) may be a single or multiple layer structure, for example, a multiple film layer, or a laminate of a film and nonwoven fibrous layers. A suitable liquid impermeable layer (120) may be composed of materials such as those described in U.S. Patent No. 4,578,069 of Whitehead et al., U.S. Patent No. 4,376,799 of Tusim et al., U.S. Patent No. 5,695,849 of Schober et al., U.S. Patent No. 6,075,179 of McCormack et al., and U.S. Patent No. 6,376,095 of Cheung et al., each of which is incorporated herein by reference in its entirety.

[0059] Exudate management layer :

[0060] In an exemplary embodiment, the absorbent article (100) may have an exudate management layer (140) in fluid communication with the top sheet layer (110). The exudate management layer (140) may also be referred to herein as a "transfer layer." In various exemplary embodiments, the exudate management layer (140) may be located between the top sheet layer (110) and the absorbent core (130).

[0061] The exudate management layer (140) may be made of a material capable of transferring body exudate to the top sheet layer (110) in the transverse direction (T). Any of the various materials may be used as the exudate management layer (140). In various exemplary embodiments, the material may be a synthetic material, a cellulose material, or a combination of a synthetic material and a cellulose material. In exemplary embodiments, the exudate management layer (140) may be composed of a woven or non-woven material. For example, the exudate management layer (140) may be composed of an airlaid or TABCW material. For example, airlaid cellulose tissue may be suitable for use in the exudate management layer (140). Airlaid cellulose tissue may have a basis weight in the range of about 10 or 100 gsm to about 250 or 300 gsm. Airlaid cellulose tissue can be formed from hardwood and / or softwood fibers. Airlaid cellulose tissue can have a microporous structure and can provide excellent wicking ability, particularly for menstrual blood.

[0062] The exudate management layer (140) may have a first lateral end edge (142), a second lateral end edge (144), and a pair of opposite longitudinal lateral edges (146) extending between the lateral end edges (142, 144) and connecting them. In an exemplary embodiment, the first lateral end edge (142) may be the leading edge of the exudate management layer (140) closest to the first lateral end edge (103) of the absorbent article (100) in the front region (102) of the absorbent article (100). In an exemplary embodiment, the second lateral end edge (144) may be the rear end edge of the exudate management layer (140) closest to the second lateral end edge (105) of the absorbent article (100) in the rear region (104) of the absorbent article (100).

[0063] The exudate management layer (140) may generally have any desired shape and / or size. In an exemplary embodiment, the exudate management layer (140) may have a rectangular shape, a curved rectangular shape, an oval shape, an elliptical shape, a circular shape, an hourglass shape, a square shape, or a curved square shape. In various exemplary embodiments, each of the edges (142, 144, 146) of the exudate management layer (140) may be straight. In an exemplary embodiment, at least one of the edges (142, 144, or 146) of the exudate management layer (140) may be arched, and the remaining edges may be straight. In an exemplary embodiment, at least two of the edges (142, 144, or 146) of the exudate management layer (140) may be arched, and the remaining edges may be straight. In an exemplary embodiment, the longitudinal side edge (146) of the exudate management layer (140) may be straight, and the lateral end edges (142, 144) may be arched. In FIG. 1, the lateral end edge (142) may have an arched shape, which, when combined, may form a configuration complementary to the lateral end edge (144) of the two edges (142, 144). In various exemplary embodiments, at least three of the edges (142, 144, or 146) of the exudate management layer (140) may be arched, and the remaining edges may be straight. In various exemplary embodiments, all of the edges (142, 144, 146) of the exudate management layer (140) may be arched.

[0064] In an exemplary embodiment, the exudate control layer (140) may have a longitudinal length that is smaller than the total length of the absorbent article (100) when measured from the first lateral end edge (142) to the second lateral end edge (144). For example, the exudate control layer (140) may have a longitudinal length of about twenty (20), thirty (30), forty (40), fifty (50), or sixty (60) millimeters (mm) to about one hundred (100), one hundred fifty (150), one hundred seventy-five (175), two hundred (200), two hundred fifty (250), or three hundred (300) millimeters (mm). In various exemplary embodiments, the exudate control layer (140) may have a longitudinal length of about fifteen (15), twenty (20), twenty-five (25), thirty (30), thirty-five (35), or forty (40) percent (%) of the longitudinal length of the absorbent article (100) to about fifty (50), fifty-five (55), sixty (60), seventy (70), seventy-five (75), eighty (80), eighty-five (85), or ninety (90) percent (%). In various exemplary embodiments, the exudate control layer (140) may have a lateral width that is less than or equal to the total width of the absorbent article (100) when measured from a first longitudinal side edge (146) to a second longitudinal side edge (146). For example, the exudate management layer (140) may have a lateral width of about 10 (10), 15 (15), 20 (20), or 30 (30) millimeters (mm) to about 60 (60), 80 (80), 100 (100), 110 (110), 115 (115), 120 (120), 125 (125), 130 (130), 140 (140), or 150 (150) millimeters (mm).In various exemplary embodiments, the exudate control layer (140) may have a lateral width of about fifteen (15), twenty (20), twenty-five (25), thirty (30), thirty-five (35), or forty (40) percent (%) of the lateral width of the absorbent article (100) to about fifty (50), fifty-five (55), sixty (60), seventy (70), seventy-five (75), eighty (80), eighty-five (85), or ninety (90) percent (%).

[0065] The exudate control layer (140) may have a body-facing surface (148) and a garment-facing surface opposite to the body-facing surface (148) along the transverse direction (T). The exudate control layer (140) may provide an exudate control layer (140) having a height in the transverse direction (T). In various exemplary embodiments, the height of the exudate control layer (140) may be about 5 / 10 (0.5), 75 / 100 (0.75), 1 (1), 1 and 5 / 10 (1.5), 2 (2), or 3 and 5 / 10 (3.5) millimeters (mm) to about 3 (3), 3 and 5 / 10 (3.5), 4 (4), 4 and 5 / 10 (4.5), 5 (5), 6 (6), or 10 (10) millimeters (mm). In various exemplary embodiments, the first lateral end edge (142) of the exudate management layer (140) may be about fifteen (15) millimeters (mm) to about one hundred fifty (150) millimeters (mm) from the first lateral end edge (103) of the absorbent article (100).

[0066] Acquisition layer :

[0067] In addition to the exudate management layer (140), the absorbent article (100) may include a gain layer (150) that can be connected to the exudate management layer (140) in an exemplary embodiment. However, as illustrated in FIG. 7, the absorbent article (100) may omit the gain layer (150) in a given exemplary embodiment. The gain layer (150) may be located between the absorbent core (130) and the exudate management layer (140). The gain layer (150) may help to slow down and diffuse surges or eruptions of liquid body exudates penetrating the top sheet layer (110). The gain layer (150) may have any longitudinal length dimension as suitable. In an exemplary embodiment, the longitudinal length of the gain layer (150) may be the same as the longitudinal length of the absorbent core (130). In an exemplary embodiment, the longitudinal length of the acquisition layer (150) may be shorter than the longitudinal length of the absorbent core (130). In such an exemplary embodiment, the acquisition layer (150) may be located at any desired position along the longitudinal length of the absorbent core (130). As an example of such an embodiment, the absorbent article (100) may include a target region where repetitive liquid surges typically occur in the absorbent article (100).

[0068] In an exemplary embodiment, the obtained layer (150) may comprise natural fibers, synthetic fibers, superabsorbent materials, woven materials, nonwoven materials, wet-laid fibrous webs, substantially unrestrained airlaid fibrous webs, operablely bonded and stabilized airlaid fibrous webs, as well as combinations thereof. Alternatively, open films such as those available from film suppliers such as Texol in Italy and Tredegar in the United States may be used. In an exemplary embodiment, the obtained layer (150) may be formed from a substantially hydrophobic material, such as a nonwoven web composed of polypropylene, polyethylene, polyester, etc. and combinations thereof. In various exemplary embodiments, the obtained layer (150) may comprise staple or conjugate, binary and / or homopolymer fibers of different lengths, and mixtures of such fibers and other types of fibers. In an exemplary embodiment, the obtained layer (150) may have fibers having a denier greater than about 5 (5). In an exemplary embodiment, the acquisition layer (150) may have fibers having a denier of about 5 (5) or less. In various exemplary embodiments, the acquisition layer (150) may be a bonded carded web or an airlaid web. In various exemplary embodiments, the bonded carded web may be, for example, a powder bonded carded web, an infrared bonded carded web, or a through-air bonded carded web.

[0069] In an exemplary embodiment, the basis weight of the obtained layer (150) may be about 10 or 20 gsm or more. In various exemplary embodiments, the basis weight of the obtained layer (150) may be about 10, 20, 30, 40, 50, or 60 gsm to about 65, 70, 75, 80, 85, 90, 100, 110, 120, or 130 gsm. In various exemplary embodiments, the basis weight of the obtained layer (150) may be less than about one hundred thirty (130), one hundred twenty (120), one hundred ten (110), one hundred (100), ninety (90), eighty-five (85), eighty (80), seventy-five (75), seventy (70), sixty-five (65), sixty (60), or fifty (50) gsm.

[0070] cavity :

[0071] As illustrated in FIGS. 1 and 2, the absorbent core (130) may include a plurality of pockets or cavities (136). The absorbent core (130) may include an inner surface (132) and an outer surface (134) spaced apart along the transverse direction (T). The inner surface (132) of the absorbent core (130) may face the top sheet layer (110), and the outer surface (134) of the absorbent core (130) may face the liquid impermeable layer (120). For example, the inner surface (132) of the absorbent core (130) may be located on and / or in contact with the top sheet layer (110), and the outer surface (134) of the absorbent core (130) may be located on and / or in contact with the liquid impermeable layer (120), the exudate management layer (140), and / or the acquisition layer (150). The cavity (136) may extend inward from the outer surface (134) of the absorbent core (130), for example, along the transverse direction (T). For example, the cavity (136) may be open at or adjacent to the outer surface (134) of the absorbent core (130), for example, in the garment-facing layer of the absorbent core (130). In an exemplary embodiment, the cavity (136) may be, for example, essentially, devoid of cellulose fibers and / or superabsorbent material.

[0072] The top sheet layer (110) and the exudate management layer (140) can be bonded or joined to the absorbent core (130) through a plurality of embossing portions (138). Thus, the top sheet layer (110) and the exudate management layer (140) can be embossed into the absorbent core (130). The embossing portions (138) can correspond to absorption holes formed by a pin embossing process, and a densified area (139) can be placed at the bottom of the absorption holes as part of the pin embossing process. Thus, as used herein, "embossing portion" may refer to absorption holes formed by an embossing process. In FIG. 2, the embossing portion (138) may extend downward, for example, along the transverse direction (T), into the absorbent core (130), for example, through the top sheet layer (110) and the exudate management layer (140), to a densified area (139). The acquisition layer (150) may also be bonded or joined to the absorbent core (130) through the embossing portion (138), such as the densified area (139) in the exemplary embodiment. In the exemplary embodiment, the embossing portion (138) may be, for example, essentially, nonwoven fiber.

[0073] The top sheet layer (110), the absorbent core (130), and the exudate management layer (140) can be compressed into densified regions (139) in the embossing sections (138). For example, the absorbent core (130) can be compressed from a thickness (TA) to a thickness (TE) in the embossing sections (138) when the top sheet layer (110) and the exudate management layer (140) are embossed into the absorbent core (130). The thickness (TE) of the absorbent core (130) in the embossing sections (138) may be smaller than the thickness (TA) of the absorbent core (130) between the embossing sections (138). For example, the thickness (TA) of the absorbent core (130) in the embossing sections (138) may be less than half the thickness (TE) of the absorbent core (130) between the embossing sections (138). Therefore, the absorbent core (130) may be denser in the embossed portions (138) than between the embossed portions (138).

[0074] Each of the cavities (136) may be aligned with one of the embossed portions (138) and / or densified areas (139), for example, along the transverse direction (T). For example, the densified areas (139) may be located between the cavities (136) and the embossed portions (138), for example, along the transverse direction (T), directly above the cavities (136). Alignment between the cavities (136) and the embossed portions (138) and the cavities (136) facilitates the flow of menstrual blood from the contaminated area in the top sheet layer (110) to the absorbent core (130), thereby making the absorbent article (100) more comfortable than conventional absorbent articles. Accordingly, alignment between the cavities (136) and the embossing portions (138) and the cavities (136) can advantageously reduce the residence time of menstrual blood on the top sheet layer (110) and maximize the use of the absorbent core (130). Menstrual blood on the top sheet layer (110) can flow into the cavities (136) of the absorbent core (130) through the top sheet layer (110) and the exudate management layer (140) (e.g., through the embossing portions (138)). Menstrual blood can be collected within the absorbent core (130) and then diffuse outward into the absorbent core (130) along, for example, the longitudinal direction (L) and / or the lateral direction (A).

[0075] As illustrated in FIG. 1, the cavities (136) may be distributed in the central portion of the absorbent core (130), for example, in the central region (106) of the absorbent article (100). The absorbent core (130) may contain a suitable number of cavities (136). For example, the cavities (136) may include nine (9) or more and thirty (30) or fewer cavities, for example, ten (10) or more and twenty (20) or fewer cavities. Such locations and / or numbers of the cavities (136) can advantageously facilitate the flow of menstrual blood from the contaminated area in the top sheet layer (110) to the absorbent core (130). For example, such locations and / or numbers of the cavities (136) can advantageously provide a distribution of cavities (136) that reduces the residence time of menstrual blood on the top sheet layer (110) and maximizes the use of the absorbent core (130).

[0076] As illustrated in FIG. 2, the width (WC) of each cavity (136) along the lateral direction (A) may be greater than the width (WE) of each embossing portion (138) along the lateral direction (A). The width (WC) of the cavities (136) along the lateral direction (A) may correspond to the average width of the cavities (136), and the width (WE) of the embossing portions (138) may correspond to the average width of the embossing portions (138). In an exemplary embodiment, the width (WC) of each cavity (136) may be at least twice the width (WE) of the embossing portions (138). Furthermore, for example, the cross-sectional area of ​​each cavity (136) in a plane perpendicular to the transverse direction (A) may be greater than the cross-sectional area of ​​each embossing portion (138) in a plane perpendicular to the transverse direction (A). The cross-sectional area of ​​the cavities (136) may be between 5 square millimeters (5 mm²) and 90 square millimeters (90 mm²), for example between 10 square millimeters (10 mm²) and 80 square millimeters (80 mm²), for example between 20 square millimeters (20 mm²) and 70 square millimeters (70 mm²). The cross-sectional area of ​​the embossing portions (138) may be between 15 hundredths (0.15 mm²) and 8 square millimeters (8 mm²), for example between 1 square millimeter (1 mm²) and 6 square millimeters (6 mm²). The height (HC) of each cavity (136) along the transverse direction (A) may be between 30 percent (30%) and 80 percent (80%) of the height (TA) of the absorbent core (130) along the transverse direction (A). The height (HE) of the embossing portions (138) along the transverse direction (A) may be forty percent (40%) or more and seventy percent (70%) or less of the height (TA) of the absorbent core (130) along the transverse direction (A). In an exemplary embodiment, the cross-sectional area of ​​the cavities (136) may be measured at the center of the height (HC) of the cavities (136) along the transverse direction (T), and the cross-sectional area of ​​the embossing portions (138) may be measured at the center of the height (HE) of the embossing portions (138) along the transverse direction (T).The aforementioned sizing of the cavities (136) and embossing portions (138) facilitates the flow of menstrual blood from the contaminated area in the top sheet layer (110) to the absorbent core (130), thereby making the absorbent article (100) more comfortable than conventional absorbent articles. Thus, such sizing of the cavities (136) and embossing portions (138) can advantageously reduce the residence time of menstrual blood on the top sheet layer (110) and maximize the use of the absorbent core (130). For example, the embossing portions (138) can facilitate the capillary flow of menstrual blood into the cavities (136) due to the size difference between the cavities (136) and the embossing portions (138).

[0077] As illustrated in FIG. 3, the cavities (136) can be arranged in an array (200). The array (200) can be placed in the central part of the absorbent core (130), for example, in the central region (106) of the absorbent article (100). The array (200) can be sized to provide a desired distribution of the cavities (136). For example, the length (LA) of the array (200) can be, for example, between 80 millimeters (80 mm) and 120 millimeters (120 mm) along the longitudinal direction (L), and the width (WA) of the array (200) can be, for example, between 35 millimeters (35 mm) and 60 millimeters (60 mm) along the lateral direction (A). Thus, the array (200) can be elongated along the longitudinal direction (L). The cavities (136) can be distributed in a certain pattern within the array (200). In an exemplary embodiment, the pattern may include columns along the longitudinal direction (L) (e.g., two, three, four, or more columns) and rows along the transverse direction (A) (e.g., three, four, five, or more rows). In an exemplary embodiment, the columns and rows may be linear, arched, or curved to provide a desired pattern for the cavities (136). For example, within the array (200), the distance between adjacent cavities (136) may be between five millimeters (5 mm) and twenty-five millimeters (25 mm), for example, in the longitudinal direction (L) and / or lateral direction (A). Thus, for example, each of the cavities (136) may be spaced between five millimeters (5 mm) and twenty-five millimeters (25 mm) from the nearest adjacent cavity (136) within the array (200), for example, along the longitudinal direction (L) and / or lateral direction (A). Such an arrangement of the cavities (136) can advantageously facilitate the flow of menstrual blood from the contaminated area in the top sheet layer (110) to the absorbent core (130).For example, such an arrangement of cavities (136) within the array (200) can advantageously provide a distribution of cavities (136) that reduces the residence time of menstrual blood on the top sheet layer (110) and maximizes the use of the absorbent core (130).

[0078] Formation System and Method:

[0079] FIGS. 4 through 6 illustrate a system (300) and a method for forming an absorbent article. The system (300) is described in more detail below in the context of the absorbent article (100). However, it will be understood that the system (300) may be used to form any suitable absorbent article in other exemplary embodiments.

[0080] As illustrated in FIG. 4, the system (300) includes a supply roll (310) for a bottom carrier sheet (312). The formation of the absorbent core (130) can begin by unwinding the carrier sheet (312) from the supply roll (310). The bottom carrier sheet (312) may be composed of any natural or synthetic material. The bottom carrier sheet (312) may be formed of a material that allows not only air but also liquid or fluid to pass through. A material that works well as a bottom carrier sheet (312) is tissue. Tissue may be formed of one or more types of cellulose fibers.

[0081] The system (300) also includes an absorbent feeder (323) for cellulose pulp and / or superabsorbent material. The absorbent feeder (323) may include a feed roll for unwinding a cellulose pulp sheet. The cellulose pulp sheet may be formed from cross-linked pulp, hardwood, softwood, synthetic fibers, or any combination thereof. The cellulose pulp sheet may be guided to a fiberizer in which the cellulose pulp sheet is broken down into individual fibers. The fiberizer may include a hammer mill or other similar equipment for breaking or beating the cellulose pulp sheet into individual fibers. Subsequently, the individual fibers are mixed with air or pressurized air to acquire a fluffy appearance. Those skilled in the art usually refer to such fibers as "fluff." After exiting the fiberizer, one or more streams of superabsorbent material may be injected into the fluff. The superabsorbent material may be in the form of small particles, fibers, flakes, or other forms. The percentage of the superabsorbent material within the absorbent fluff / SAM mixture may vary from 1% to about 95%, for example, from about 10% to about 80%, for example, from about 25% to about 65%. The superabsorbent material may be dispersed throughout the fibrous structure. Alternatively, the superabsorbent material may be dispersed in one or more pre-selected areas or zones of the absorbent fluff. The precise localization of the superabsorbent material within the absorbent fluff will depend on the size and shape of the absorbent core, as well as the type of absorbent core produced.

[0082] Subsequently, a mixture of superabsorbent and / or fluff (fibrous pulp) may be deposited onto the surface of the forming drum (320). The peripheral surface of the forming drum (320) may be composed of a fine mesh screen that allows air to pass through while gathering the fluff / SAM mixture to a predetermined thickness. This fluff / SAM mixture is formed into a web (302), which is deposited onto the upper surface of the bottom carrier sheet (312).

[0083] As illustrated in FIGS. 4 and 5, the forming drum (320) may include a forming surface (322) for receiving a mixture of superabsorbent and / or fluff (fibrous pulp). The forming surface (322) may include a plurality of pins (324) for forming cavities within the web (302). Thus, the number, size, and distribution of the pins (324) on the forming surface (322) may correspond to the cavities (136) formed within the absorbent core (130). The pins (324) may be placed within a recess (328) radially inward of the outer surface (326) of the forming drum (320).

[0084] The fluff / SAM web (302) remaining on the upper surface of the lower carrier sheet (312) can be passed between a pair of nip rolls (340), whereby the fluff / SAM web (302) is reduced in volume or thickness. This volume reduction step is optional and can be removed or used later downstream. The volume reduction can reduce the thickness of the fluff / SAM web (302) by about 10% to about 95%, for example, about 20% to about 90%, for example, about 30% to about 85%.

[0085] As illustrated in FIG. 4, the system (300) includes a supply roll (330) for an upper carrier sheet (332). Forming the absorbent core (130) may include unwinding the upper carrier sheet (332) from the supply roll (330). The upper carrier sheet (332) may also be composed of any natural or synthetic material. The upper carrier sheet (332) may be formed from a material that allows air as well as liquid or fluid to pass through, for example, the same material as the lower carrier sheet (312). The upper carrier sheet (332) may be applied over the fluff / SAM web (302) on the lower carrier sheet (312) to form an absorbent strip. In another exemplary embodiment, the carrier sheet (312) may be wrapped or folded around at least a portion of the fluff / SAM web (302) by a folder rather than being used as a separate upper carrier sheet (332).

[0086] The absorbent strip (304) can be trimmed longitudinally by a cutter into a predetermined shape. Trimming removes material from locations on the absorbent strip (304) that will ultimately become the crotch area of ​​the absorbent core. Longitudinal trimming of the absorbent strip (304) can remove less than about 50% of the material forming the width of the absorbent strip (304), for example, less than about 40% of the material, for example, less than about 30% of the material.

[0087] The system (300) may also include a cutter (350) for cutting or slicing the absorbent strip (304) into a plurality of individual absorbent members (306), such as the absorbent core (130). The cutter (350) cuts the absorbent strip (304) transversely, which is aligned approximately perpendicular to the machine direction (MD). Once the individual absorbent members (306) are created, the absorbent members (306) are separated from each other longitudinally. The exact separation distance will depend on the final design of the absorbent core, the operating speed of the equipment, etc. Separation can be easily achieved in various ways as illustrated, known to those skilled in the art of machinery. One method is to use a pair of conveyor belts in which a first conveyor supports the absorbent strip (304) and a second conveyor supports the individual absorbent members (306). Individual absorbent members (306) can be separated longitudinally at a predetermined distance from each other in the machine direction (MD) by acceleration of the second conveyor, deceleration of the first conveyor, or a combination of acceleration of one conveyor and deceleration of another conveyor.

[0088] As illustrated in FIG. 4, the system (300) includes a supply roll (360) for an exudate management material (362), such as an exudate management layer (140). The system (300) can unwind the exudate management material (362) from the supply roll (360). The system (300) further includes a supply roll (370) for a top sheet material (372), such as a top sheet layer (110). The system (300) can unwind the top sheet material (372) from the supply roll (370). The exudate management material (362) and the top sheet material (372) can be bonded to the absorbent members (306). In an exemplary embodiment, the exudate management material (362) and the top sheet material (372) can be bonded to the absorbent members (306) adhesively, thermally, ultrasonically, or otherwise. Accordingly, as illustrated in FIGS. 4 and 6, the system (300) further comprises an embosser (380) for bonding the exudate management material (362) and the top sheet material (372) to the absorbent members (306). As illustrated in FIG. 6, the embosser (380) may include a plurality of pins (384), such as channel embossing pins extending radially outward on an embossing roll (382). The raised pins (384) can be used to create compressed and embossed sections on the exudate management material (362), the top sheet material (372), and the absorbent members (306) by imparting a desired embossing pattern. Thus, the embosser (380) can form densified regions (139) that bond the exudate management material (362), the top sheet material (372), and the absorbent members (306) together. For example, the embosser (380) may be configured for thermal bonding, wherein the exudate control material (362), top sheet material (372), and absorbent member (306) pass between two rolls (e.g., steel, rubber, etc.), including an embossing roll (382) and another flattening roll. Thus, in an exemplary embodiment, the embossing may be formed from only one direction. One or both rolls may be heated.The number, size, and distribution of the pins (384) may correspond to the embossing portions (138) within the absorbent article (100). In some exemplary embodiments, for example, to allow body fluids that would contaminate the absorbent core to be transferred quickly and efficiently from the exudate management layer (140) to the absorbent core (130), there may not be any adhesive between the exudate management material (362) and the absorbent members (306). However, if necessary, one or more adhesive spots or lines may be applied between these two members, namely the exudate management material (362) and the absorbent members (306).

[0089] The system (300) also includes a supply roll (390) for a liquid impermeable material (392), such as a liquid impermeable layer (120). The system (300) can unwind the liquid impermeable material (392) from the supply roll (390). The liquid impermeable material (392) can be bonded together to the absorbent members (306), the exudate management material (362), and the top sheet material (372) to form a core precursor web (308). In an exemplary embodiment, the liquid impermeable material (392) can be bonded to the absorbent members (306), the exudate management material (362), and the top sheet material (372) adhesively, thermally, ultrasonically, or otherwise. The precursor web (308) can be cut or sliced ​​at predetermined locations and bonded together to form, for example, an absorbent article (100).

[0090] Example:

[0091] Sample Preparation: An absorbent article was prepared for testing according to the following procedure. The re-wetting of the absorbent article of the present invention was compared with a conventional commercially available absorbent article using the following test procedure.

[0092] Test Procedure: The apparatus used for the rewetting calculation included a 4"×4" Lucite cylinder block with a 1" diameter opening used to define the area to be tested, a 0.05 kilogram plate (4"×4"×⅛ Lucite square), a 2.2 kilogram weight, a 25 ml volume cylinder, and a top-loading electronic balance with an accuracy of ±0.01 g. In addition, a stained 1% saline solution (see STM-2000), VWR filter paper, Grade #417, 9 cm in diameter, or an equivalent was used.

[0093] Experimental protocols for measuring rewetting properties are known to those skilled in the art, and related disclosures are further described in various patent publications such as U.S. Patent No. 6,852,905 and U.S. Patent No. 6,610,391, incorporated herein by reference.

[0094] The table below summarizes the results obtained through the above test procedure for several examples of the absorbent articles of the present invention and control absorbent articles. The articles of the present invention and the first set of control absorbent articles (Comparative Example #1 and Comparative Example #3) were constructed of the same material, wherein the articles of the present invention included cavities and embossed portions in the manner described above. The first and second sets of control absorbent articles (Comparative Examples #1 to #4) were commercially available absorbent articles. Comparative Example #1 was a "New GoodFeel Original" absorbent article from the Yuhan-Kimberly company having a polyethylene / polypropylene TABCW top sheet. Comparative Example #2 was a "Unicharm Sofy" absorbent article from the Unicharm company having a polyethylene / polyester TABCW top sheet. Comparative Example #3 was a "GoodFeel Good Cotton" absorbent article from Yuhan-Kimberly Company having a 100% spunlace cotton top sheet, and Comparative Example #4 was a "Unicharm Sophie" absorbent article from Unicharm Company having a 100% spunlace cotton top sheet.

[0095] [graph]

[0096]

[0097] As described, the samples of the present invention provided significantly better re-wetting performance compared to the comparative samples, which may indicate that the absorbent articles of the present invention are more comfortable to wear by keeping the skin drier.

[0098] These and other variations and modifications to the present invention may be practiced by those skilled in the art without departing from the spirit and scope of the invention, as more specifically set forth in the appended claims. Furthermore, it should be understood that various embodiments may be interchangeable, in whole or in part. Additionally, those skilled in the art will understand that the foregoing description is merely illustrative and is not intended to limit the invention as further described in these appended claims.

[0099] Exemplary embodiments

[0100] First exemplary embodiment: as an absorbent article, an inner layer; a transfer layer; and an absorbent core disposed between the transfer layer and the outer layer.

[0101] Includes,

[0102] An absorbent article, wherein a transfer layer is disposed between an inner layer and an absorbent core, the absorbent core comprises a cellulose fluff, the absorbent core has an inner surface and an outer surface spaced apart along the transverse direction, the inner surface of the absorbent core faces toward the inner layer, the outer surface of the absorbent core faces toward the outer layer, the absorbent core defines a plurality of cavities extending inwardly along the transverse direction from the outer surface of the absorbent core, the inner layer and the transfer layer are coupled to the absorbent core through a plurality of embossing portions, each of the plurality of cavities is aligned with its respective embossing portion among the plurality of embossing portions along the transverse direction, and the cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​its respective embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction.

[0103] Second exemplary embodiment: An absorbent article in the first exemplary embodiment, further comprising a gain layer disposed between an inner layer and an absorbent core.

[0104] Third exemplary embodiment: An absorbent article in which, in the first exemplary embodiment or the second exemplary embodiment, the acquisition layer is bonded to an absorbent core through a plurality of embossing portions.

[0105] Fourth exemplary embodiment: An absorbent article in any one of the first to third exemplary embodiments, wherein the thickness of the absorbent core in a plurality of embossed portions is smaller than the thickness of the absorbent core between the plurality of embossed portions.

[0106] Fifth exemplary embodiment: An absorbent article in any one of the first to fourth exemplary embodiments, wherein the thickness of the absorbent core in the plurality of embossed portions is less than half the thickness of the absorbent core between the plurality of embossed portions.

[0107] Sixth exemplary embodiment: An absorbent article in any one of the first to fifth exemplary embodiments, wherein each open end of a plurality of cavities is disposed on an outer layer.

[0108] Seventh exemplary embodiment: An absorbent article in which, in any one of the first to sixth exemplary embodiments, a plurality of cavities are distributed in the central portion of an absorbent core.

[0109] Eighth exemplary embodiment: An absorbent article in any one of the first to seventh exemplary embodiments, wherein the cross-sectional area of ​​a plurality of cavities is 5 square millimeters or more and 90 square millimeters or less, and the cross-sectional area of ​​a plurality of embossed portions is 0.15 square millimeters or more and 8 square millimeters or less.

[0110] Ninth exemplary embodiment: An absorbent article in any one of the first to eighth exemplary embodiments, wherein the height of a plurality of cavities along the transverse direction is 30 percent or more and 80 percent or less of the height of the absorbent core along the transverse direction, and the height of a plurality of embossing portions along the transverse direction is 40 percent or more and 70 percent or less of the height of the absorbent core along the transverse direction.

[0111] 10th exemplary embodiment: An absorbent article in any one of the 1st to 9th exemplary embodiments, wherein the distance between adjacent cavities among a plurality of cavities is 5 millimeters or more and 25 millimeters or less in a direction perpendicular to the transverse direction.

[0112] Eleventh exemplary embodiment: An absorbent article in any one of the first to tenth exemplary embodiments, wherein a plurality of cavities are arranged in an array, the length of the array is 80 millimeters or more and 120 millimeters or less, and the width of the array is 35 millimeters or more and 60 millimeters or less.

[0113] 12th exemplary embodiment: An absorbent article in any one of the 1st to 11th exemplary embodiments, wherein the length of the absorbent core is 150 millimeters or more and 250 millimeters or less, and the width of the absorbent core is 50 millimeters or more and 80 millimeters or less.

[0114] 13th Exemplary Embodiment: An absorbent article in any one of the 1st to 12th exemplary embodiments, wherein the inner layer comprises a liquid-permeable nonwoven liner and the outer layer comprises a liquid-impermeable film.

[0115] 14th exemplary embodiment: An absorbent article in any one of the 1st to 13th exemplary embodiments, wherein the plurality of cavities comprises 9 or more and 30 or fewer cavities.

[0116] 15th Exemplary Embodiment: An absorbent article comprising an inner layer; an outer layer; and an absorbent core disposed between the inner layer and the outer layer, wherein the absorbent core comprises a cellulose fluff, and the absorbent core has an inner surface and an outer surface spaced apart along the transverse direction, the inner surface of the absorbent core faces the inner layer, and the outer surface of the absorbent core faces the outer layer, and the absorbent core defines a plurality of cavities extending inwardly along the transverse direction from the outer surface of the absorbent core, and the inner layer is coupled to the absorbent core through a plurality of embossing portions, each of the plurality of cavities is aligned with its respective embossing portion among the plurality of embossing portions along the transverse direction, and the cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​its respective embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction.

[0117] 16th Exemplary Embodiment: An absorbent article in which, in the 15th Exemplary Embodiment, a plurality of cavities are distributed in an array in the central portion of an absorbent core; the length of the array is 80 millimeters or more and 120 millimeters or less, the width of the array is 35 millimeters or more and 60 millimeters or less, the length of the absorbent core is 150 millimeters or more and 250 millimeters or less, and the width of the absorbent core is 50 millimeters or more and 80 millimeters or less.

[0118] 17th Exemplary Embodiment: An absorbent article, wherein in the 15th Exemplary Embodiment or the 16th Exemplary Embodiment, the cross-sectional area of ​​the plurality of cavities is 5 square millimeters or more and 90 square millimeters or less, and the cross-sectional area of ​​the plurality of embossing portions is 0.15 square millimeters or more and 8 square millimeters or less; the height of the plurality of cavities along the transverse direction is 30 percent or more and 80 percent or less of the height of the absorbent core along the transverse direction, and the height of the plurality of embossing portions along the transverse direction is 40 percent or more and 70 percent or less of the height of the absorbent core along the transverse direction; and the distance between adjacent cavities among the plurality of cavities is 5 millimeters or more and 25 millimeters or less in a direction perpendicular to the transverse direction.

[0119] 18th exemplary embodiment: In any one of the 15th to 17th exemplary embodiments,

[0120] 19. Exemplary embodiment: A method for forming an absorbent article comprises the steps of: applying a cellulose fluff onto a plurality of pins on a forming drum; forming an absorbent core with the cellulose fluff, wherein the absorbent core defines a plurality of cavities extending inwardly along a transverse direction, each of the plurality of cavities corresponding to a respective pin among the plurality of pins; embossing an inner layer and a transfer layer on the absorbent core through a plurality of embossing portions, wherein each of the plurality of cavities is aligned with a respective embossing portion among the plurality of embossing portions along the transverse direction, and the cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​each embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction; and attaching an outer layer to the absorbent core on the opposite side of the inner layer.

Claims

Claim 1 As an absorbent article, inner layer; transfer layer; outer layer; and includes an absorbent core disposed between the transfer layer and the outer layer, wherein the transfer layer is disposed between the inner layer and the absorbent core, the absorbent core includes a cellulose fluff, the absorbent core has an inner surface and an outer surface spaced apart along the transverse direction, the inner surface of the absorbent core faces toward the inner layer, and the outer surface of the absorbent core faces toward the outer layer, the absorbent core defines a plurality of cavities extending inwardly along the transverse direction from the outer surface of the absorbent core, the inner layer and the transfer layer are coupled to the absorbent core through a plurality of embossings, each of the plurality of cavities is aligned with its respective embossing among the plurality of embossings along the transverse direction, and the cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is the plurality of embossings in a plane perpendicular to the transverse direction An absorbent article that is larger than the cross-sectional area of ​​each of the embossed parts. Claim 2 An absorbent article according to claim 1, further comprising a gain layer disposed between the inner layer and the absorbent core. Claim 3 In paragraph 2, the absorbent article, wherein the acquisition layer is bonded to the absorbent core through the plurality of embossing portions. Claim 4 An absorbent article according to claim 1, wherein the thickness of the absorbent core in the plurality of embossed portions is smaller than the thickness of the absorbent core between the plurality of embossed portions. Claim 5 An absorbent article according to claim 4, wherein the thickness of the absorbent core in the plurality of embossed portions is less than half the thickness of the absorbent core between the plurality of embossed portions. Claim 6 An absorbent article according to claim 1, wherein each open end of the plurality of cavities is disposed in the outer layer. Claim 7 In claim 1, the plurality of cavities are distributed in the central part of the absorbent core, an absorbent article. Claim 8 An absorbent article according to claim 1, wherein the cross-sectional area of ​​the plurality of cavities is 5 square millimeters or more and 90 square millimeters or less, and the cross-sectional area of ​​the plurality of embossing portions is 0.15 square millimeters or more and 8 square millimeters or less. Claim 9 An absorbent article according to claim 1, wherein the height of the plurality of cavities along the transverse direction is 30 percent or more and 80 percent or less of the height of the absorbent core along the transverse direction, and the height of the plurality of embossing portions along the transverse direction is 40 percent or more and 70 percent or less of the height of the absorbent core along the transverse direction. Claim 10 An absorbent article according to claim 1, wherein the distance between adjacent cavities among the plurality of cavities is 5 millimeters or more and 25 millimeters or less in a direction perpendicular to the transverse direction. Claim 11 An absorbent article according to claim 1, wherein the plurality of cavities are arranged in an array, the length of the array is 80 millimeters or more and 120 millimeters or less, and the width of the array is 35 millimeters or more and 60 millimeters or less. Claim 12 An absorbent article according to claim 11, wherein the length of the absorbent core is 150 millimeters or more and 250 millimeters or less, and the width of the absorbent core is 50 millimeters or more and 80 millimeters or less. Claim 13 An absorbent article according to claim 1, wherein the inner layer comprises a liquid-permeable nonwoven liner and the outer layer comprises a liquid-impermeable film. Claim 14 An absorbent article according to claim 1, wherein the plurality of cavities comprises 9 or more and 30 or fewer cavities. Claim 15 An absorbent article comprising: an inner layer; an outer layer; and an absorbent core disposed between the inner layer and the outer layer, wherein the absorbent core comprises a cellulose fluff, and the absorbent core has an inner surface and an outer surface spaced apart along the transverse direction, wherein the inner surface of the absorbent core faces the inner layer and the outer surface of the absorbent core faces the outer layer, and the absorbent core defines a plurality of cavities extending inwardly along the transverse direction from the outer surface of the absorbent core, wherein the inner layer is coupled to the absorbent core through a plurality of embossing portions, wherein each of the plurality of cavities is aligned with its respective embossing portion among the plurality of embossing portions along the transverse direction, and the cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​its respective embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction. Claim 16 An absorbent article according to claim 15, wherein the plurality of cavities are distributed in an array in the central part of the absorbent core; the length of the array is 80 millimeters or more and 120 millimeters or less, and the width of the array is 35 millimeters or more and 60 millimeters or less; the length of the absorbent core is 150 millimeters or more and 250 millimeters or less, and the width of the absorbent core is 50 millimeters or more and 80 millimeters or less. Claim 17 An absorbent article according to claim 15, wherein the cross-sectional area of ​​the plurality of cavities is 5 square millimeters or more and 90 square millimeters or less, and the cross-sectional area of ​​the plurality of embossing parts is 0.15 square millimeters or more and 8 square millimeters or less; the height of the plurality of cavities along the transverse direction is 30 percent or more and 80 percent or less of the height of the absorbent core along the transverse direction, and the height of the plurality of embossing parts along the transverse direction is 40 percent or more and 70 percent or less of the height of the absorbent core along the transverse direction; and the distance between adjacent cavities among the plurality of cavities is 5 millimeters or more and 25 millimeters or less in the direction perpendicular to the transverse direction. Claim 18 In paragraph 15, the above plurality of cavities comprises 9 or more and 30 or fewer cavities, an absorbent article. Claim 19 A method for forming an absorbent article, comprising: applying a cellulose fluff onto a plurality of pins on a forming drum; forming an absorbent core with the cellulose fluff, wherein the absorbent core defines a plurality of cavities extending inwardly along a transverse direction, and each of the plurality of cavities corresponds to a respective pin among the plurality of pins; embossing an inner layer and a transfer layer on the absorbent core through a plurality of embossing portions, wherein each of the plurality of cavities is aligned with a respective embossing portion among the plurality of embossing portions along the transverse direction, and the cross-sectional area of ​​each of the plurality of cavities in a plane perpendicular to the transverse direction is greater than the cross-sectional area of ​​each embossing portion among the plurality of embossing portions in a plane perpendicular to the transverse direction; and attaching an outer layer to the absorbent core on the opposite side of the inner layer.

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